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Miscellaneous Carb Questions FAQ

1. Just make sure your battery is always charged up and clean connections Pooshkin Noise 28 OK thanks Now that takes care of the clicking but what about the other sound The one that can hear at the injection module sounds a second after turn off the key and the way I d describe it is like an electrical antenna going down in a car after you turn off the stereo http faq f650 com FAQS StrangeNoises htm 10 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ know there is no antenna in there it just sounds a bit like that to me balam o Feedback went out in the garage and turned the key on and then off About a second after turning off the key mine makes the antenna going down sound also had never really noticed it before Maybe you just have a case of I worked on my bike and now l m nervous i did something wrong Best cure is to just go for a ride The bike will let ya know if it s happy or not Tom McCallum Noise 29 Sometimes hear a noise which believe comes from the engine haven t dug any deeper into the location of the sound yet but have found this The noise is a scraping mid frequent noise and has about one evolution per second when the bike is idling The noise is only audible sometimes when start the bike 1 of 5 10 times and it always disappears when the engine gets hot after a few minutes that is The noise is audible when start the bike in neutral It also accelerates along wit
2. Noise 27 After the valve job my bike is acting really weird Now when the key switch is turned to off can hear a rythmic clicking sound coming from the instrument panel am still experiencing great difficulty in starting the bike cold When turn the key switch to on and then to off after a second can hear a strange sound comming from the injector s area not the familiar sound comming from the rear when you turn the key on The sound is like something electromechanical shutting off don t remember hearing this sound before see also Noise 28 balam o Feedback 1 The clicking could also be the Starter Solenoid Next to the battery What causes that is a Low Battery Check your Terminals and check the battery once more You did refill it only with distilled water right Kristian 562 See the Battery FAQ o Feedback 2 actually it doesn t have to be a weak battery If for some reason the engine just won t crank in my case it was a cylinder full of gas you ll get the same symptom veggie_deluxe o Answer The engine has automatic decompression lever on one of the valves that opens the valve when the engine is stopped Sometimes the lever does not fall into place and all the valves are closed that causes the lockup during cranking or when the starter has to overcome the compression you get too much current draw and the voltage drops below normal thus resetting the computer That will cause clicking ABS noise hard starting
3. Organ Pipes Alternative Carbs amp Carb Parts Refer the JetKit FAQ for information on Length of Carb Springs etc if you re not sure your bike has part of or an entire Jet Kit e Refer the Idle Mix Screw FAQ for where it is and Tips on Adjustment Carb Nomenclature Note that Slide is also often called Slide Piston or Piston or Slide Barrel The Slide Carrier is often just referred to as the Carrier http faq f650 com FAQS Carb_Clean htm 1 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ Why should I clean out re condition my Carburettor A 1 If you ve read the Hard Starting FAQ and the Poor Mileage FAQs and nothing helps 2 When the bike has been standing a long time and it sputters and stalls and pops and wheezes but try some carb cleaner in a tankful of gas first and you re worried or you know the rubber O Rings have deteriorated 3 When the bike falls victim to the Pukin Petrol Syndrome and you have to take it out anyway for that reason 4 When the bike bogs down at anything above just past idle a sign of a Split Diaphragm and you KNOW it s not your Voltage Rectifier or Plugs or Plug Caps 5 When you are getting Poor Gas Mileage 6 When you are Rejetting Warning Rejetting is a long slow process and you may NEVER be satisfied with the results 7 When your bike seems to Surge or Stumble even if it is NOT an F650GS and you KNOW it s not your Chain Sprockets or a dirty Air Filte
4. Remove the seat Remove the side covers Remove all the screws that secure the gas tank to the fairing Remove the left and right engine covers Remove the big bolt at the back of the tank Pull the fuel line off the petcock Pull the tank upward and note that there are a couple of vent hoses If you have removed your canister one hose is short and plugged If you haven t you should The other hose has a connector inline where you can break it Remove the tank and set it aside on top of something so that it doesn t hurt the petcock nipple Remove the tank support bracket from the frame Loosen the hose clamps which clamp BOTH the rubber carb boots and the Air Intake Boots You might want to use a flat screwdriver to sort of pop the lip of the boot up and spray some Armour All tm or Son of A Gun tm or other rubber treatment lubricant in there to get the rubber unstuck from the metal and lubricated all around the lip Repeat for all the rest Wiggle the rubber pull on the carbs and cuss a lot until they are free Pull them out Install in reverse order For more details about removing the Gas Tank see the Gas Tank Removal FAQ Feedback In trying to get the carbs out without removing the airbox exhaust etc the sharp edge of the carby intake opening sliced its way into the air box rubber while was wiggling pulling the carbys out Its not a really deep cut and hopefully the hose clamp will hold the cut to
5. Step 3 Apply the multiplication factor shown to the main jet size recommended in the chart at the top of the page Step 4 Your operating conditions will vary by the change of seasons If your engine experiences performance Miche young difficulties a review of your jetting may be necessary Return to step 2 most of the information you want on one page Step 5 Humidity is also a variable in determining air density A high humidity means a lower air density of air to be consumed by combustion Because we are generally not equipped with a way of easily reading the of humidity present this can be read in to this chart by adding altitude on high humidity days and subtracting altitude on in very dry climates http www nightrider com biketech main_jet_correction htm 1 of 4 18 02 2007 12 30 51 Main J et Correction Create you base line jetting for standard conditions If your base line tuning was at 86 degrees and a 1500 altitude with a 155 Main Jet Calculate Base Line 155 Main Jet 97 160 Base Line Jet or specifically 159 8 To correct for local conditions of 100 degrees and 4500 altitude Calculate Corrected Jetting 160 Base Line Jet x 94 150 Main jet to use Altitude Feet 0 1500 3000 4500 6000 Temperature Co T COo TT 22F 1 04 1 03 1 01 1 00 EE 4F 1 03 1 02 1 00 0 99 O 14F 1 02 1 01 0 99 0 98 0 96 32F 1 01 1 00 0 98 0 97 0 95 50F 1 00 0 99 0 97 0 96 0 95 59F 1 00 0
6. The Very Strange Noises FAQ AFTER it is warmed up It does not make the noise when you rev in nuetral through those RPM s The sound is something like a engine knock chain rattle keys in the cylinder sound kraberry2 o Feedback First DO NO USE HI TEST FUEL Run regular gas Next remove your cam chain tensioner If it comes out in more than one piece it is broken Flash 412 Noise 36 Starting about 100kms after oil change have had what sounds to be a plastic type rattle note Temperatures today when rattle started were about 8C colder than yesterday when bike was fine Sound may have been there longer since tend to stick to gt 4000rpm when riding but have not noticed it The rattle has the same beat as the engine ie 1 rattle for 1 rev from what I can guess It occurs in lower gears from what I can tell 1st through 4th It happens with clutch engaged or dis engaged happens while in neutral Always between about 3500rpm and 4500rpm Occurs equally going up and down hill accel or decel ed Oil changed second time rattle returned Winter o Answer The new improved tail latch door 04 05 model GS was causing the rattle It just so happened had put my drink down on the door and that stopped it from rattling Just to be sure put everything back on the bike and took it out for a spin sound was there Removed the tail latch door sound gone Used some foam Winter Noise 37 Just like you did an oil chang
7. fire it up and ride off immediately It will not idle correctly without choke _ever_ if do not ride it But if ride off and kill choke ASAP it will idle fine within moments say at the next stop light kinda weird but that s how it works NormJ 473 Seattle e The phenomenon you see is that the lever actually operates an enrichener not a choke which is why do not use the terms open and closed as most people get confused Your problem is likely that your idle is adjusted incorrectly And it s too low Before you do ANY other adjustments get the bike fully warmed up to regular running temperature with a good ride with reasonably fresh gasoline Then adjust the idle to 1400 rpm real easy to do takes 10 seconds Run it a while and confirm that when fully hot your idle is stable around 1400 rpm Yes it s a bit fast but that s the way it was designed Now you can see how your cold idle and choke works the next time you ride Do NOT adjust the idle cold while operating the choke lever Vary the choke lever instead This will likely solve your idle problem if nothing else is wrong with the engine Todd 389 e The choke changes the air to fuel ratio by either supplying more fuel than normal or limit choke hence the name the air supply Your bike will consume more fuel on choke sometimes it will also run badly on low revs and probably pollute more Not having to remember the choke is one of the nice things about fuel injection know o
8. Charlie 070 from Pennsylvania Some parts are exactly the same parts as a Suzuki GS500E Note the GS500E uses Mikuni BST33 x 2 Carbs The Suzuki 98 DR350SE uses a MIKUNI Carburettor BST33 BST33SS CA Model Single The Suzuki DR350 EU model 1994 uses Mikuni Type BST33SS but US Model 1990 Mikuni uses TM33SS The Suzuki DR750S and 800S Specs also show a MIKUNI BST33 twin The Suzuki 1996 GSX600FT also show a MIKUNI BST33 four The Suzuki GSF 400 Bandit has MIKUNI BST33 four These are from a Suzuki GS500E http faq f650 com FAQS CarbMiscFAQ htm 19 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ For GS500E 1989 1996 GS500ECarburetorKLMNPRST 1989 1996 e SUZUKI GS500E Carburetor KLMNPRST 1989 1996 PartsList 1997 2000 GS500ECarburetorV 97 W 98 X 99 Y 00 e SUZUKI GS500E Carburetor V 97 W 98 X 99 Y 00 PartsList The Aprilia Pegaso Sister of the Funduro also uses the same Mikuni BST33 Carb as the http faq f650 com FAQS CarbMiscFAQ htm 20 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ Fundu Notes ro Note there MAY be a Yamaha that also uses a Mikuni BST33 B316 carb Might be worth some odd digging to see Note the 1994 Triumph Daytona 1200 has Mikunis BST 36mm CV carbs but the 36m is the horizontal opening size and Diaphragms MAY be the same as the F650 You CAN get some Carb parts from Sudco at www sudco com but they do not list our carb g
9. Kristian Is there any way of Setting Checking the Float Height with the Carbs ON the bike by Richard 230 The Downtime Files of the April issue of Motorcycle Consumer News has a really great tip for checking float level height without removing the carbs Connect a piece of clear tubing to the float bowl drain tube bend the tubing up against the outside of the float bowl and turn on the float bowl drain screws The gas will rise in the tubing and you can take your measurement by observing the top of the level of the fuel in the tubing as it will rise to the same level that is in the inside of the float bowls The Classic has bowl drain taps on the bottom of the float bowls that you can hook up a plastic tube to The only problem would be finding clear plastic tubing that will fit tightly over the drain nozzles think you could find this tubing in a pet fish store If the tubing was a bit large you could use wire wrapped around the tubing and twisted with pliers to compress it over the nozzles so that the fuel wouldn t leak while you were checking the float level The best way to use the tip is to check your float level when the bike is new or at least running well Place the tube on the float bowl drain and then turn on the bowl drain tap Wait until the level stabilizes then scribe a mark on the bowl for future reference Then in the future if you have a carb problem you can perform the test again and check it against the mark If it is high
10. Personally think it needs to be brightened by the addition of some chrome parts On the other hand didn t want to chrome the entire engine so that it looks identical to the motor in a Low Rider Harley offers a chrome engine kit to do just that wanted to retain the basic black heads cases and exhaust system but add some chrome to brighten up the overall look of the bike didn t want to add a lot of weight to the bike so most of the parts listed below are merely replacements for stock parts of equal weight Here are the chrome engine transmission parts ordered to replace identical stock black parts on the test bike chrome V Wing derby cover 25335 99 chrome V Wing timer cover 32665 99 chrome transmission side cover 37105 99 chrome primary chain inspection cover 60529 90A chrome transmission top cover 34469 99B chrome air cleaner cover 29350 99 chrome starter end cover 31535 91 chrome horn cover 69102 93A chrome coil cover 31644 99 and chrome electrical cover 66333 99 Whenever have the engine oil and oil filter changed specify the chrome finish oil filter The result is what call a Holstein engine chrome and black thought a few other areas on the test bike could use some help so also added the following chrome trim parts chrome tank trim panel 67221 97 chrome battery top cover 66368 97 and chrome battery side cover 66375 97 The photo at the top of this article sh
11. Took about 20 min Put them back together and the bike runs like a charm Thanks again for all your help and everyone here JAMES http fag f650 com FAQS CarbMiscFAQ htm 15 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ e Oh yes was talking about the float mount The left one slides over and seats on a brass tube and the end of the float mount has a restrictor The tube am referring to is connected to the choke the left float o ring side slides over this tube noted that the left float has a restrictor built into it therefore there is a different float assembly for left and right carbs am not too familiar with carbs dealt mostly with FI On the right carb there is a drilling with a hole for a tube but compressed air will not flow through it I am assuming it is a blind and not used wonder why there is a restrictor on the left float and not on the right unless the float assemblies were switched at some point am baffled at this point the only reason got into this mess was because Dyno jet sold me a jet kit that does not work on the 1998 F650 continuously fouled plugs and called and they told me this kit was not for the 1998 So went back to stock And could not adjust the right carb Bottomed out or 5 turns out no difference So then decided to look at float height This is when discovered these differences Again thanks to all JAMES The parts in my kit are stock needles 5 clip settings 5E94 stock main
12. along with needle size and adjustment on the air fuel mixture that reaches the cylinder All the wisdom I ve heard is that floats which are made of plastic they appear to resemble extruded closed cell styrofoam can over time absorb fuel and become less buoyant The way older ones and some newer ones may be made of copper but that s another story Floats that are less buoyant will allow the fuel level in the bowl to become too high before they shut off the flow even if they are properly adjusted This in turn will permit more fuel to be sucked up which will enrich the air fuel mixture which will affect fuel economy Floats are cheap and relatively easy to replace As someone said it makes sense to replace them now and then 13 years seems a long time to me The post about weighing the floats was very interesting and this should permit a very precise determination of their condition ouoyancy However a visual examination can also help If they re heavily stained porous looking or just plain cruddy change em See also e htto www airheads org contrib fuel html e htto justkdx dirtrider net floatlevel html Proper Choke Use Q Ok here is my question Is the choke supposed to move by itself have found that when the bike is cold and have the choke fully on and ride aggressively read rev to 7000 then shift then wide open again the choke closes and often time the bike will stall going down the off ramp when declutch Is
13. are not designed to cope with As a result he has added a fork brace and a steering damper and rebuilt the front forks of his 1999 FXDX fully adjustable forks did not became standard until 2000 and later models He also replaced the wheels rear shocks and swingarm with very high performance after market units The 1999 FXDX came with single piston calipers for its twin front discs and Hein replaced these with six piston calipers His FXDX is a very impressive well balanced high performance motorcycle have not found these modifications to be necessary because simply don t ride as fast or as hard as Hein does Riding the Super Glide Sport When you swing a leg over the Sport you appreciate its low seat height and the narrow design of the engine It is an easy bike to straddle and balance despite its considerable weight Its low center of gravity makes it relatively easy to paddle around with the engine off or maneuver at low speed under power The locking side stand is very secure the best around To start the bike when the motor is cold it is necessary to first pull out the enrichener knob located beneath the left side of the gas tank Then twist the throttle all the way on slowly about three times this primes the carburetor Press the starter button on the right handlebar housing and the TC 88 engine will come to life shaking and spitting beneath you It will soon warm up settling into its characteristic loping idle With
14. carb vacuum front actuated airflow Exhaust header brass connector restrictive cat air injection line a a metal tube right side gas cap with Charcoal tenkivant Lija vent checkvalve emissions canister gas fuel fs tank Ne left side filler well drain ends by left footpeg interior filler well Drain by right Proper vacuum hose and original canister footpeg USA bikes with Catalytic converter Canister Removal Notes Note Even with the vacuum lines correctly installed a missing orifice would probably cause excess vacuum in the fuel tank the orifice is meant to limit the vacuum in the system Installation without it would likely cause excess vacuum in the fuel tank and subsequent fuel flow problems vapor lock http faq f650 com FAQS Canisterectomy htm 4 of 6 18 02 2007 12 30 27 The Canisterectomy FAQ With regards to the Brass Orifice there is no contradiction in the above description as we are looking at 2 different cases The FAQ deals with two items A Canister Removal amp B Vacuum Line Re Routing as the Title Suggests The Outta Gas Symptoms could be A or B as per the first line in the symptoms section Case 1 If you DO REMOVE your Canister you should take out the Brass Restriction and Some people replace it with the smallest size plastic fuel filters some people use a similar plastic nylon connector which is not restricted that is leftover from the removal of
15. dynamometer and a flatter torque curve than the visually almost identical SE II mufflers usually recommended This was determined by dyno testing both types one after the other A decision was made to stay with the modified 80313 99 mufflers A SE performance 6200 rpm ignition module and coils 31710 99 had previously been installed on the test bike before the big bore kit and cams were installed and Hein said that they would work fine which they have Note however that the 31710 99 performance ignition system used in this engine is not the preferred high compression race ignition system 31775 00 Harley recommends for engines with cams raised compression and added displacement Screaming Eagle spark plugs 32321 91 and plug wires 31944 99 and SE performance exhaust gasket kit 17048 98 complete the engine modifications as tested for this review The result as noted above is very similar to Harley s Stage III kit On the Dynojet dynamometer at Doyle s Harley Davidson in Eugene Oregon this engine produced 86 6 horsepower at 5250 RPM and 96 4 ft lbs of torque at about 4000 RPM measured at the rear wheel Remember that all dynamometers differ and Doyle s dyno is generally a little stingier than the one used at the Harley Davidson test center Performance A stock Super Glide Sport has a top speed of approximately 115 mph Motorcyclist magazine ran their stock FXDX test bike through the quarter mile in 13 54 seconds
16. except as the filler funnel bit is all one piece of plastic used a hacksaw to remove that unwanted section be sure to leave the part that the gas cap gasket http faq f650 com FAQS Gas_Tank_Removal Replacement htm 11 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank seals against and be sure not to contaminate the tank with plastic sawdust Resulting filler hole is now larger in diameter and easier to fill while still being able to watch the level It s been over 18 months since did this mod remember the six bolts only half of which have to be removed if you know which ones are which The single one that you talked about was a pain to remove and even more so to replace the spring loaded cap keeps interfering If remember correctly you may also have to remove the decorative tank cover the painted shell that covers the stock gas tank to remove the funnel bit also remember a gasket that was finicky to get lined up just so to realign all the parts under the funnel Know the funnel bit IS removable because distinctly remember hacking away on it while sitting on my front porch I touched up the rough cut edges with a file There is a little vent tube and or hole cast into the funnel don t mess these up This was on a 97 Classic maybe the design changed Absolutely keep the funnel away from the gas tank while cutting I d also wonder what this particular BMW part costs if it should NEED to be replaced EPA regs
17. tonight was poking around the front end re inspecting everything could see the headlight adjusting screw which never before realized existed wasn t loose no unauthorized parts bouncing around inside of the headlamp but noticed that the front brake line and the accompanying ABS sensor wire are free to rattle against the after part of the front fender Tapping these two against the hard plastic part actually produced a sound much like that which has been driving me nuts taped the two cables to the fender and drove a few miles At first no rattle at least I m pretty sure The rattle did reappear but after dismounting realized that the tape had come undone timagination Noise 45 have a sporadic grating noise coming from what seems like the tranny on the right side It comes and goes lasting for a few minutes then kicking off as fast as it kicked on The http faq f650 com FAQS StrangeNoises htm 16 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ sound follows the engine RPMs and does not change if pulling in the clutch The bike is running very strong and whatever the noise is it does not affect performance yet Unfortunately it is getting louder the BMW dealer here in Istanbul changed the generator bearings and put ina new starter for no effect The problem does seem to occur when running at lower speeds but that could be at higher speeds can t hear it over the rumble from my ultra cool Adve
18. will bleed the vac off slower 2 Change the rate the return spring A heavier spring will have the same effect as a larger vent hole 3 Change the position and shape of the needle You can use any combination you wish provided it produces the results that you or should say the engine wants I ve seen it done all three ways by different shops and kits know one successful race shop that prefers to use the stock needles straight taper and slides He only changes spring rates and jet sizes Others Dyno Jet kits included use custom needles stepped taper adjustable position and larger vent holes in combination with stock spring rates And some just alter the needle shape while leaving the vent and springs alone The results are all that matter btw this is usually a mid range adjustment Low range is still governed primarily by the pilot jets amp float height and top end by the jet size Flat spot in carburetion Refer the Canisterectomy FAQ Idle Mix Screws FAQ Poor Mileage FAQ Carb Clean FAQ The following responses are for PRIMARILY from people with Stock setup If you know or suspect you have a Jet Kit please also refer the Performance Modifications FAQ e figured out what the problem was On the air filter side at the bottom of the Venturi there are two orifices a small one and slightly larger one The smaller one was clogged big time used carb cleaner and a piece of stiff wire and finally got it cleared
19. 12 30 23 HOW TO Remove the Tank e Check you aren t mistaking Reserve for the Main Tank Easily done and you basically run the WHOLE tank dry then switch to what you THINK is reserve and it s the main so of course there s no Gas there either e Also check that the tubes seat properly and are not warped to the point that fuel can still pass where they join the petcock http faq f650 com FAQS Gas_Tank_Removal Replacement htm 16 of 16 18 02 2007 12 30 23 F650 Idle Mix Screw FAQ by Kristian 562 12 September 2001 Please read the Disclaimer before attempting any work in this FAQ Last Updated 13 June 2006 by Winter 1935 Where is the Idle Screw Where on Earth is the Idle Mix Screw Other Related FAQs e Carbs Misc FAQ Carb Cleaning FAQ Where is the I dle Screw To the LHS of the LH Carb it is a flexible Wand that sticks down with a spring wound around it about 2 1 2 inches long and sheathed in rubber sounds kinky doesn t it with a Knurled knob at the bottom end It is nestled close to the Preload knob Here in the red box is the upper art of it Idle Screw Location Sorry no pic of it ON the bike The Classic F Idle Speed is 1300 1400 rpm Where on earth is the I dle Mix Screw Here Idle Mix Screw Location The Idle Mix Screw Circled GREEN is under the Black Plug if it s still there in front of the Carb Float Bowl and under the Carb body This is the LHS One and is accessible fr
20. Circuits are additive See Sudco Carbs 1 amp Sudco Carbs 2 Dynojet gives you the Needle and the Main Jets and says THESE are the settings if it doesn t work try the needle one clip either way then adjust the Float Bowl Height Do NOT change the Pilot Jet These last three you SHOULD only need if you rejet which can be a REAL Trial PITA There is also a good list at the Bottom of the Page Q What Parts of the Carb get worn A Pretty much all the moving parts or parts against which moving parts work like any mechanical device However there are some parts which don t move that deteriorate with age some to a greater extent than others The parts that most often wear or deteriorate are the Carb O Rings Needles shown are the Stock L vs Dynojet R needles Diaphragm Rubbers shown on top of the Slide Slide Carrier Grey Plastic Block and the Slide Black barrel with two Side Fins The jets Main Jet Pilot Jet do not really wear except for the so called Carb Venturis or Needle Jets due to the action of the needle vibrating within in it Here s a link to an Oblong Venturi Jet on Factory Pro s Website to give you some idea of the wear that can occur in the needle jet It is this wear along with the corresponding rubbing scratching of the needle See Worn Needles also on Factory s Site However if the gas is dirty the Main or Pilot Jets can also get blocked fairly common and the hole CAN wear bigger although t
21. It helps if you angle the feeler gauge towards the float to reduce the distance between the two a little Tilt the carb the same way you did in the previous method and watch for the tang on the float to just make contact with the needle rod protruding from the float valve If the two are not parallel at this point the bend the tang and recheck Ideally you would reassemble the carb and recheck it with the fuel level gauge If you don t have a gauge you ll have to trust you set the height properly http justkdx dirtrider net floatlevel html 3 of 4 18 02 2007 12 30 31 Float Level Adjustment David If you have any comments or suggestions smack the e mail icon and send them my way or visit the ustKDX Forum http justkdx dirtrider net floatlevel html 4 of 4 18 02 2007 12 30 31 Keihin Carburetors Home Tech Tip Articles Fun to Ride Guide Custom Engine A alysis Custom Engine Building Other Products and Services Perry s IzS Ko Friends 6f if mele L HEADWORKS FLO Headworks Harley Davidson Performance Specialists Keihen Carburetors Blueprinting Keihin Carburetors After much time and testing FLO Headworks is pleased to announce to Harley Davidson owners everywhere a new service to blueprint your 1989 to present day 40 and 44 mm CV Carburetors with accelerator pump We have designed a computer program that enables us to blueprint the Ke
22. NOT the original it is too big but the old one was missing at the time took the Photos It is hard to find the correct washer because it is a very small diameter and not very wide so try not to lose them The order shown is the order it gets installed You can screw these back in now Screw them down until they are LIGHTLY seated Do NOT screw them up real hard you will damage the fine tip Then back them out 3 5 turns with a screwdriver This is the STOCK setting Removing and Inspecting the Slide Carriers and Carb Venturis With the innards of the Carb Bowl out there s nothing to break if you turn it over so turn it back upright and undo the Diaphragm Cover again Now that the Main Jet which actually Screws into the bottom of the Carb Venturi Jet is out you can remove the Slide Carrier and the Venturi Assuming your Diaphragm Slide Barrel and Needles have already been removed do this by grabbing the Grey Plastic Frame Slide Carrier and simply pulling it upward out the Top of Carb Don t worry about the 4 Plastic Tabs at the sides they just pull up If you don t pull it out too vigorously they will be just fine When you pull it up the Carb Venturi comes with it because there is a Flange at the top of the Venturi which sits in the bottom of the Slide Carrier It should look like this Slide Carrier Venturi attached You can just push the Carb Venturi toward the top of the Slide Carrier to remove it Underneath the Slide Carr
23. Needle Spacer and Washer This also allows you to change the E Clip position or add a small thin washer for an equivalent 1 2 E clip position change all without removing the carb from the Bike Great for fine tuning Rejetting Not so good if it s snowing outside and your bike lives outside Q Should run the carbs dry by turning off the petcock and running the engine until it dies before http faq f650 com FAQS Carb_Clean htm 7 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ remove the tank Or when you remove the tank and drain the fuel hose going from the petcock to the carbs do the carbs drain too If not is there a reason this is not mentioned in the FAQs Perhaps work on the carburettors is easier better with their bellies full A No You don t need to run the carbs dry After you turn off the Petcock if you are REALLY paranoid you CAN empty the bowls using the drain screws if you really want to The Drain Screws are here Float Bowl Drain Screws Circled Red Wind them out a few turns either on the bike beforehand or after you get the Carb s out and rotate the Carbs around until all the GAS you can get out of it comes out DON T SMOKE Enough of the Preamble How do actually Clean amp Replace Carb Parts Tools 1 You should get hold of a can of Carb Cleaner any Motorbike Shop should have one or simply use Petrol and a few small brushes with soft non metallic bristles that are not affect
24. Too early to tell if fuel economy has improved it wasn t all that bad before but now that I m back to stock here s what s happening Throttle response is better at low RPM It would tend to bog if sat at idle too long and then went to take off you like at traffic lights Plugs aren t fouling any more am now going to restrict the airbox so it s as close as can get it to stock to see what happens That s about all guys don t know if there s anything there at this point that merits an addition or change to the FAQ will say that moving the hose clamps as far back on the rubbers as possible makes all the difference as far as insertion and removal And clumping cat litter makes a great absorbant for gasoline spills or draining the little hoses Sean 1015 Ottawa Canada FINALLY rebuilt those carbs 26K Surprisingly the needles and emulsion tubes looked good replaced anyway stashed the old ones for spares Both diaphragms had small tears both idle mix screws were only 2 25 turns out and both floats had to go WAY too high to shut off flow float needles were well grooved as well Here s hoping that the changes back to stock will improve my gas mileage significantly running 30 35 MPG at last check boy did miss my Acerbis tank which is ALSO repaired now Maybe that 17 tooth front sprocket won t feel so tall now Marty 436 e Note to all who helped me with advice on returning the carbs to stock Kristian 562 Todd 389 Richar
25. With the choke circuit on these carbs it usually runs really bad with a partially on choke I ve seen the choke cable get hung up halfway which leads to no running stalling no idle with choke seemingly off but will run fine but horribly rich with it full on Never leave mine 99 Classic on choke for more than a few minutes if it s above 10 C 50 F all need is the choke to start after starting it ll run fine with no choke totally stock cept for silly K amp N Shank NYC USA Turned up the idle and this seemed to fix the problem The whole bike seems to run a bit better but it is probably just my imagination Don Apart from theoretical problems has anyone noticed actual ill effects on the classic F650 from either driving with the choke partially open for miles forgetting to shut if off promptly or not closing the fuel petcock after riding I m not guilty of the second but am the first now and then Think there s enough extra fuel on the cylinder walls to effect ring lubrication Johnny 862 Don t know about theoretical but gas mileage is a little worse when you ride with the choke on but not much that know from experience have never noticed any other problems never fouled a spark plug think it s a throttle advance not an actual choke i e air restriction never shut off the fuel except when transporting the bike on a trailer Haven t noticed any ill effects from that either mark 403 The small amount of ex
26. altitude operation we would remove the air filter and pull any removable baffling out of the muffler s when the bike started to slow down With CV carbs you will likely not have a problem except that your idle may be lumpy and slow If things get too bad you may want to turn your idle mixture http faq f650 com FAQS CarbMiscFAQ htm 12 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ screws in a turn Just remember to turn them back out to 3 5 4 turns out when you get below 5000 feet Richard 230 e would and did do nothing you will lose some power but hey its not a race anyway Lance 1303 01 F650GS 96 G650ST y_kiwi e live at 1400 feet have had two different experiences in Colorado and Utah at elevation 1998 Triumph Sprint Three Keihin Carbs Factory stock probably a little lean Ran SMOOTH and perfect all the way to over 12 100 feet on the road to Fall River Pass Noticeable loss in power over 9 000 feet Smooth and comfortable at 12 000 feet but way down on power Really a non issue was loaded for a solo 10 day trip and had a blast Didn t use sixth gear much 1996 Moto Guzzi Sport 1100 Two Del Ortos with accelerator pumps Aftermarket exhaust and jetting mods probably runs a little rich Ran like shite at anything over 6 000 feet Had to keep it at 5000rpm or more the whole friggin way from Colorado Springs to Park City the long way Had it rejetted and dyno d at Salt Lake City with some
27. and check for leaks as per the procedure for the Gaskets at the Cylinder Head e Some sort of vapour may come out from the collector but not under any pressure and possibly some WD40 burning if you used that to loosen your nuts bolts e Some pulses of air may come out from the new gasket Tighten the clamp a little bit if this happens e Check the air tightness over the next few days The new gasket is supposed to heat and shrink a bit so retighten if necessary The whole thing is quite easy and takes less than an hour you just need two Allen keys from the bike tool set pliers and a 13mm wrench The bike now sounds fine power is back and there is no backfiring Mechanic s advice Do not tighten the gasket fully straight off Ride about 150 km the gasket will shrink a bit then do a final tighten The clamp is specially designed so that it can t be tightened to less than a certain minimum diameter On the road Alternatives Take it off and head to an auto supply shop to look for a suitable ish temporary replacement When we blew an exhaust gasket on our off road buggy in the middle of Baja we went to a shop in Geurro Negro and got the closest match we could find worked long enough to finish our trip and save our hearing and the valve Cold air being sucked onto a hot exhaust valve is bad One trick you might use we did is to use a pair of shears to cut away sections at the bolt hole locations so you can simply slip the
28. and let it drop out into your hand It has holes in the sides as well the end and should be stamped 41 3 if it is the Stock Pilot Jet Check you can blow though it and all the holes are clear Again use a plastic brush bristle to clear any obstructions but not one from a Wire Brush That s all the things inside the Carb Bowl that need tending to Now s a good time to put it back in its little hole One less thing to lose Screw it in until it seats then a little more Just FIRMLY Use the correct size screwdriver or you will ruin the slot and burrs from a poor Screwdriver mangling pieces of the slot could jam in the holes you just cleaned Removing and Inspecting the Idle Mix Screw While it can be done with the Carb Bowl done up it is a VERY good idea to check the Idle Mix Screw with the Carb Bowl off and everything out The reason is this As you can see the 3 4 and finest hence easily broken replaceable O Ring is located on the Mixture Screw If it wears out or there has been too much vigorous screwing of the Idle Mix Screw in and out sounds horrendous doesn t it bits of the broken O Ring can get stuck in the little hole that allows fuel from the Carb Bowl enter directly into the main Carb Venturi NOT the Venturi JET at idle Unscrew the screw all the way out check the condition of the spring the washer and the tip of the Screw Replace the O Ring btw the Washer in this picture between the Spring and the O Ring is
29. another table spoon or more poured out In the morning there was almost an INCH of gas in the coffee can pulled the bike outside and parked it on the centerstand while drank my coffee When went to leave a half hour later there was about a two foot diameter wet spot on the concrete under the bike It was hard as hell to start stalled it at the bottom of the driveway happened to look back and see a trail of drips from the big wet to where was rode it about eight miles and stopped just to check things out No more drip I ve smelled gas in the garage every night this week even when parked with more than 100 miles on the tank The temps lately have not been extreme think there was not such a great differential between the temp of gas in an underground tank and the temp last night If anything the air was cooler So what causes it Pukin Petrol The Answer 1 When you remove the float bowl there is a plastic assembly which consists of the floats and a holder 2 The float needle clips on to the floats There is an o ring on holder 3 This o ring had a positive feel to it when removed and reinstalled the holder 4 With the assembly removed there is a bronze piece which is or contains the SEAT 5 This bronze piece also has an o ring However BOTH of the seats just plain fell out when turned the carbs upside down 6 figured that if the o ring did not have enough interference to hold the thing in then it wo
30. are a couple of vent hoses If you have removed your canister one hose is short and plugged If you haven t you should The other hose has a connector inline where you can break it Remove the tank and set it aside on top of something so that it doesn t hurt the petcock nipple Remove the tank support bracket from the frame Loosen the hose clamps which clamp BOTH the rubber carb boots and the Air Intake Boots You might want to use a flat screwdriver to sort of pop the lip of the boot up and spray some Armour All tm or Son of A Gun tm or other rubber treatment lubricant in there to get the rubber unstuck from the metal and lubricated all around the lip Repeat for all the rest Wiggle the rubber pull on the carbs and cuss a lot until they are free Pull them out Install in reverse order For more details about removing the Gas Tank see the Gas Tank Removal FAQ Feedback In trying to get the carbs out without removing the airbox exhaust etc the sharp edge of the carby intake opening sliced its way into the air box rubber while was wiggling pulling the carbys out Its not a really deep cut and hopefully the hose clamp will hold the cut together when the carbs go back in place but can anyone provide me with the BMW part number for the airbox rubber Also what is the BMW part number for the engine rubber My engine rubber had a lot of fine racks in it which were especially noticeable when pushed bent around
31. are suspended from the slide in a manner that allows one to change how far they hang down by moving a clip to a different notch You can imagine a tapered needle withdrawing from a hole the further out it is the more surface area of the hole is available to flow fuel This circuit works up to about 3 4 throttle when the jet needle is completely withdrawn from the needle jet At that point the limiting factor becomes the main jet The main jet is used at wide full open WFO throttle How much fuel does the engine NEED when it is breathing as fast as it can That is THE limiting factor for your motor for any given combination of exhaust system Airbox filter setup temperature altitude or barometric pressure http faq f650 com FAQS CarbMiscFAQ htm 2 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ Tuners tune first to get the bike to start and run idle circuit then make power on the mains THEN be streetable between idle and WFO HOW to go about tuning is a different subject maybe for a different day Many whole books have been written on the subject PULLING THE CARBS by Flash 412 October 01 m e 12 13 14 15 oS ee ee Remove the seat Remove the side covers Remove all the screws that secure the gas tank to the fairing Remove the left and right engine covers Remove the big bolt at the back of the tank Pull the fuel line off the petcock Pull the tank upward and note that there
32. at a terminal speed of 96 48 mph H D says the Sport s triple disc brakes will bring a bike at maximum loaded vehicle weight traveling 60 mph to a dead stop in 155 feet Gas mileage is good even when ridden fairly hard a stock Sport will get about 42 miles per gallon This is good all around performance all that most owners will actually ever need This test bike s modified engine is reliable tractable starts easily and runs well In these respects it seems no different than a stock engine It sounds like a high performance engine with an obvious lope from its cam at idle and loud mufflers It runs very strong at all rpm s and is excellent for accelerating out of corners or passing slower vehicles on the highway which were the principle design requirements Average mileage is reduced to approximately 39 5 mpg The WinPEP Dynojet Performance Program based on the dyno results from Doyle s http www chuckhawks com super_glide_sport htm 9 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT Dynojet dynamometer as quoted above predicts a best 0 to 60 mph acceleration time of 2 6 seconds and a top speed of approximately 140 mph This doubt and have made no attempt to verify these figures However Hein Vandenberg told me he has ridden his 1999 FXDX which has a motor very similar to the one tested here to speeds well in excess of 120 mph He feels that this motor will propel the FXDX to speeds its chassis and suspension
33. between the Carb and the Throttle on the Handlebars Replace the Tank as indicated in the Gas Tank Removal Replacement FAQ That s it Sounds long and arduous but in reality it s not just wrote a lot of detail can get the tank off whip the Carbs out change the Jets and Needles put it back and get the Tank back on in about 45 minutes during my lunch hour and still have time for a sandwich But I ve done it way too many times I m not suggesting you should hurry through it though take your time A job worth doing is worth doing right It s a job you can do in a few hours over the course of a leisurely day Any comments on the FAQ improvements or suggestions drop us a line For all you poor people with F I aren t Carbs FUN Thanks to Flash and Todd who always manage to be both entertaining and informative to Mark for getting out there and doing it and to Craig Tom and the other guys who went and are still going crazy trying to get the jetting right having pulled their Carbs for the umpteenth time Big thanks to Mal for his great close ups of the Float Valve Note have no affiliation with Factory Pro who are mentioned often in this FAQ though they do have some very good tips They didn t like it when started asking questions about their jet kits without buying it but hey if you can t ask about something they want to sell Others have had a good experience with them and find them helpful Cheers amp Rgds
34. brown T Piece connector between the Carbs Refer the Carb Cleaning FAQ for more Details Fuel Lines e Believe it or not the BEST fuel line is BMW fuel line from the dealer It is rubber covered with cloth weave Some dealers sell it by the meter some by the yard Some can make the conversion some cannot The hose that came on the bike was Italian Flash 412 had nothing but problems with the fabric covered line don t know exactly what ate it up but it just started cracking and leaking The hose that came on the bike was not the fabric covered line but a single walled line with no internal reinforcement This stuff just got really hard and inflexible The Gates line is double walled with a woven fabric reinforcement sandwiched in it Beefy Chris in Santa Cruz CA e You can usually buy clear fuel line sometimes in designer colors or black at the nearest Jap http fag f650 com FAQS CarbMiscFAQ htm 22 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ bike dealer 6mm is closest to US equivalent 1 4 although 5 16 is also available had some of the old BMW cloth covered stuff in stock it works fine so far Marty 436 Chicago 97 F650F http faq f650 com FAQS CarbMiscFAQ htm 23 of 23 18 02 2007 12 30 06 Carburettor Cleaning FAQ Carburettor Cleaning FAQ by Kristian 562 Please read the Disclaimer before attempting any work in this FAQ Carb Nomenclature Why should I clean out
35. but none fixed the problem believe that the biggest problem was the fact that my bash plate and engine guard bolts were loose and after changing the oil in the bike got all those bolts tight like they should be dgriffin 1696 Noise 41 So I m leaving work yesterday and it sounds like a playing card is clothespinned to my wheel The sound goes away by the time get home Last night was heading out to eat and strange knocking sounds started coming from the bottom end The knocking slows down as slow down Bangs a couple of more times when stop Seems to be from low on the right side Generator Clutch Crank Water pump Fuel pump guess I ll find out soon enough It s a 01 Dakar with 21 000 miles have noticed a buzzing noise lately as pass a wall or something close on my right side Almost a chain sound Troutrider o Answer got to work this morning and sat down on the curb and took off the sprocket cover While checking everything out noticed that the chain roller was clunky and grooves were appearing on it I ve got 10 000 miles on the gold DID chain and it looks decent ordered a new roller assembly Troutrider http faq f650 com FAQS StrangeNoises htm 14 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ Noise 42 When shut off my 01 GSthere is a noise sometimes It kind of sounds like its coming from the starter Its like something is releasing tension and it makes a big CLICK Doesnt always do it thoug
36. cap parked the bike in the garage At about 4AM my wife woke me up because she smelled gas There was a large puddle below my bike put a coffee can under the hose and mopped up the puddle Thinking to improve the situation put the bike on the centerstand When did another table spoon or more poured out In the morning there was almost an INCH of gas in the coffee can pulled the bike outside and parked it on the centerstand while drank my coffee When went to leave a half hour later there was about a two foot diameter wet spot on the concrete under the bike It was hard as hell to start stalled it at the bottom of the driveway happened to look back and see a trail of drips from the big wet to where was rode it about eight miles and stopped just to check things out No more drip I ve smelled gas in the garage every night this week even when parked with more than 100 miles on the tank The temps lately have not been extreme think there was not such a great differential between the temp of gas in an underground tank and the temp last night If anything the air was cooler So what causes it Pukin Petrol The Answer 1 When you remove the float bowl there is a plastic assembly which consists of the floats and a holder 2 The float needle clips on to the floats There is an o ring on holder 3 This o ring had a positive feel to it when removed and reinstalled the holder 4 With the assembly removed ther
37. carbon fouled actually they look brand new 60 000 KM F650 1995 Spakur in Sweden http faq f650 com FAQS Carb_Clean htm 20 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ 1117 95F e was just reading the carb cleaning FAQ and perhaps you could add to my comments at the bottom of the FAQ that my float heights were off by 1 5mm too low and that after these changes the fuel consumption is now 15 20 lower e Woooohoooo 55mpg How many miles were on the bike carbs when you did your rebuild 28 5k miles What year classic 1999 What kind of environment has the bike been stored in when not in use Outside but covered in the mild Seattle climate i e never super hot nor frigid cold How often did you or someone ride it At least weekly except for last winter when put it up for 12 weeks using proper storage protocols drain carbs tank etc all kinds of use city commute touring some dirt roads The precipitous decline in mpg occurred while on my 13k mile trip this summer Normd 473 Here so far is the sequence of events March 02 removed Ron Woods muffler replaced with stock No other mods Bike runs rich but otherwise well July 02 inspected carbs for presence of DynoJet kit There was one dropped the needle on that kit to see if it would lean out my mixture It did but not enough Aug 02 replaced all DynoJet bits and bobs with stock carb parts Also replaced K amp N air filter with stock
38. caused some of the problems we ve heard about plan to periodically check this tube to make sure it s clear and free breathing http faq f650 com FAQS Canisterectomy htm 5 of 6 18 02 2007 12 30 27 The Canisterectomy FAQ Bob 550 Olympia WA e We have no cannisters in Canada and the two tubes come together at a T junction on the left hand side of the tank bracket just under the seat or at least they do on my bike So all you have to do is make one disconnection at the T Just to be sure you don t have a cannister look for a big ugly black thing at the back of the bike near your coolant reservoir It looks about the size and shape of a small can of baked beans Sean 1015 Ottawa Canada Wet weather problems Since they re 99 models checking the vacuum lines from the carbs would be my first recommendation Mine also a 99 were reversed from the factory Simply connecting the high vacuum one nearer the engine to the airbox and the low vacuum one furthest from the engine to the cannister made it run much better left my cannister on for the first 16000 miles with no problems even in the rain At the 18000 service in my own garage it finally fell off Bob 550 Olympia WA Wet weather problems Side stand kill switch Canisterectomy and Vacuum lines Has anyone fitted a Container where the Canister WAS Ron 304 from Texas has this set up on his bike The PVC pipe mounts where the canister was He used a cap on on
39. chop test after a longish run would seem to be the order of the day to see if the choke is set to start even when the lever is http faq f650 com FAQS CarbMiscFAQ htm 7 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ set to off Andy Leeds UK 982 e fire it up and ride off immediately It will not idle correctly without choke _ever_ if do not ride it But if ride off and kill choke ASAP it will idle fine within moments say at the next stop light kinda weird but that s how it works NormJ 473 Seattle e The phenomenon you see is that the lever actually operates an enrichener not a choke which is why do not use the terms open and closed as most people get confused Your problem is likely that your idle is adjusted incorrectly And it s too low Before you do ANY other adjustments get the bike fully warmed up to regular running temperature with a good ride with reasonably fresh gasoline Then adjust the idle to 1400 rpm real easy to do takes 10 seconds Run it a while and confirm that when fully hot your idle is stable around 1400 rpm Yes it s a bit fast but that s the way it was designed Now you can see how your cold idle and choke works the next time you ride Do NOT adjust the idle cold while operating the choke lever Vary the choke lever instead This will likely solve your idle problem if nothing else is wrong with the engine Todd 389 e The choke changes the air to fuel ratio by either supplyi
40. dealing with the wind noise generated at 30 mph It almost sounds similar to the clicking clacking noise made by a standard computer keyboard or somewhat like a small plastic object being shaken gently inside of a 35mm film canister The noise doesn t seem to be coming from anything in the suspension as uneven road surfaces potholes etc don t seem to affect it timagination o Feedback 1 Don t know how the Dakar is set up in this regard but check your headlight adjustment screw On my 03 CS had a rattle up front and it turned out that the adjusting http faq f650 com FAQS StrangeNoises htm 15 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ mechanism had failed Zeke BBG 26 o Feedback 2 get the cluster rattle from my garage door opener as well as the windshield mounts ceebaileys The windshield noise comes and goes and the GD opener goes in the pocket on long hauls gsatlanta o Feedback 3 ed Similar rattle So the first time took the entire front of the bike apart searched for the culprit found nothing and put it all back together Rattle gone Sa weet Then it started happening again took it all back apart again but this time put black weather stripping in places where assume the rattling could have been originating Once got it all weather stripped put it all back together again This was about 3000 miles ago and no more rattle billmallin 1629 o Feedback 4 have a similar rattle It is
41. diaphragm was just fine and everything looked in order Then tried to refit the diaphragm and its top cover back in place No go After an hour of failed attempts finally smeared a little engine oil on the edge of the diaphragm thinking that may help it slip into place It did and was finally able to close everything up What is the Effect of Dropping the Needles Flash 412 December 01 Effect of Dropping the Needles Flash vs Matthew Flash CV carbs sometimes called Constant Velocity or sometimes called Constant Vacuum use the pressure differential between the two sides of a diaphragm to raise the slide The needle is attached to the slide By removing the snorkle you lower the effort required by the motor side to raise the slide You have effectively raised the outside air pressure by removing the snorkle In other words for a given manifold vacuum the slide now rises higher than it did before you removed the snorkle This means that the needle is allowing more fuel in for the same throttle plate opening than it was before To counteract this effect you need to drop the needle physically one notch You do this by putting the clip in the next higher notch physically Matthew CV carbs operate of the velocity of the air passing through them Removing the snorkel or opening up an airbox will slow the speed the slide raises It will have no effect on the distance the slide rises Can anyone enlighten us on Practical Ob
42. e Pet Cocks revisited always turn off the petcock when parking the bike Don t want the weight of the fuel on my float pins wearing out the rubber nipples that s nipples not niggles Also the petcock is getting easier to turn but then that may be because it s warm out Very warm Shank Aftermarket Fuel Filter FAQ by Steve Johnson F6501 updated by Kristian 562 In line Fuel Filter Fuel Filter Vapor lock What about Clamps to re attach the Hoses In line Fuel Filter This filter is similar to Prime Line 7 02357 and available at O Reilly Auto Parts One very necessary item that every bike should have is an external fuel filter A see thru type is the best The rider can see what kind of garbage is collected before it gets to the carb Easy to install and cheap it is the best insurance around Shut off the gas cut a short section out of the line and install the filter Be sure to check for correct flow direction usually indicated by an arrow on the fuel filter See photo Here s a close up of a couple of Aftermarket Fuel Filters be http faq f650 com FAQS Gas_Tank_Removal Replacement htm 8 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank Note the following when buying installing a fuel filter There is already an inline fuel filter in the T Piece connector between the Carbs Refer the Carb Cleaning FAQ for Details of where it s at e ALOT of people of have had problems with vapour lock w
43. even with the 15 49 sprog set Definitely before a stall dlearl 476 o Solution 3 Take a look at wheel bearings and the rear chain sprocket carrier bearing s They can definitely make crunch crunch noises probably louder crunches the more weight that is on them You DON T want to wait until they fail completely Noise 33 hit the ignition and all the lights dimmed but it did try to turn over almost started only had the starter button depressed for about 5 10 seconds which is usually plenty of time for it to fire Released the button gave it a couple of seconds and tried again and got nothing at all when pushed the starter Also noticed that there was a buzzing coming from the front of the bike Turned the key off no buzzing turn it back on without touching anything and it is back Push the starter button and the buzzing stops and the lights dim ed battery on recharger for 10hours If turn the heated grips on the buzzing goes away as well though can see the lights dim a bit This seems similar to Noise 8 though the noise goes away when actually try to start it The noise is coming from in front of and below the battery apostate 1618 o Answer 1 If your battery is carked this can cause all sorts of possible things including buzzing noises etc from relays First of all you must eliminate the battery problem jack o Answer 2 Well off to buy a new battery Tested battery with key off 12V no problem With key on dr
44. factory recommended modifications if desired The FXDX that is the test bike for this review has essentially a Stage IIl engine with the usual SE air cleaner and breather kit SE 1550cc big bore cylinders and SE high compression cast pistons 10 25 1 But there are some significant differences The SE 44mm CV carb and intake manifold were substituted for the SE Mikuni 42mm flat slide carb usually recommended This was done primarily to enhance high altitude performance since it was envisioned that this bike would be used for occasional trips across the Cascade and Rocky Mountains CV carbs tend to be self compensating at high altitudes the flat slide carb does not Somewhat more radical Andrews TW 50 cams specifically designed for high compression Harley motors were chosen on the advice of Hein Vandenberg owner of HVR Dyno Service in Union Bay B C The TW 50 cams allow use of the stock pushrods which Hein also recommended The stock pushrods are both lighter and stronger than the SE adjustable pushrods required to install the SE 203 cams used in H D s Stage II and Stage III engines Harley Davidson 80313 99 black baloney cut slip fit mufflers with the baffles http www chuckhawks com super_glide_sport htm 8 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT completely removed had previously been installed on the test bike It was found that these mufflers produced slightly higher horsepower and torque figures on the
45. float mount The left one slides over and seats on a brass tube and the end of the float mount has a restrictor The tube am referring to is connected to the choke the left float o ring side slides over this tube noted that the left float has a restrictor built into it therefore there is a different float assembly for left and right carbs am not too familiar with carbs dealt mostly with FI On the right carb there is a drilling with a hole for a tube but compressed air will not flow through it I am assuming it is a blind and not used wonder why there is a restrictor on the left float and not on the right unless the float assemblies were switched at some point am baffled at this point the only reason got into this mess was because Dyno jet sold me a jet kit that does not work on the 1998 F650 continuously fouled plugs and called and they told me this kit was not for the 1998 So went back to stock And could not adjust the right carb Bottomed out or 5 turns out no difference So then decided to look at float height This is when discovered these differences Again thanks to all JAMES The parts in my kit are stock needles 5 clip settings 5E94 stock main jets 132 5 Dyno stage Il jets 138 a set of springs anyone know how to tell stock springs from DynoJet springs Refer the Jet Kit FAQ Two black rubber plugs Idle Mix Screw covers Two small tiny needle jet washers So this is my plan Buy a packing kit o rings pull c
46. gasket between the manifold and header without having to take the header completely off then clamp it down not the best solution but as said it worked when you don t http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 6 of 8 18 02 2007 12 30 55 Exhaust Gasket Replacement FAQ have a lot of options you make do Mark 403 What about the GS Exhaust Gasket Unlike the Classic the GS has only ONE Large Exhaust Gasket At the present time there is no procedure to follow for its replacement but is likely to be very similar to the Classic Meanwhile here is some feedback found out the exhaust manifold on my F650GS was loose caused by two loose exhaust pipe nuts tried to fasten the nuts but decided to take everything off to see if the gasket was all right The gasket is are the two thin metal parts right Now the strange part measured the stud length with the nuts fastened and found out the space is to big to tighten the manifold The end of the studs were damaged by the cap nuts because they were turned on the studs to far The studs are not loose have driven the bike 6000mls now never had any trouble Recently the dealer installed a Remus exhaust and 1000mls later this Does anyone have any experience with this Maarten What about those Rusty Exhaust Nuts Studs by Flash et al Q have a F650ST and am concerned at the state of the exhaust studs that hold the exhaust to the cylinder head They are look
47. got too much fresh air the bike would run too lean When the carb vacuum hoses are reversed there is too much vacuum from the carb into the canister Instead of very gently sucking gas fumes that have collected in the charcoal canister too much air is sucked thru the canister and up the drain This can cause problems in wet weather when the canister drain hose near the right footpeg sucks up water into the carbs Then canister can fill with water or dirt and clog or eventually suck water into the carb or clog one of the smaller vacuum tubes So instead of getting too much fresh air it sucks on the tank creating a vacuum which makes the bike act like it is out of gas What to do if your Canister mysteriously falls off i You take the little hose from the carb and plug it up The best place is to cap or plug the rear port on the carb One http faq f650 com FAQS Canisterectomy htm 2 of 6 18 02 2007 12 30 27 The Canisterectomy FAQ handy place is the junction on top of the airbox just behind the tank under the seat You take the long hose from the tank to the canister and reroute it to the place where the hose that used to go from the canister to the footpeg went In this configuration the carb doesn t suck on the inside of your tank And the tank can breathe fresh air if it wants to have a canister in a box in my garage NOTE In the event that the canister has fallen off the rear carb port must be capped or it will a
48. great sound They are also completely illegal for street use take that EPA environmental wacko running dogs Instruments include a soeedometer odometer trip odometer tachometer and fuel gauge There are indicator lights for in order from left to right left turn high beam neutral oil circulation the lack of and right turn Simultaneously depressing and holding down the right and left turn signal buttons activates the 4 way hazard flasher Nice features shared with other Dyna models include an attractive teardrop gas tank with a vacuum operated fuel supply valve rubber mounted engine to isolate vibration electronic ignition self canceling turn signals halogen headlight maintenance free battery and belt final drive There is also a spring loaded throttle friction adjustment screw manual cruise control fork lock Harley s superbly shaped clutch and brake levers and a side stand that locks in the down position when the weight of the bike is on it The latter is a good thing as no center stand is http www chuckhawks com super_glide_sport htm 2 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT provided The ignition switch is located on the right side just below the seat between the battery and the upper rear shock mount This location takes some getting used to and is almost impossible to reach with a passenger on the bike The following specifications are taken from the 2000 Harley Davidson Dyna Own
49. hence the frame so it stays on or use bit of bluetack to temporarily hold it in place Here s a picture with all three parts not yet in the Carb Body on it s side of the Float Valve in the Float Valve Seat and attached to the Tang on the Float Frame Checking the Float Height Checking the float height is like a mixture between Art Black Magic Science Witchcraft and Acupuncture i e It s a really really hard measurement to make Even more so without the right tools Factory s Site gives a fairly good description of the measurement plus they sell a Special Tool also shown on that site Like said earlier the tool is a neat idea but the workmanship for the money is terrible Read their instructions first then read on here What they do NOT mention at least on that page is that the Float Bowl clamps the frame down and holds it in position You might have wondered how it worked flopping around in there to the Carb Body It does this by clamping the two little plastic tabs that can be seen on the side of the Frame in the front of this picture Float Tab On You WILL need to hold these two down also firmly while making the measurement Use a Bulldog clip a Wife a Girlfriend a Son a Dog whatever It must be clamped down to make the measurement Make sure the Stalk with the O Ring is also firmly in place Now what you need to do is tilt the carbs so the floats swing out far enough that they do NOT compress the Float Valve at all
50. interesting all the same This letter is the culmination of many hours of trouble and tinkering with Ellen s 1100G s carbs Riding my new 1200 Bandit back to back with her 1100G really highlighted the gross carb troubles her bike had with the original carbos You may have read my earlier fixes on the Worship page little did know how wrong actually was My fixes were more of a band aid that made the bike run better but didn t cure the root cause A letter sent in to the November 2000 issue of Cycle World magazine s Service section by Sasha Shapiro of New Paltz New York describing the exact symptoms had experienced prompted me to finally get hot on the problem must note that Cycle World s response was way off target will be sending them a letter regarding the true cause of her troubles contacted her and she eventually replaced her carbs curing the bike finally got fed up enough to do some serious research and found a letter on the Web from a guy in England that said he had noted emulsion tube wear on his 1200 Bandit and after replacing them it cured his low speed mixture problem reasoned http faq f650 com FAQS CarbMiscFAQ htm 16 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ that with 56K on our bike we must have this problem as well rushed out and bought new needles emulsion tubes and slides confident that had solved the problem at last Wrong The bike ran no differently which prompt
51. it supposed to move like this If pull the choke back it runs fine again It can be a pain staling like that Is this indicative of another problem do know you are supposed to let it warm up a bit before opening up but it seems to be warming up slower Is that a symptom of some other problem and if so what Thanks for all your help A No this is not normal When the choke is off it is supposed to stay off It should have a spring near the choke mechanism on the carbs that must be overcome to activate the choke It this spring missing The reverse problem is more typical with the choke refusing to stay on because the tension is too loose at the choke lever on the handlebar Usually it is not too hard to increase the friction of the plastic choke lever by placing some heavy grease or rubber cement between the choke lever and the adjacent housing If that doesn t work try using a small plastic shim between the choke lever ring and the mirror clutch handle mount to provide some additional drag on the ring Looking at my bike don t believe that there is a screw http fag f650 com FAQS CarbMiscFAQ htm 6 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ to tighten would just loosen the mirror lever mount and move it over closer to the choke ring and see if you can put a little more friction on the ring don t have an answer about your idle just turn it up to 1400 rpm and see what happens Richard 230 Pacifica CA thoug
52. jets 132 5 Dyno stage Il jets 138 a set of springs anyone know how to tell stock springs from DynoJet springs Refer the Jet Kit FAQ Two black rubber plugs Idle Mix Screw covers Two small tiny needle jet washers So this is my plan Buy a packing kit o rings pull carbs change main jets to stock 132 5 change to stock needles four slots down from the top anyone think should use a washer on each clip switch to stock springs again not sure how to tell the difference check replace all rubber and double check diaphragm Set the idle mixture screw to stock setting 3 5 turns out from lightly seated Double check floats and float heights Now for the big question When my lovely wife and purchased her 97 F650 which has the jet kit was really impressed with the 5000 rpm and up power and throttle response Shortly after that bought a 99 F650 without a jet kit but with a 15 tooth sprocket Her bike has a noticeable amount of power above 5 grand rpm s It also lurches and bucks in lower RPM s she is also a noob but member A6501188 Is that the trade off power for drivability If that is the case then back to stock and the jet kit can gather dust Is the factory pro kit any better or is it a lot of playing around and compromise between power vs drivability Both of our bikes have the snorkel yet should we pull those XtreemLEE Slide Barrel Wear Morgan Seim has a solution for the G s carb crappiness Not for the F650 but
53. leak gunk into the carb by reacting with the petrol and give a proper seal and or block the start jet The engine runs lean and hot You then retune and all is well until the main jets block and you hit them with carb cleaner The choke jet seal de gunks and its sooty plugs time again At this point you sell the bike and buy one with FI if you have any sense The F carb doesn t have this exact problem because the rubber bits are petrol proof but am wondering if something similar is possible guess you ve already checked the choke cable for tightness Andy Leeds UK 982 e Less air in mixture than usual This results in the engine running a little hotter which is never a great thing normally ride to the second stop street with my choke on about 2 3 Classic By this stage the engine is warm enough to tick over smoothly by itself do however frequently check my choke turn signal and low beam switches while ride just a habit really Bernard http faq f650 com FAQS CarbMiscFAQ htm 8 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ Make sure the choke is off check at the carb not the bar lever are you sure your choke goes completely off With the choke circuit on these carbs it usually runs really bad with a partially on choke I ve seen the choke cable get hung up halfway which leads to no running stalling no idle with choke seemingly off but will run fine but horribly rich with it full on Never leave
54. little rough and get poor fuel mileage It ll be a blast I m taking my new DAKAR to Colorado next week I m hoping Fall River Pass is open so can see how this fancy fuel injection works at 12 000 feet guzzimike e I have ridden my 01 GS two up around the same areas you are talking about and was fine Sure there was power loss but like it was said before it is not a race Besides power loss means slower speeds more time to take in the amazing scenery Have fun and ride safe facito 2001 F650GSA Las Vegas Nevada Do I need to Synchronise the Carbs Randy 748 Synchronization is possible with anything more than one carb Two as in F650 s case can be synched and may not be noticeable to rider other than less HP am assuming a bit here because the 650 carbs may have no adjustment ability I ve not looked individually but my experience with other bikes has always been that the individual carbs can be adjusted separately Usually a screw on the actuating bar for each carb Factory set these are rarely off but possible Most Japanese bikes with multiple carbs have single cable bar actuating all four as unit and they are synch d as a regular service item Single cylinder has no input here except acting as a single the input to rider will be less obvious in rough running vs less HP The domes on F650 carbs do have access ports Two 33mm throats feed the 650 and less than two equally opened butterflies will mean less HP imagine the set
55. mine 99 Classic on choke for more than a few minutes if it s above 10 C 50 F all need is the choke to start after starting it ll run fine with no choke totally stock cept for silly K amp N Shank NYC USA Turned up the idle and this seemed to fix the problem The whole bike seems to run a bit better but it is probably just my imagination Don Apart from theoretical problems has anyone noticed actual ill effects on the classic F650 from either driving with the choke partially open for miles forgetting to shut if off promptly or not closing the fuel petcock after riding I m not guilty of the second but am the first now and then Think there s enough extra fuel on the cylinder walls to effect ring lubrication Johnny 862 Don t know about theoretical but gas mileage is a little worse when you ride with the choke on but not much that know from experience have never noticed any other problems never fouled a spark plug think it s a throttle advance not an actual choke i e air restriction never shut off the fuel except when transporting the bike on a trailer Haven t noticed any ill effects from that either mark 403 The small amount of extra fuel when the throttle is open is not likely to cause a ring oiling problem However it might shorten the life of the spark plugs and the catalytic converter if you still have the stock muffler through fouling over a long period of time Richard 230 Pacifica CA
56. not accustomed to it but the frequency is low and not uncomfortable As you accelerate the vibration diminishes The rubber engine mounts and other rubber mounted parts and the Sport s chassis tuning effectively isolates the rider from intrusive engine vibration At cruising speed the bike is surprisingly smooth less tiring than many of the multi cylinder bikes have ridden The weight and steering geometry of the FXDX lets its rider ignore wind blast from trucks and crosswinds that would upset lesser bikes The supple suspension soaks up road irregularities with ease It takes a substantial pothole to get the rider s attention The engine s monster torque allows you to pass slower vehicles with a twist of the wrist throw in a downshift and it s like they went into reverse The test bike s modified V twin engine has quite a bit more roll on acceleration at cruising speed than many sport bikes especially fours You must be careful not to run them down from behind when passing cars if you are riding in a mixed group Handling The Super Glide Sport is one nice handling motorcycle Static stability is good it will run straight and true hands off The tubeless H D Dunlop 591 sport compound tires do a good job of sticking to the road under hard cornering or breaking forces The Sport s good manners and ability to attack corners belies its size and weight For reasons don t fully understand it feels like a much lighter and shorter motorcyc
57. not even that little piston at the top talked about earlier Then slowly and gently rotate the carb body back until the Float JUST touches but DOES NOT compress that little piston on the Float Valve Try it a couple of times until you get the feel of it So now holding the Carb in this rather awkward position with your Special Tool or your ruler or your custom made gizmo if you made one measure from the Carb Gasket Surface i e where the Float Bowl Gasket makes contact with the Carb Main Body to the TOP of the HIGHEST Float With the Tool SET at the correct measurement the tool should just graze the top of the float If it clears it by miles your FUEL LEVELS at which the Fuel gets cut off will be too high and may be the reason for the rich sooty residue on your Spark Plugs Remember you are measuring the FLOATS upside down don t get confused between FLOAT HEIGHTS and FUEL LEVELS The HIGHER the Float Height i e what you measure the LOWER the FUEL LEVEL at Fuel cut off To RAISE the Float Heights Raise the Fuel LEVEL you need to bend the little Metal Tang shown in this Picture Float Tab On DOWN Do this by hand using one finger a small amount at a time Conversely if the first measurement you make forces the Float Down it is too high i e the Fuel gets cut off too quickly Lean and you will need to need the Metal Tang UP Remember small movements when bending the Tang Repeat until the measurement is right Keep the beers on i
58. o Feedback 2 IMHO unless your bike has 60 000 plus miles AND is running crappy it http faq f650 com FAQS StrangeNoises htm 17 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ think you re wasting time and money replacing your timing chain Your decompression release is SUPPOSED to make noise below 1000 RPM dlearl 476 o Feedback 3 I d pull the valve cover rotate the engine until the DR has a little play and wiggle it If it s EXTREMELY loose I d worry about it if it isn t wouldn t With your mileage seriously doubt there s anything seriously wrong with your engine unless it s been horribly abused by a previous owner dlearl 476 o Answer None provided Noise 47 When turning off my 2002 GS hear a moderately pitched MP clunk sound It sounds like its coming from the valve cylinder area Its not as high as a ping or as low as the clunk you get when you shift from Neutral into 1st Whatever it is it s probably not healthy and the bike would be better off without it can sometimes get rid of the MP clunk sound by turning the bike off in Neutral or with the clutch pulled in but there s not a consistent correlation checked the Strange Noise FAQ and something in me says that it has to do with the Compression Releaser Either that or its something I m doing meribona o Feedback 1 Hmm might be what mine did assumed it was something to do with the starter If so its nothing to worry about echo o Feedbac
59. of the slide is the jet needle The jet needle is a tapered needle that moves in and out of the needle jet Normally both the needle jet and jet needle can be changed Needle jets have different size holes in them Jet needles have different lengths and tapers Usually they are suspended from the slide in a manner that allows one to change how far they hang down by moving a clip to a different notch You can imagine a tapered needle withdrawing from a hole the further out it is the more surface area of the hole is available to flow fuel This circuit works up to about 3 4 throttle when the jet needle is completely withdrawn from the needle jet At that point the limiting factor becomes the main jet The main jet is used at wide full open WFO throttle How much fuel does the engine NEED when it is breathing as fast as it can That is THE limiting factor for your motor for any given combination of exhaust system Airbox filter setup temperature altitude or barometric pressure http fag f650 com FAQS CarbMiscFAQ htm 2 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ Tuners tune first to get the bike to start and run idle circuit then make power on the mains THEN be streetable between idle and WFO HOW to go about tuning is a different subject maybe for a different day Many whole books have been written on the subject PULLING THE CARBS by Flash 412 October 01 m e 12 13 14 15 oS ee ee
60. picture of a 1995 with the holes ALREADY open from the factory Factory Airbox Q What are the Carb Parts Numbers A Steve 417 supplied these Thanks Steve 13112343398 Valve Assembly 13112343379 Diaphragm 13112343397 Needle 13112343395 Venturi Jet 13112343318 Idle Jet 13112343412 O ring idle mixture 13112343404 Bracket Float with O ring Here is the OEM Parts List FCarbParts1 FCarbPartsList1 FCarbParts2 FCarbPartsList2 http faq f650 com FAQS Carb_Clean htm 4 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ e FCarbParts3 FCarbPartsList2 Refer also the Carb Alternatives Q Are there any Websites to tell me how to tune my Carb A Well the best thing you can do if you have a Stock Setup or even Stock Carb with an aftermarket exhaust is to Check for and Replace all the worn parts discussed above and set the Carburettor Floats Idle Screw Clip Location to the specified Stock Settings Otherwise e Factory s is pretty good Factory Pro s CV Tuning FAQ Their approach is to tune the Carburettor from the Main Jet size and work DOWN through the Needle Clip Setting Float Bowl Height SOMETIMES Pilot jet and then the Idle Mixture Screw e Sudco have a Manual called the Sudco Mikuni Manual which cannot give you because it is copyrighted however they work UP from the Idle Mixture Screw Pilot Jet Needle Clip Settings Float Bowl Height to the Main Jet size and claim that each of the Carburettor
61. power and a richer mixture A K bike gets better mileage above 4 000 feet because the injection system switches to a leaner program to compensate for the altitude The vacuum carbs can adjust to an extent but not anywhere near as well Going from High to Low Altitude Possible Symptoms You may experience popping on throttle slowdowns i e popping minor backfiring during compression braking deceleration BUT check your carbs are adjusted correctly not worn and also check the Backfiring FAQ Exhaust Gasket Replacement FAQ and Strange Noises FAQ So do need to adjust it The idle mixture screws are not self compensating as they as well as the throttle cutaway are not affected by the constant vacuum feature of the carbs They need to be manually adjusted Inthe Manual there are no instructions related to re jetting or adjusting the high speed mixture http fag f650 com FAQS CarbMiscFAQ htm 11 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ only adjustments are for idle mixture and idle speed e Most people have no difficulty changing altitude Re examine the Backfiring FAQ FIRST for minor adjustment of your idle mix screws or possibly a leaking exhaust gasket If you fixed the Pukin Petrol Syndrome and you were leaking gas before you were running rich and likely would not have the lean idle mixture backfiring By fixing that rich condition you have leaned out the fuel mixture and now have the min
62. re condition my Carburettor General FAQ s about the F650 Carbs So how do I get the Carb Out Enough of the Preamble How do I actually Clean amp Replace Carb Parts How Do I Replace the Carbs Inline Filter Carburettor LINKS Checking the Float Height with the Carbs ON the bike Opinions On Carb Cleaning Particular Parts Replacement Detailed Feedback on Carb Reconditioning Identifying a Float Valve Problem Looking for the OEM Inline Filter or the Aftermarket Fuel Filter Please Note that this FAQ only deals with the resetting of your Carb to the STOCK configuration Re Jetting Needle Changes and Modifying Float Heights are covered to some extent in the Exhaust Rejetting Spreadsheet Have a look there if this is the kind of information you need Nor is this a treatise on how a Carb Works There are lots of references about that on the Web will try and add some links think are worthwhile references at a later date as come across them Perhaps you might like to suggest some too Dynojet has pretty good simple one here Dynojet s Carb Theory need to refine some parts of the pictures and circle some specific parts of the photos and need a few additional pictures Write to me and tell me what you think would make it better Refer the Carbs Misc FAQ for other information on Carbs e Refer also the General Performance Modifications Guidelines amp Tips Dynojet Settings Snorkel
63. rides The somewhat more expensive Sundowner touring seat mentioned above is also good The low sissy bar and sideplate kit above with a standard size backrest pad 52545 84 matches the pillow look seat and sport rack above make a convenient place to mount a nylon Brief Sac briefcase 94797 00 or Overnight Bag 94719 98 Both bags are also available in leather H D s Low Profile detachable compact smoked windshield 581 12 96 combines adequate protection and good visibility It can be removed or replaced in seconds Dyna Slant style leather saddlebags are available with several trim options All Slant style leather saddlebags accept easily removable water resistant bag liners that make it easy to take whatever is inside with you Other useful accessories include an engine guard 49007 90 to protect your bike in case of a low speed tip over Halogen fog lights 68913 98 attach to the engine guard and can be used to increase conspicuity in daytime as well as augment nighttime lighting A Dyna fan kit 91551 00 will Keep your V twin cool when you are stuck in traffic jams It reportedly lowers the engine oil temperature by over 20 degrees Sporting accessories While the stock seat would be an adequate sport seat for a rider who found it comfortable not many do Most riders will be more comfortable and better positioned on the Dyna Sport Seat 52999 99 Compared to the stock seat this seat offers the rider a better
64. seem to know from other bikes Marty 426 did note he went back to stock height his floats WERE going too HIGH to shut off gt his must have been about 12 too guess THAT makes sense if the tang spring weakens due to float pressure or the Plastic cage wobbles about Don t forget when you measure it to HOLD THE PLASTIC TAB on the CAGE down so it s firmly fixed If you replace the O rings on the cage seat it properly first before re measure No cats were harmed while rebuilding my carbs 3 My Description vs Factory Website Description of the Float Bowl Measurement This FAQ Says Now what you need to do is tilt the carbs so the floats swing out far enough that they do NOT compress the Float Valve at all not even that little piston at the top talked about earlier Then slowly and gently rotate the carb body back until the Float JUST touches but DOES NOT compress that little piston on the Float Valve Factory says 1 Tilt the carbs so that the floats just flop over towards and into the carb body 2 Tilt just enough to touch and close the float the float valve but 3 Do NOT compress the float valve spring when measuring 4 With the metal adjustment tang on the float just touching but not compressing the float valve spring place the Setting Gauge over the highest part of the float If there is a gasket or o ring stuck to the carb body remove it while measuring The Factory Website and the FAQ actually say exactly the s
65. snagged the spring loaded linkage at the carb body moved the connector back and away from the carb and all was well until decided to check the diaphragms that control the needles in the carbs took the top off the right carb first and checked things out The rubber diaphragm was just fine and everything looked in order Then tried to refit the diaphragm and its top cover back in place No go After an hour of failed attempts finally smeared a little engine oil on the edge of the diaphragm thinking that may help it slip into place It did and was finally able to close everything up What is the Effect of Dropping the Needles Flash 412 December 01 Effect of Dropping the Needles Flash vs Matthew Flash CV carbs sometimes called Constant Velocity or sometimes called Constant Vacuum use the pressure differential between the two sides of a diaphragm to raise the slide The needle is attached to the slide By removing the snorkle you lower the effort required by the motor side to raise the slide You have effectively raised the outside air pressure by removing the snorkle In other words for a given manifold vacuum the slide now rises higher than it did before you removed the snorkle This means that the needle is allowing more fuel in for the same throttle plate opening than it was before To counteract this effect you need to drop the needle physically one notch You do this by putting the clip in the next higher
66. the cap Todd 389 e Pull the tank and follow the hoses find the right one and give er a big blow OR find where ya pinched the tube last time the tank was off Mike That s why there are drain screws at the bottoms of the float bowls to let out the water that migrates down there Flash 412 CO http faq f650 com FAQS Gas_Tank_Removal Replacement htm 12 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank Gas Cap Vent Cleaning by Flash 412 CO Q assume have to take it apart to clean it Are small pieces and springs or something going to come flying out Fairly recently somebody on the site said the check valves in the cap can get plugged up In the FAQ it says If the canister is gone then the hole in the vent cap may be clogged with dirt or some words to that effect A The gas tank vents via a hose not through the cap Revisit the Canisterectomy FAQ The cap lets pressure past the seal between the cap and the inside of the inner tank to the area between the cap and the outside of the inner tank You are not looking for a hole that goes THROUGH the cap to the outside air You re looking for the action of the spring loaded portion of the cap that contacts the inner tank in order to vent properly The spring loaded thing need withdraw only slightly to allow it to burp to the enclosed area where the hose hole resides I m not even sure that there is anything to clean or SEE associated with gas tank venting Yea
67. the carbs out at some later date to reinstall the clamp Meanwhile will inspect the connection for a while used 6mm Gates PVC fuel line This MAY allow you to remove the OEM In line Fuel Filter Maybe If anyone can confirm this great The inline fuel filter is in the brown T Piece connector between the Carbs Refer the Carb Cleaning FAQ for more Details Fuel Lines e Believe it or not the BEST fuel line is BMW fuel line from the dealer It is rubber covered with cloth weave Some dealers sell it by the meter some by the yard Some can make the conversion some cannot The hose that came on the bike was Italian Flash 412 had nothing but problems with the fabric covered line don t know exactly what ate it up but it just started cracking and leaking The hose that came on the bike was not the fabric covered line but a single walled line with no internal reinforcement This stuff just got really hard and inflexible The Gates line is double walled with a woven fabric reinforcement sandwiched in it Beefy Chris in Santa Cruz CA e You can usually buy clear fuel line Sometimes in designer colors or black at the nearest Jap http faq f650 com FAQS CarbMiscFAQ htm 22 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ bike dealer 6mm is closest to US equivalent 1 4 although 5 16 is also available had some of the old BMW cloth covered stuff in stock it works fine so far Marty 436 Chica
68. the other canister hoses Case 2 If you DIDN T REMOVE the Canister but are Routing the Vacuum Lines you should NOT remove the orifice as Note Even with the vacuum lines correctly installed a missing orifice would probably cause excess vacuum in the fuel tank the orifice is meant to limit the vacuum in the system Installation without it would likely cause excess vacuum in the fuel tank and subsequent fuel flow problems vapor lock If you re considering venting under the seat the only problem with venting high under the seat instead of the footpeg if you ever lay the bike down or slightly upside down or if you overfill the tank there s a possibility that raw gas will discharge from the end of that hose There s a good reason why the emissions canister drain was originally located at the footpeg Canister Feedback My canister created a vacuum in my tank from the first day that owned my bike My dealer then retrofitted my tank vacuum line with a new and improved restrictor which did nothing to improve the venting of my tank When removed my canister plugged the line to the carb and removed the restrictor that found on the vent line near the rear of the tank Now the only restrictor that have on my tank vent line is a small gas filter that installed where the restrictor was located which is attached to a hose that routed to the rear of the bike and stuck through a hole in the black plastic cover near the former locati
69. this piece would be designed for this The Symptoms were e Increased backfiring e A Loss of power e A Louder Exhaust Note Part Number The BMW part number is 18 11 2345 037 cost 10 e The gasket is asymmetric and the rolled edge should be inserted facing backward i e toward the rear of the bike e The new gasket looks like a section of tube made by rolling up a piece of metallic paper with one section slightly biased The Gasket Dimensions are External diameter 35 mm Internal diameter 30mm e Thickness 2 5 mm Length 20 mm Replacement http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 5 of 8 18 02 2007 12 30 55 Exhaust Gasket Replacement FAQ Removal of the old Gasket is fairly easy Take off both side fairing panels the long pieces e Unbolt the Gasket Connection Allen Key e Unbolt the U pipe at the Head These 13mm nuts come undone pretty easily e The interior of the exhaust was dark leaving a thin black powder on the finger Remove the remaining parts of the old gasket Insert the New Gasket e You may need to use pliers to widen a bit of the end of the external exhaust pipe which is factory notched because the clamp narrows it and the new gasket may not fit in e Put the U pipe in place and re fasten the two nuts at the Head Torque the collector bolt As advised by the mechanic left about 2 mm from maximum tightening of the clamp Testing Start the engine
70. to get to the plastic nut Again please do NOT over tighten the Nut It s just Plastic The Throttle cable can be reconnected after you get the Carbs back in but you can do it now to save yourself the trouble Affix the Wire Head to the Throttle Plate then twist the throttle Plate or pull the wire until there is enough slack to get the bend back into its mounting Work the Carbs down into the cavity again pulling back the softer Airbox side rubbers to fit the Engine Side first After you get the Carb ports mounted into the Engine Intake Manifold Rubbers They are stiffer and relatively easy the Airbox side rubbers will probably still be all squished up Try and free the bottom first and get them fitted to the Carb then with a finger or BLUNT instrument e g Flash notes a Tyre Iron works well working from the sides towards the top stretch the rubbers over the Airbox Side Intake Ports These Ports are not that wide only about the width of the Steel Hose Clamps so after you get them in place pull the whole assembly Horizontally BACK toward the Airbox so you know they are as far on as they can go THEN do up both sets of clamps lining the clamp heads up so they are easy to access with a screwdriver Replace the Tank Seating Plate making sure the choke and throttle cables drape OVER the top of it http faq f650 com FAQS Carb_Clean htm 17 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ and they are free and not caught anywhere
71. town in desperate haste Finally tried the Yamaha shop With the short section of exhaust my hand the wonderful woman behind the counter came to my rescue The 20 part was just what needed Yamaha 4DN 14714 01 also indicated 863066 http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 8 of 8 18 02 2007 12 30 55 The Very Strange Noises FAQ by Kristian 562 20 10 01 Please read the Disclaimer before attempting any work in this FAQ Last Updated 18 Feb 2007 by Winter 1935 My Bike seems to make a Strange Noise How can fix it Do you have a short list to help me So what does it sound like and where does it come from list of noises e Other Comments Hints to help you find the noise What Should Mention in the Forums So we can help you e What is the Mechanics Stethoscope For other helpful FAQs Hard Starting Poor Running FAQ Troubleshooting FAQ My Bike seems to make a Strange Noise How can I fix it There a number of common sources of Noise on the F650 If you re looking for Vibrations see this FAQ Do you have a short list to guide me in the right direction The table below should help guide you to your noise However if you can not find it based on the table read through all the noises http faq f650 com FAQS StrangeNoises htm 1 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ Noise 5 Can be rev dependant Buzzing or R
72. tube appears to be removable by simply pulling it free but it is not necessary for cleaning it well http faq f650 com FAQS Gas_Tank_Removal Replacement htm 6 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank J If you are having trouble with the lever being sticky or stubborn CAREFULLY remove the two small screws holding the plate and lever in place BEWARE the petcock body is very soft Several inmates have ruined their petcocks by stripping the metal when disassembling or screwing the plate back on Clean and reassemble as per the Sticky Petcock FAQ Gently reinsert the petcock into the tank and re secure the bolts be careful you re screwing them into plastic Be Gentle At this stage you re wondering should use a Sealant Mine and quite a few others didn t leak the gasket was just fine but guess in case it dribbles a sealant is one cure although a new gasket might be a better solution If you use a sealant then find one one NOT affected by Petroleum If you have not yet installed an inline fuel filter between the petcock and the carbs highly suggest you do it now found several particles in my filter that cannot understand how got past the petcock screens So can I clean it without removing the TANK Classic F650 by Johnny 862 1 Maybe l m the last one here to figure this out but the fuel screens can be cleaned or the petcock replaced in my case without pulling the fuel tank as instructed by the f
73. water first and gasoline after the water go out You can see the width of the water flow line is a bit wider than the width of the gasoline flow line Better if you put some rag or paper below the carbs avoiding the gasoline spreading Fede You might also make sure you keep the gas tank full When it is less than full condensation forms in the tank in cold weather and probably also in wet weather If you don t have cold weather where you are then Fede s answer applies more Find a way to keep water out of the airbox Colorado Bob If the Gas Filler Cap Leaks it gets first into the Gas Tank then into the Carbs Q How can I drain water from my float bowls e Here Float Bowl Drain Screw Locations e The Screws Circled RED are the Float Bowl Drain Screws for emptying Crud Water out of the Carbs The screws circled Green are explained here Idle Mix Screw Fuel Line Replacement by Chris in Santa Cruz CA It is possible to replace the fuel line without removing the carbs You must have long fingers You remove the rear shock preload adjuster this ones an Ohlins but the location is the same grease the hose a little and do without the clamp will take the carbs out at some later date to reinstall the clamp Meanwhile will inspect the connection for a while used 6mm Gates PVC fuel line This MAY allow you to remove the OEM In line Fuel Filter Maybe If anyone can confirm this great The inline fuel filter is in the
74. weeks It is a rather labour intensive undertaking but it sure beats 1500 for some plastic pieces that should cost 10 each So far have found about seven different types of bikes that use carbs with this same configuration mainly big Suzuki s and the fix is applicable to all of them as well Pretty much any bike with 36 38mm Mikuni s Please post this ASAP welcome correspondence from other Worshippers Happy Trails Morgan Carb Alternatives Complete by Mtbiero Cugino Pegaso http fag f650 com FAQS CarbMiscFAQ htm 17 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ found a pair of 39mm Keihins here http www rotax net BMW_F650 htm for 760 and more cheaply here http www pro flo com proflo keihin fcr carb _kits htm BMW for 625 However think dual 39 s is best for all out racers and feel the dual 36mm Mikunis offered here http www team pami de ENGLISCH index htm for 448 euros 392 would work best Since the F650 and Pegaso share dual Mikuni BST33 s think the F650 carbs would work on my Pegaso Info got from Team Pami The Mikuni flat slides have both 36mm diameter both open together the carbs have an acceleration pump e The stock cable doesn t fit you have to make a cable Yes the stock choke cable fits and works e Minimum 2 3hp more and the throttle response you can t compare this all with stock cams Gottfried Team Pami PAMI Performance Kits by Mtbier
75. you describe on my 1995 On my bike it is evident in most gears at least 2 4 but most often in third gear at 50km h It always happens in low rpm like 2500 3500 or so under acceleration especially slow acceleration and disappears after a few seconds The sound also goes away as soon as http faq f650 com FAQS StrangeNoises htm 8 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ you engage the clutch pull it in The sound looks like it is coming from beneath the engine so first thought it was one of the stands that was vibrating The problem has been there since last summer about 7 8000Km ago started to notice it when was travelling offroad in Iceland have not yet figured out what the problem is have done the 60 000Km service this autumn after the trip to Iceland and couldn t find the source to the problem then am starting to think that it could have something to do with the chain since changed my chain in the beginning of last summer and the chain has some really tight spots and some which are very loose spots bad chain or perhaps to much gravel has killed it If you find out what it is I d be very interested in knowing what it was When get back home later this month I ll take a look at the problem again and checking all the reasons listed in the Strange Noise FAQ Another thought that struck me was that it could perhaps be the cam chain but there is no problem at idle where the cam chain proble
76. 0 com FAQS StrangeNoises htm 23 of 23 18 02 2007 12 31 03
77. 1 000 feet will probably be about an hour What you really need to do is make sure the engine is tuned up and running properly before leaving A climb to altitude will expose any flaws in the engine and when people have trouble with their vehicles on a trip to the mountains that s why they have trouble So forget about rejetting the engine F650GS Dakar Camden New Jersey echo e A clean air filter is pretty important if you re not going to rejet for altitude If you re only going to be at altitude for a few days you probably shouldn t worry about rejetting If you are comfortable removing your carbs going one size smaller on the main jet is a good idea BMW dealers will be useless when it comes to supplying alternate jets But the jets are the same as run of the mill Japanese bike Mikuni carbs Mikuni BST B316 CV carbs to be exact available wherever Japanese bikes or parts are sold According to the FAQ your stock mains should be 132 5 believe the next smaller size in that numbering scheme is 130 If you plan to change main jets get two one for each carb See Performance Mods Flash 412 CO Inthe good old days in order to lean out the mixture for a few hours of high altitude operation we would remove the air filter and pull any removable baffling out of the muffler s when the bike started to slow down With CV carbs you will likely not have a problem except that your idle may be lumpy and slow If things get too bad you may want t
78. 1 htm Also on Harley CV Carbs Mods On Spark Plugs and Spark Plug Reading On Reading Spark Plugs with colours of Plugs Dynojet http www dynojet com motorjet shtml On Carb Circuits in general Detonation OOOO STC htto www factorypipe com Technical M Detailed inf r ET Tech AnidesDenets himi ore Detailed information on Fuel Detonation Carb Carb Circuits si http www speedandsport com jet html Diagram of Dragan of Ovetangng Cab ORCS See Carb Circus 56e Diagram under needles amp jets Opinions On Carb Cleaning Particular Parts Replacement Some of the comments below might seem to indicate the 14 6mm measurement is no good But if it is measured properly believe this measurement is fine At present there is just not enough feedback to say either way So set it stock measuring it right and if it doesn t work for you runs outta gas at HIGH rpm flat out speeds LET US KNOW e The 99 model s carburettor is specified to be set with a 56 inch clearance from the float bowl face used those exact specs and had the bike stall from insufficient gas in the carb after a brief time the bowl fills enough for another short distance I ve set it down about twenty percent lower than this spec but has anyone else had trouble with performance attributable to setting the float bowls to this much of a gap from the measuring surface Unknown I ve been working on my bike since the last posting of my problems carbon fouled plugs an
79. 391 See Exhausts Heatshield Noise 15 Front of Bike Rattle The large nut under the handle bars Loosen the top pinch bolts on the fork tubes and re torque the Steering Head Nut in Middle Mine has come loose a couple times Re torque the pinch bolts to 25nm Steve 417 See the section Triple Tree amp Handlebar Clamp Replacement in the Steering Head Bearing Replacement FAQ for how to do it up Noise 16 Rear LHS Rattle Check the bolt that secures the muffler to the frame Above muffler below seat Rear Exhaust Bolt Location Marty 436 Noise 17 Update on Popping when shifting posted a message about 3 4 weeks ago about our 97 F650ST popping when shifting from 3rd to 4th My 97 F650ST has gotten a popping noise the last 1500 miles sometimes when shifting from 3rd to 4th It happens about 1 of 4 times or so It has happened a few times from 2nd to 3rd It happens when the clutch lever is in all the way disengaged and after the shift lever is shifted just before letting out the clutch checked the http faq f650 com FAQS StrangeNoises htm 7 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ front sprocket and it seems fine I ve adjusted the chain and lubed it Still is there at times Bike has 13 000 miles and looked in the FAQ and couldn t find anything similar There is not a vibration when this happens but the sound seems to be coming from the front of the bike in the area of the front sprocket maybe or mayb
80. 6 have a 2001 F650Gs with 34 000 miles After a bizarre buzzing sound from what can only assume was in the engine somewhere the bike just stopped propelling foward The engine is fine and turns right over and hums just fine but kicking it into gear does absolutely nothing Up and down the gears go and not one gear engages except neutral the neutral light even comes on adjusted the clutch and just can t for the life of me figure out what the problem is The clutch is obviously no engaging but why A sensor maybe OreSka 1874 o Answer Did your chain fall off Are your sprockets so worn that the chain cannot grab them If your chain and sprockets are in good shape then your clutch is probably worn out THAT is well covered in the FAQ and the DVDs Other Comments Hints These are some of the questions you might get asked or some of the things to think about to identify and fix the noise http faq f650 com FAQS StrangeNoises htm 20 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ A knock Mmmmm need some more description Is it a deep knock like clonk clonk etc OR is more of a tap tap What side of the engine and is it up the top OR lower down on the motor When did this noise start Slowly over time after you did something with the bike like after a mad 3 day desert race Has it ever run low on oil some prior history may help the diagnosis IF its lower down and a heavy clonk noise then
81. 7 12 29 59 Miscellaneous Carb Questions FAQ FCarbParts1 FCarbPartsList1 FCarbParts2 FCarbPartsList2 FCarbParts3 FCarbPartsList2 For the diaphragm try one from a Suzuki GS500 part number 13507 17c01 don t know if the other parts are the same or not Charlie 070 from Pennsylvania Some parts are exactly the same parts as a Suzuki GS500E Note the GS500E uses Mikuni BST33 x 2 Carbs The Suzuki 98 DR350SE uses a MIKUNI Carburettor BST33 BST33SS CA Model Single The Suzuki DR350 EU model 1994 uses Mikuni Type BST33SS but US Model 1990 Mikuni uses TM33SS The Suzuki DR750S and 800S Specs also show a MIKUNI BST33 twin The Suzuki 1996 GSX600FT also show a MIKUNI BST33 four The Suzuki GSF 400 Bandit has MIKUNI BST33 four These are from a Suzuki GS500E http fag f650 com FAQS CarbMiscFAQ htm 19 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ For GS500E 1989 1996 GS500ECarburetorKLMNPRST 1989 1996 e SUZUKI GS500E Carburetor KLMNPRST 1989 1996 PartsList 1997 2000 GS500ECarburetorV 97 W 98 X 99 Y 00 e SUZUKI GS500E Carburetor V 97 W 98 X 99 Y 00 PartsList The Aprilia Pegaso Sister of the Funduro also uses the same Mikuni BST33 Carb as the http faq f650 com FAQS CarbMiscFAQ htm 20 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ Fundu Notes ro Note there MAY be a Yamaha that also uses a Mikuni BST33 B316 carb Might be w
82. 99 0 97 0 96 0 94 68F 1 00 0 98 0 97 0 95 0 94 86F 0 99 0 97 0 96 0 94 0 93 104F 0 98 0 96 0 95 0 94 0 92 123F O 0 96 0 94 0 93 0 92 http www nightrider com biketech main_jet_correction htm 2 of 4 18 02 2007 12 30 51 Veypor VR2 Data Logger and Instrument Panel Video Installation and Demo Engine Performance How to Build a TC96 2007 Engines TC88 70HP Stage TG95 128HP Stage 3 TC95 100HP Street TC96 2007 Stage 1 2 EVO 64 HP Stage 1 EVO 74 HP Stage 2 EVO 82 HP Stage 3 EVO 95 HP Stage 3 883 to 1200 Upgrade Shovelhead Modifications New EFI for EVO and TC Performance Gallery Horsepower Gallery Evolution 80 Shovelhead Sportster Twin Cam 88 95 Evolution Unlimited Sp rtster Un limited Selecting a cam Main J et Correction http www nightrider com biketech main_jet_correction htm 3 of 4 18 02 2007 12 30 51 Install a TC 88 95 cam Install a Big Twin cam Install Sportster cams Camshaft Specifications EVO Exh ust Testing TG Exhaust Testing Khrome Werks AR100 test SHOP TALK Carburetor Troubleshooting Do Crank Vents work Exhaust Ignition Finding Manifold Leaks Camshafts Cylinder Heads Pistons and Cylinders Shop Manual Appendix 20 Bike Lift Plug Wires Spark Plugs Engine Tuning General Information WEB Links Buy Books and Manuals Miscellaneous Performanc
83. Cause Unknown Noise 21 Buzzing From around the Fairing Speedo Area Electrical Speedo Problem GS Dakar Only Q do most of the work on my bikes but the electrical systems are not my bag recently replaced the battery on my 01 GSA Which I purchased used positive first then negative and when connected the new battery the Tach made several rapid clicks for about 5 seconds After that the soeedo made four short clicks every 15 seconds for about 5 minutes You can just barely tell that the speedo and Tach are moving during the clicking Is this normal I m guessing not The bike seems to run fine Any thoughts Thanks for any feedback o Answer It s quite Normal See the Soeedo ABS Sensor FAQ Noise 22 Feedback 1 When I m pulling from 2500 3500 in 3rd upwards I have a strange metallic rattle from the engine Any ideas anyone HELP It seems that if open it hard the noise reduces It is when am trying to be frugal with the fuel and just have low throttle twist It could be mix but it sounds very loud please forgive me as have only just returned to bikes so everything seems loud GREAT but loud The noise does not happen when revved at stand still only under load It seems to come from the front of the engine as far as can tell Sounds almost like the piston is rattling under load and as the revs increase and the bike speed picks up the noise stops have no clue UKRider o Feedback 2 have I think the same symptoms as
84. Consider buying Allen Screws or Socket Head Cap Screws SHCS for the Float Bowls and also possibly for the Diaphragm Cover Cap Screws though not as likely to be stripped e You MIGHT strip one of those float bowl screws trying to get it out e g Simon in Ireland notes found the float bowl screws difficult to budge solution get an impact driver Q What about alternative Sources for the O Rings A Either but generic as noted above or try a Suzuki Dealer for the O rings Viton 5 7X1 3 Part 8 4602 fits the tiny 1X2 5mm one for the float bowl assembly The 1 5X5mm one is 13374 35C00 from Suzuki That seals the float seat These two should cure your drips Now beware These stupid o rings can cost 2 4 each That s silly but much better than the parts with O rings from BMW I think the seat needle and O ring alone for one side is about 32 plus tax and jar of Vaseline Then you have to buy a complete new float assembly and that s more ridiculous Don t break your float bowl gaskets They are 37 each from BMW Don t know what they are if you run then down from some Jap dealer Mal Q How do adjust the Idle Adjust the Idle MIX Screws ON the bike Note they ARE different A Refer the Idle Mix Screw FAQ So how do get the Carb Out A1 Complete Carb Removal DON T SMOKE Remove the Seat Remove the Tank See the Gas Tank Removal Replacement FAQ BR WwW N e Remove the Seating Pl
85. E SPORT Farther down the performance trail is the 1450cc Stage II engine This adds Screaming Eagle SE 203 cams and adjustable pushrods to the Stage motor and the result is about 88 ft lbs of torque and 73 hp at the rear wheel Beyond this level it makes sense to take advantage of H D s big bore 95 cu in 1550cc pistons and cylinders These are designed to work with the stock cylinder heads and valve train Otherwise identical to the Stage II 1450cc engine above a Stage II 1550cc engine with SE standard compression ratio 9 0 1 flat top cast pistons produces about 97 ft lbs of torque and 80 horsepower at the rear wheel The 1550cc Stage III engine is basically like the Stage II version but uses SE high compression cast pistons 10 25 1 and a SE race high compression 6200 RPM ignition kit This is good for about 100 ft lbs of torque and 81 horsepower at the rear wheel There is no difference in the price of the pistons or ignition module so it is purely up to the owner s discretion whether to build to Stage II or Stage III Stage III requires the best grade of gasoline available of course usually 92 octane Super Unleaded But then Harley owners usually buy Super anyway Note that all of the modifications above are essentially progressive and none are particularly difficult There is no machining or cylinder head work required The test bike s modified TC 88 engine Of course there is no prohibition against departing from the
86. ER GLIDE SPORT The quarter mile time above was reported in Motorcyclist magazine The top speed was estimated by the WinPEP Dynojet Performance Program from an early dyno test when the test bike s engine was still reasonably close to stock Touring accessories The first requirement for a touring bike is a decent touring seat H D offers a good one for Dyna models the Sundowner deep bucket seat 51540 01 For the long distance rider also recommend one of Harley s excellent windshields The detachable touring windshield 58570 96 gives maximum protection and can be removed when desired Saddlebags are another necessity for the touring rider H D leather Big Bags 90300 98 fit the bike well and provide decent capacity and quick opening buckles An alternative would be the injection molded color matched Dyna hard saddlebags 90126 XXXX which are available for some 1999 and 2001 Super Glide Sports If you are interested in these bags check to see if your particular year and color are available A small fork bag 91744 87T adds space for small frequently used items like sunglasses and a tire gauge Heavier small items like tools and a fork lock fit nicely in the leather toolbox 64245 97 that mounts neatly in the space in front of the rear shock on the right side of the bike A black low sissy bar upright 52426 99 and matching sideplates 52418 99 are necessary to attach the black sport rack 53852 00 A wide touring ba
87. F The water goes in through the air filter You can empty the water of the carbs by unscrewing for a few seconds 2 or 3 are generally enough the two screws located below the carbs in horizontal position taking care you have the gasoline pass key in the off position Then the water first and gasoline after the water go out You can see the width of the water flow line is a bit wider than the width of the gasoline flow line Better if you put some rag or paper below the carbs avoiding the gasoline spreading Fede You might also make sure you keep the gas tank full When it is less than full condensation forms in the tank in cold weather and probably also in wet weather If you don t have cold weather where you are then Fede s answer applies more Find a way to keep water out of the airbox Colorado Bob If the Gas Filler Cap Leaks it gets first into the Gas Tank then into the Carbs Q How can I drain water from my float bowls e Here Float Bowl Drain Screw Locations e The Screws Circled RED are the Float Bowl Drain Screws for emptying Crud Water out of the Carbs The screws circled Green are explained here Idle Mix Screw Fuel Line Replacement by Chris in Santa Cruz CA It is possible to replace the fuel line without removing the carbs You must have long fingers You remove the rear shock preload adjuster this ones an Ohlins but the location is the same grease the hose a little and do without the clamp will take
88. Item BRACKET 46 51 2 345 258 Marty 436 Chicago 97 F650F e Cracked Fuel Tank Support Bracket 1996 BMW F650 took my fuel tank off the other day and noticed that the metal bracket that bolts to the frame and supports the rear of the fuel tank a bolt passes through the tank and a bit of rubber and into the support plate in question had cracked around the right frame mounting bolt hole have the 27 litre tank Does anyone know the BMW part number for this bracket plate Anyone had this problem wonder if the extra weight of the 27 litre tank is a factor I was replacing the carb o rings and hence needed to remove the bracket to get the carbs out Thanks carOtene 1996 BMW F650 AUSTRALIA Water in the Tank Q Filler cap leakage Is it possible to get water into the fuel tank from my filler cap even if locked when for example wash the bike or under some heavy rain A Yes It is also possible to get water in the tank from condensation AND from filling up while the truck is delivering gas to the station Flash Removing the COLOURED SKIN off the Tank by Flash 412 Q Is is possible to remove the plastic body panels off of the fuel tank without removing the fuel tank In the fuel tank removal section of the FAQ is says that you aren t supposed to pry them apart but does that http faq f650 com FAQS Gas_Tank_Removal Replacement htm 14 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank mean that it is an unnecessary st
89. MiscFAQ htm 10 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ CV carbs tend to be self compensating at high altitudes the flat slide carb does not From http www chuckhawks com super glide _sport htm e Carbs are tuned to provide a certain A F ratio based upon the ambient atmospheric pressure If the pressure changes so does the A F ratio But if you are actually measuring the A F ratio the carb is more immune to pressure variance What does that mean It means a CV doesn t go rich at altitude the way a fixed jet carb does It is altitude compensating So at 10 000 feet a CV equipped bike only looses power from the loss of available air pressure while a fixed jet carb will loose power from less air and lower combustion temp from being overly rich From http www easternillinoisabate org tech_talk htm If you were moving to altitude you might consider the following Try ONE at a time depending on the Altitude e Screw in the idle air screws and or Lower the needle position and or e Possibly reduce the size of the main jet Refer http Awww nightrider com biketech main jet _correction htm for Jet Multiplication Factors for Temperature Altitude For a trip over a BIG MOUNTAIN just keep your hand on the throttle in case the bike starts to die at idle Fl systems have an advantage here as they do a pretty good job at adjusting the mixture for changes of altitude Less air means less
90. Miscellaneous Carb Questions FAQ Miscellaneous Carb Questions FAQ compiled amp edited by Kristian 562 Please read the Disclaimer before attempting any work in this FAQ If you are looking for performance related carb information See the Rejetting Spreadsheet accessed via this link Performance Mods Section Carbs for Dummies Pulling the Carbs Puking Petrol All About Floats e Proper Choke Use Do I need a Carburettor Adjustment for High Altitude Dol need to Synchronise the Carbs Fast Idle Problems What is the Effect of Dropping the Needles Flat spot in carburetion What are the Holes in the Bottom of the Slides for Slide Barrel Wear Carb Alternatives Alternative Carb Parts Water in Float Bowls How do I drain them Fuel Line Replacement Straight to the Carb Clean FAQ For Aftermarket Fuel Filter Q s and the OEM In line Fuel Filter For Petcock Q s For Idle Q s For Canister Q s Carb Primer by Flash 412 Please read the Disclaimer before attempting any work in this FAQ October 01 This is a carb primer for those with little or no understanding of this device If you re carburettor literate move on If you re carburettor ignorant you might like this Carburettor is NOT Latin for don t mess with it http faq f650 com FAQS CarbMiscFAQ htm 1 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ Fuel and air need to be mixed in th
91. My bike peed gasoline all over the garage floor cuz the petcock was left on and there were some tired o rings in the carbs Since then prefer to avoid the fire hazard and turn it off This isn t common But am not the only one it happened to See Pukin Petrol in the FAQ Flash 412 CO The fuel enrichment circuit of Mikuni carbs starts to work only when the cable is pulled about half way And I think that if you whack the throttle open it basically defeats the vacuum that the enrichment circuit relies upon so don t think riding with a partially open choke would result in any damage if it were open further the bike would just run poor lots of smoke and over the long term catcon damage maybe Shank NYC USA THIS is how much mpgs can drop with choke on Ok it s not a choke but fuel enrichment device wouldn t fit in the subject line Over the last 3 fills go 150 155 miles before getting fuel starvation symptoms which calculated out to 50 55 mpg at the fill ups During this last tankful left the fuel enrichment device aka choke on for about 10 miles on one trip My mileage to reserve dropped to 125 miles 1 don t know yet the gas mileage on this fill up had to go to reserve to get home however it looks like about a drop to around 40 mpg This is a 97 F650 ST with 26K on it So if your mileage is down make sure it s not just due to leaving the FED choke on too long Nate 97 F650ST Maryland Choke Stuck http faq
92. Q It might be Valves See also Engine FAQ Noise 25 Engine Knock A loud knock that doesn t go away off idle is quite likely the big end rod bearing If your bike is still under warranty and the dealer doesn t want to do anything about the knock INSIST that he give you written DATED documentation about the complaint and that his solution was to wait and see As Shank sez when it comes to problems and the dealer sez Wait and see what that really means is Let s WAIT until your warranty expires and then SEE how much you ll pay to get this fixed Flash 412 Noise 26 My bike makes a humming sound when under load It sounds like a domestic feline purring then silence then purring again Frequency 1 2 Hz I ve never heard it when riding solo so far or when idling It s not noticeable in 1st or 2nd gear while 2 up but you can almost tell it s there in 3rd with a bit of imagination 4th and 5th while riding 2 up especially at lower roms and in upward slopes it s definitely there As soon as the engine is under a lot of load haven t been able to tell whether the frequency of the sound is related to engine speed or road speed It does http faq f650 com FAQS StrangeNoises htm 9 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ not go over 2 Hz though even when riding FAST It s on for half a second off for another half second on ag ain etc While it s on it sounds like a friendly cat I ve
93. Suzuki shop for a quote of the GS500 diaphragms which were priced at almost 40 So ordered them from a BMW car dealership instead saving 2 compared to the bike shop guess I ll use my savings and buy a snow cone or something Emil 94 F650 Malm6 Sweden e Sound too big to me had the Tank off and the Diaphragms out on my Classic over 20 times to http faq f650 com FAQS Carb_Clean htm 16 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ swap needle positions while rejetting wrote the above description and it was exactly like that It didn t fit EXACTLY but a little oil lightly pressing down with the plastic cover and rotating it popped back in just fine Sounds like something amiss there They may have installed the diaphragms off a different carb The Suzuki GS500E ones may fit though if you need a new set What you could do if you want to check is to take them out flip the rubbers over and dab the oily lip onto a piece of paper or just take the whole thing to the dealer and ask to see a replacement if they have one in stock to measure it Do the same at the Suzuki Dealer See FAQ for Suzi Part No s and ask both the price k If you happened to be spraying carb cleaner or equivalent and it got on them they can swell up larger at least the ones on my Airhead did Let the solvent air out of them for a day or two they may shrink back if they re not already trashed by the forced installation If not agree
94. Take hand remove watch grab screwdriver hooktool rubber that is being problematic with my Finally cannot recommend the guys at http Awww factorypro com enough these guys saved my butt the SS screws and jets are nice too But saying that jets are jets you can buy them everywhere almost it s the service you need during and after the sale they most certainly provided that Identifying a Float Valve Problem See PUKING PETROL http faq f650 com FAQS Carb_Clean htm 25 of 25 18 02 2007 12 30 16 HOW TO Remove the Tank Fuel Supply FAQs compiled amp edited by Kristian 562 Please read the Disclaimer before attempting any work in this FAQ Gas Tank Removal amp Replacement Fuel Petcock FAQs In Tank Fuel Filter Cleaning e Sticky or Hard to turn Petcock Problem Close the Fuel Tap Aftermarket Fuel Filter FAQ In line Fuel Filter Fuel Filter Vapor lock What about Clamps to re attach the Hoses Gas Tank Lock e Removing the Gas Tank Restriction for Easier Filling Where does the Fuel Cap Drain Drain to e Gas Cap Vent Cleaning Broken Tank Support Bracket Water in the Tank Removing the COLOURED SKIN off the Tank Where s my Reserve For Aftermarket Tanks refer the Aftermarket Fuel Tank FAQ Classic or Aftermarket Fuel Tank FAQ GS For Mileage Feedback refer the Poor Mileage FAQ For Carb Issues refer the Carb Misc FAQ Replacing the Fuel H
95. a small piece of glass inside the headlight The Headlights isn t FULLY busted but a stone hit it just so that it whacked a chip of glass off the INSIDE of the Headlight Glass Kristian 562 o Feedback 5 Check to make sure space does in fact exist between ABS wheel speed sensor and wheel disc Prop the front wheel up and spin it Use a flashligh as believe that 001 is the minimum space allowed Then shim out appropriately There exists a bolt and nut in the center of the frame just above the crash bars don t really know what this thing is supposed to do but found it loose and retorqued it Make sure your or any chainguard hardware is securely attached I m missing a bolt on mine and it does rattle a bit jetdocs550 1546 o Feedback 6 similar noise have suspected it s a loose connector or wire flapping around due to the turbulence from backdraft or maybe stray road wind coming up from underneath Sadlsor 1444 o Feedback 7 Upon further investigation found that my headlight dash pod assembly was being held on by two threads left on the one of two bolts that should have been holding it all together New fastners from HD lockwashers and locktite and all is quiet damalden 1598 o Feedback 8 My rattle was the ignition key switch held by two allen head bolts in the upper triple clamp One bolt had fallen out the other was loose See also Noise 5 Noise 7 Noise 12 Noise 13 Noise 15 Chris in Santa Cruz CA 782 o Answer
96. acement htm 10 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank F650 Classic 91 R100 GSPD Canada What about Clamps to re attach the Hoses e did exactly what Gim did with the spring clamps If your filter has the proper size ends nipples you don t need much of a hose clamp and the screw type hose clamps for such small tubing can put excessive stress on the plastic nipple have seen several such plastic nipples crack from over tightening be careful with clamps on the radiator nipples So did what Gim wants to do Clamp11 9 BMW part 16 11 2 345 077 Actually stopped in to a Stihl garden tools dealer as they use similar metric clamps in small gasoline motors like weedwackers You can also sometimes find such clamps in packets in assorted automotive hardware displays or sometimes in the small drawers of specialty parts in hardware stores Todd 389 http www aboveboardelectronics com heyco Page5 12 htm Gim Giovanni Gas Tank Lock Q Does anyone know of an alternative to the BMW for a new lock cylinder The key broke off in the lock for the gas cap Drilling the lock through worked well enough to remove the cast piece for the cap Further filling and hammering with a nail set removed the the remaining bits of the lock The most frustrating thing has been the dealer When asked about price for a new cylinder they quoted me 280 Canadian After regaining my composure said all needed was the lock cylinder an
97. ach of the Exhaust manifold connections to the Cylinder Head which look like this This is a close up of one of them It is the Silver Ring which is very soft crushable metal sandwiching a Gasket Material One where one of the Exhaust Manifold pipes meets the Collector pipe to Cylinder Head which look like this One where the Exhaust Collector Pipe meets the Exhaust Proper i e at the crossover pipe VERY often you can fix the problem by simply tightening the Exhaust Header Cylinder Clamp Nuts Here is the RHS Upper One RHS Lower one LHS Lower One You can also try tightening the Exhaust Collector Clamp Testing You can check these with a bit of smoke like from a cigarette in a still area wafting around the joints Headers also crack and split sometimes Watch for the smoke being blown away by leaking exhaust gases For Exhaust Gasket Replacement see that FAQ 4 Has your bike been rejetted New Pipe Open Airfilter Poor jetting can ruin a well running bike just went through this agree loose the DynoJet went back to stock and have a Staintune exhaust Check the orifices on the lower edge of the Airfilter side Venturi on both carbs make sure they re clean My bike runs great also got rid of the pipe from the header to the air cleaner No more backfire on Decel James http fag f650 com FAQS BackfiringFAQ htm 2 of 4 18 02 2007 12 30 52 The Backfiring FAQ If you want to rejet see the Perfor
98. ack Covers lifted the diaphragm covers today in order to check the diaphragms and needles out as I ve been getting rather few mpg have no idea when the insides of the carbs were changed out the last time but guess it s probably been done since the bike s got more than 62 000 kms on it The needles looked brand new to my untrained eyes though So did the diaphragms and thorough checking revealed no rips or punctures of any size or kind HOWEVER did get a bit puzzled over the fact that my diaphragms are way too large to fit in the circular indentations they re supposed to settle in before you screw the covers back on They were indeed pinched under the covers by whoever screwed them back on previously I ve checked the FAQs but only found this from the carb cleaning faq Press the Diaphragm into the Groove on the Carb Body and make sure it more or less stays in It might try to pop out but don t worry when you put the Cap on it will slip into the groove so to speak So put the Cap on and slide it around a little bit on the rubber just to make sure the rubber is down in that groove and you haven t pinched it somewhere My problem is that it is positively impossible to get the entire edge of the diaphragm into said groove My diaphragms are at least a couple of millimeters too large across to fit and after 45 minutes of trying to get the edge to seat in the groove all the way around gave up had to screw the covers ba
99. actory manual It takes a bit of fidgeting with the Allen wrench but it can be done didn t take the time to do it but best would be to weld about a foot of steel rod to the 4mm Allen wrench needed so you could get at the two securing screws from below the bodywork As it was loosened the panel under the fairing at the front two 3mm screws and that provided room needed to get the wrench in there The screens were perfectly clean at 9k miles but there was quite a collection of black plastic shreds at the base of the screens which were likely left overs from machining the tank Pretty harmless sitting there Ah sorry yes it s a 98 classic should have mentioned too that was impulsive enough to take this on with a full tank Holidays now so felt have the time to do this used a manual gas pump from Griot s to remove several gallons and then pulled the gas line off the petcock and replaced it with a short piece of tubing to drain the rest on reserve of course can t tell that there was anything wrong with the original valve but was definitely able to ride for miles with it closed occasionally might have massaged the old valve and got it to work did take it apart and could find nothing obviously wrong but neither could explain why at times could run for miles with the thing off The replacement Made in Italy is only about 20 so just replaced it This one is much stiffer to turn Feedback Coincidentally just cam
100. ad to go to reserve to get home however it looks like about a drop to around 40 mpg This is a 97 F650 ST with 26K on it So if your mileage is down make sure it s not just due to leaving the FED choke on too long Nate 97 F650ST Maryland Choke Stuck http fag f650 com FAQS CarbMiscFAQ htm 9 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ If it is idling high just Check the Cables BOTH Choke Cable and Throttle cables If you don t normally use the choke fully when the weather is warmer suspect that the cable isn t running freely and it s not going back all the way to the closed position In that situation would lubricate the choke cable with a very light oil and if you can just keep opening and closing it to work the oil along the length of the cable When the lever is closed is the end piece on the cable sat nicely in its socket or is there a pit of play there If there is a bit of play or you can see a small bit of the inner cable then it just needs that lubricant to get it working again Trevor 999 UK 01 GS Do need a Carburettor Adjustment for High Altitude by Kristian 562 Dick 420 Mark 403 HsN Richard 230 amp Unknown Generally the F650 Classic can cope with MOST Altitude changes with no changes to the Carbs Any Changes should normally only constitute MINOR adjustments to the idle mix screws The F650 CV carb provides crisp throttle response and lessens jetting sensitivity to temperature
101. al Control on the Slide That s all you can inspect that comes out of the top for now You won t be able to get the Slide Carrier or the Carb Venturis out until after you ve extracted the Main Jet Inspecting the Float Bowls At this point I d recommend just gently screwing the Diaphragm Cap BACK on but without any of the other bits you just took out The reason is so when you turn the Carbs over and stand them on the Diaphragm Caps to remove try and remove the Float Bowl Screws you have a stable end on which they can stand The Float Bowl Screws are Very Tight and again you run the risk of mangling the screws Again you may even need to gently tap the end of the screwdriver or get to work with a bit of WD 40 In despair you can use a pair of Vice grips and get some new Screws later Don t try heat except as a last resort EXTREME http faq f650 com FAQS Carb_Clean htm 10 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ FIRE HAZARD and make DAMN sure the Bowls are DRY Many people have actually replaced these Phillips screws with Allen Screws and l d recommend it if you intend to take your Carb apart often for re jetting or whatever When you get the Bowls off they look like this on the inside Float Bowl Not much to do there but give it a little cleaning and inspect the Gasket for cracks Again don t use Harsh Solvents on the Rubber Gasket Inspecting the Main Jets What you should see now is something like this ex
102. ame thing however they do not clarify how sensitive that little piston is found it easier with the floats already flopped over toward the carb body to tilt the floats away from that little piston then tilt the carb so they go back into the body until the tang just touches that little piston Performance could be saying drop them into the body compressing the piston then tilt the body so they come out SUCH THAT the piston is not compressed However believe by saying floats just flop over they are saying the same as this FAQ NO the valve is not open during the measure it is STILL closed It ONLY opens when that little wire on the tang pulls the whole valve up As long as the tang is not pulling up on the valve it is closed under it s own weight gravity What you have to remember is that valve is up the other way normally so what the little piston does because it is spring loaded is work against the valve pushing it up to close off the supply to the bowl Replacing the Float Bowl Smear a little oil on the Gasket making sure it is seated properly in its groove then replace the Bowl and do up the Float Bowl Screws Allen Head screws are a http faq f650 com FAQS Carb_Clean htm 15 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ good replacement Repeat from Inspecting the Carb Needles down for the Second Carburettor Diaphragm Trouble Diaphragms don t go back into place after lifting off the Bl
103. and a B cylinder and rings and mine were mismatched was surprised by this but the tech allowed me to view the parts in question and there was no doubt that the bore was too big for the piston ring combo in my case It was tight enough to go unnoticed when brand new but as it wore in a bit and loosend up the eror became apparent Bario Noise 38 have noticed on my last few months that a strange noise occurs from the front of the bike when am at 30 to 35 mph Best way to describe it is like this If you put a metal ball in a cup and then shake it so the ball goes round and round That is what it sounds like recently had my 6000 check and it happened before that forgot to mention it but figured the mechanic would catch it am a little concerned It sounds like it might be coming from under the speedometer or top of the fork It makes the same sound whether in gear or with the clutch in Bobcatou 1157 http faq f650 com FAQS StrangeNoises htm 13 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ o Feedback Wheel bearings jack up the bike spin front wheel and listen front wheel balance check torque on the brake caliper mounting bolts plastic bodywork cam chain tensioner loose rocks on top side of bash plate o Answer Unknown not listed Noise 39 I ve experienced two occasions where it sounds like the engine I m assuming it s the engine it may not be is making a loud grinding squeal that s the
104. and altitude changes All constant velocity CV carburettors are designed to compensate for changes in altitude and barometric pressure From http www floheadworks com Products keihin_carburetors htm The FI should have no problem at all as it has lots of sensors and copes better with Altitude Air temperature What does constant velocity mean When you open the throttle the engine draws more air through the carb A large quantity of air must move faster being drawn through the same diameter Venturi than a smaller quantity of air does In a non CV carb the air would be speeding up and slowing down in the Venturi depending on the demand of the engine In a constant velocity carb the Venturi automatically gets smaller when the engine isn t drawing much air and gets larger when the engine draws more air this keeps the velocity speed of the air close to the same at all throttle openings and provides a more consistent metering of fuel in the Venturi It is supposed to give better fuel economy cleaner emissions and adjust itself to altitude changes Most tuners dislike constant velocity carbs and use round or flat slide carbs in which the slide is raised directly by the throttle cable instead of indirectly by airflow as in a CV carb From http www sonic net blaineh xs1icarb html Going from Low to High Altitude Possible Symptoms You may experience rich running stalling hard starting and irregular idling at slow engine rpms at high a
105. ar bill which is very flexible and wave it around in the vicinity of ALL of the Exhaust Joints to check for leaks Is there a Temporary Fix so I don t wake up the Neighbours coming Home http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 2 of 8 18 02 2007 12 30 55 Exhaust Gasket Replacement FAQ Stuff the offending hole with aluminium foil and lo the whole thing will be quieter fart less wish could do the same and the fan won t come on as often D So how do fix it properly OK lets do a little naming for clarity Assuming Lex Left Exhaust Rex Right Exhaust 8 Exhaust Gaskets at the Head This has been reported as a corrugated sleeve that fails under the clamp The Replacement gasket is no longer corrugated 5 Gasket between Tail pipe and Mid pipe 7 Gasket between Lex head pipe and mid pipe The numbers will make sense if you have le partsfiche a I i clair That s the Parts gif for Details refer Documentation or Shh don t tell BMW Exhaust gif Note You can get sockets on Rex You CANNOT get sockets on Lex e Remove the LEFT sidecover Remove the black plastic panels that cover both sides of the motor e Remove both screws from the FRONT of the belly pan and just loosen the rear ones a turn or three The belly pan just needs to drop down a couple or three inches in the front to make your life a little easier Loosen the Allen screw on the clamp that holds the u pipe into the c
106. arbs change main jets to stock 132 5 change to stock needles four slots down from the top anyone think should use a washer on each clip switch to stock springs again not sure how to tell the difference check replace all rubber and double check diaphragm Set the idle mixture screw to stock setting 3 5 turns out from lightly seated Double check floats and float heights Now for the big question When my lovely wife and purchased her 97 F650 which has the jet kit was really impressed with the 5000 rpm and up power and throttle response Shortly after that bought a 99 F650 without a jet kit but with a 15 tooth sprocket Her bike has a noticeable amount of power above 5 grand rpm s It also lurches and bucks in lower RPM s she is also a noob but member A6501188 Is that the trade off power for drivability If that is the case then back to stock and the jet kit can gather dust Is the factory pro kit any better or is it a lot of playing around and compromise between power vs drivability Both of our bikes have the snorkel yet should we pull those XtreemLEE Slide Barrel Wear Morgan Seim has a solution for the G s carb crappiness Not for the F650 but interesting all the same This letter is the culmination of many hours of trouble and tinkering with Ellen s 1100G s carbs Riding my new 1200 Bandit back to back with her 1100G really highlighted the gross carb troubles her bike had with the original carbos You may have
107. as going on Throw away the glass thing for two reasons GLASS on a dirt bike is not a good idea And as you have found out the BIG thing will vapor lock Buy a 1 throwaway item in any dirtbike shop http faq f650 com FAQS Gas_Tank_Removal Replacement htm 9 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank Flash 412 CO and as flash has so eloquently told me before purge the air from the line used a small plastic Karcoma that would never quite fill all the way up purged the air from the line voila works like a charm for an letricul ngeneer he does make some good suggestions Nick 1085 Glenwood NJ 07418 e You know I have been thinking about this one and remember back when the F650 classic first arrived at the dealership we uncreated it did the PDI and the darn thing would not start Happened on most of them and have seen this happen when they sit for a while am a bit surprised haven t read more of this problem with the classics Problem is the gas doesn t flow on its own It is like a pump that loses prime You sometimes have to prime them pump coined the phrase the you need to give it a blow job You do this by disconnecting the fuel line from the tank and blow the gas into the float bowls Taste bad works good don t know if this will fix your problem but it has worked many times for me on classics that have fuel spark and compression that still won t start Good Luck F650GS Dakar Oreg
108. as the IDLE The Idle Screw just limits the minimum throttle when you take your hand off the throttle The Idle Mix Screws and there are TWO of them one for each Carb actually controls the Gas Air Mixture at Idle Obviously this is not applicable to the GS For the location of the Idle http fag f650 com FAQS BackfiringFAQ htm 1 of 4 18 02 2007 12 30 52 The Backfiring FAQ Mix Screws and useful tools to turn them see This FAQ Most riders find that enriching the idle mixture by backing off the screws by 1 8 to 1 2 a turn will eliminate the popping Enrichen as little as necessary work in small increments and test the results before backing out the screws another 1 8 turn For more information on the Idle Mix Screws the Carb Cleaning FAQ 3 Exhaust Gaskets Can be Replaced Classic F and GS Dakar These seem to be one of the most frequent cause of Backfiring Problems and an item that has been seen to fail quite often Recently went to replace gasket where header pipe meets cylinder head After pulling left header pipe found culprit of noise blown out header pipe to collector gasket This was a corrugated sleeve that failed under the clamp Replacement gasket is no longer corrugated Added bonus was the commonly reported backfiring problem thought I had to live with is now completely gone Try this 11 00 fix if your bike is backfiring There are actually FOUR Exhaust Gaskets on the Stock Exhaust Pipe One on e
109. at could have gone wrong The bike has 70K on it and normally runs well with no major problems other than a bit of oil in the airbox It MUST be a float or FUEL VALVE problem The fuel is gravity fed from the gas tank to the carbs The carbs is design to work with a certain height of fuel inside If this level is a bit too height it is like running with the choke on and if it is far too high it will overflow by the small pipe s The device to keep this level right is called a float and resides in the float chamber at the bottom of carbs It works like the device that you might find in your toilet bowl When it drops a bit it opens a valve to let more fuel in and when the fuel raises it it will close the valve If the valve gets stuck partly open by some small impurity in the fuel or the float does not rise due to it being punctured or stuck the fuel level will rise until it overflows Haakon 626 Norway 12 1999 F650GS Read the FAQ on how to get the carbs out Take them out Take the float bowl off Remove the floats Spray some carb cleaner through where the fuel normally goes IN to knock out any impurities You should probably change the little fuel filter in the T while you have them out If you don t have an inline filter installed between the petcock and the T you d be advised to add one Flash 412 CO Q Can not should you still drive with Puking Petrol syndrome e You should try to shut the fuel off 1 4 mile or so BEFORE you
110. ate at the Rear of the Tank held in Place by two 10mm Bolts http faq f650 com FAQS Carb_Clean htm 6 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ 5 10 A2 U Ae UNBE Undo the 2 Hose Pipe Clips on the Air Intake Side Rear of Carb and the 2 on the Cylinder Head Side Front of Carb and Remove the Carbs For Carb Removal see Flash s FAQ This is a bit hard on the rubbers and you might think you re doing some serious damage but if you do it right and don t use a sharp screwdriver it s fine The alternative is to remove the exhaust pipe and take out the Airbox which is VERY time consuming and a Royal PITA When you do it in addition to Flash s great comments I d recommend pushing each of the Clamps back away from the Carb as you can and also to wear thick cotton gloves for your hands as the Metal edges specially the Airbox Side are a bit Sharp Lift the Air Intake Side up first and get them past the thinner and more pliable Air intake rubbers by pushing the rubbers down past the Carb while simultaneously pulling the Carbs up and out Unlatch the Throttle Cable To do this first twist the throttle at the Carb against the spring then with the cable now slack pull the little steel bend out of the socket in the side of the Carb With the wire now slack but still attached to the throttle at the Carb just rotate the cable in its holder at the throttle mounting until the cylindrical head and the wire c
111. attling Front Not an engine noise Noise 15 Under certain load Rattle up front vibration conditions Noise 19 Lowering kit Buzzing several rapid clicks Fairing Speedo Area E aE Noise 27 rythmic clicking instrument panel ee Noise 52 Stops when starter depressed Stops when heated Noise 33 grips turned on Headlight dims under the speedometer SLO leh Mosse metal ball rolling in a cup in gear or with the Noise 38 top of the fork clutch in heard when riding over headlight steering head expansion joints or Noise 40 keyboard clicking clacking small plastic object shaken peeked ae poses gently inside 35mm film canister metalic rattle off road downhill can be rev dependant possibly temperature dependant mainly 2nd 3rd gear ruler twanging on desk edge front Noise 50 after turning bike off can last for several front instruments minutes Noise 51 tach speedo needle twitches http fag f650 com FAQS StrangeNoises htm 2 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ Farting and aloud popping and a loud popping E not not backfiring Noise When mo a mainly Noise 17 Engine somewhere ficar wrest gear in gear 2500 3500 in 3rd upwards Noise 22 hard the noise reduces metallic rattle Gets Faster as Idle Raised seen when in neutral clutch Noice at lt E em e e e E drowned out f Khat Khat Khat LHS Engine En
112. ature Altitude For a trip over a BIG MOUNTAIN just keep your hand on the throttle in case the bike starts to die at idle Fl systems have an advantage here as they do a pretty good job at adjusting the mixture for changes of altitude Less air means less power and a richer mixture A K bike gets better mileage above 4 000 feet because the injection system switches to a leaner program to compensate for the altitude The vacuum carbs can adjust to an extent but not anywhere near as well Going from High to Low Altitude Possible Symptoms You may experience popping on throttle slowdowns i e popping minor backfiring during compression braking deceleration BUT check your carbs are adjusted correctly not worn and also check the Backfiring FAQ Exhaust Gasket Replacement FAQ and Strange Noises FAQ So do need to adjust it The idle mixture screws are not self compensating as they as well as the throttle cutaway are not affected by the constant vacuum feature of the carbs They need to be manually adjusted Inthe Manual there are no instructions related to re jetting or adjusting the high speed mixture http faq f650 com FAQS CarbMiscFAQ htm 11 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ only adjustments are for idle mixture and idle speed e Most people have no difficulty changing altitude Re examine the Backfiring FAQ FIRST for minor adjustment of your idle mix screws or possi
113. b open in front of you There aren t a lot of parts there but they need to be reassembled the same way they came out You see the metal tang just in front on the pivot That s where you re going to make your adjustment Also note that there is a small metal clip that attaches the needle to the metal tang Be gentle removing the floats so you don t damage it OK remove the pivot pin and then the floats Pull the needle from it seat and have a look at the tip It should be smooth with out any deformation grooves scratches etc If there are replace it with a new one Now that you have inspected the needle you can reassemble it all again but don t reinstall the float bowl Float Valve Assembly Needle Inspection lt lt Float Needle lt lt Float Valve Clip m E cer i fi Feii Good lt lt Fldal Ivot As a side note if you re disassembling the carb now would be a great time to clean the internals especially if your KDX is more than a couple years old It is an easy job all yov ll need is a can of carb cleaner and a couple more tools You ll want to remove the pilot jet using a bladed screwdriver and the main jet using a 6mm socket Spray carb cleaner through both jets and through the rest of the carb Follow the instructions and warning on the can Allow the carb to dry visually check that there is nothing obstructing the jets and reinstall them Click Here For Exploded View gt gt gt gt gt gt ht
114. bber knob makes it very easy to do the adjusting It is called Keihin FCR Carb Wrench Kit MP 08 0181 and is sold by Motion Pro Quality Tools amp Controls found it at a non BMW dealership Thanks to Andrew 870 for the piccie of the location http faq f650 com FAQS Idle_Mix_Screw htm 3 of 3 18 02 2007 12 30 25 The Canisterectomy FAQ Canisterectomy amp Vacuum Line FAQ a k a I can t be out of GAS compiled amp edited by Kristian 562 Please read the Disclaimer before attempting any work in this FAQ by Flash 412 Bob 550 Hombre sin Nombre et al May 01 Symptoms So which way around SHOULD the vacuum lines go So why Does the Bike feel like it is out of Gas What to do if your Canister mysteriously falls off l don t have a Canister and still have I can t be Outta Gas Symptoms What is the Stock Configuration for these hoses Canister Removal Notes Canister Feedback Has anyone fitted a Container where the Canister WAS There is a bit of repetition here for clarity and because there are more questions than answers So don t think you re missing something out Symptoms Several F650 riders report an engine that dies and that the solution involves poor electrical connections If your carburetted bike surges and stalls sometimes particularly in the rain and it is NOT electrical it could be your Canister or your Carburettor Vacuum lines e First chec
115. best way can describe it It happened once after attempting to start the bike after it stalled and happened again when was actually riding on the highway and was shifting down about to come to a stop The bike is relatively new with only 250 miles on it so far know the manual says not to slip the clutch I m assuming that this means not to use the friction zone cheri o Feedback make sure it s got oil and water coolant Check your rear caliper brake assembly o Answer unknown not included Noise 40 When riding 01 F650GS 2k miles have a rattle coming from the front area around the headlight or steering head Rattle is only heard when riding over expansion joints or small potholes Have checked various things but cannot find source of rattle Just afraid something is going to fall off the bike dgriffin 1696 o Solution 1 ed someone else with similar noise found it was the windshield replaced the Dakar windscreen with one that does not use the normal mounting points Riding offroad a few weeks ago in the Mojave National Preserve could hear a noise like china plates banging around Taking the front end apart found the problem there is a wing shaped piece of sheet metal that was no longer being anchored by the Dakar screen mounting screws This part was bouncing around on top of the headlight Jerrya o Answer A while back posted asking what could be rattling around up front on the bike received many answers
116. bike opened up the mixture screws a bit and raised the needles about 040 After getting her bike all buttoned up anxiously started it and it idled perfectly was so relieved was nearly beside myself with disbelief Of course when buying anything used you are at the mercy of the guy at the junkyard who usually has a different perspective To him if the donor bike was in good shape it must be low mileage but fortunately these carbs actually were suspect the wear problem with the plastic pieces starts to affect carburetion around the 15 20K point think not everybody notices how bad their bike has begun to run since it is a very gradual degradation and some people are not as particular about their vehicles as am Here s the arrangement with the carbs and why haven t had any luck getting the parts need Suzuki buys the carbs from Mikuni Japan and in order to get the part that wears out you have to buy the entire carb body for approximately 350 and of course you need four of them Dealer reps told me to contact Mikuni so did and it turns out that Mikuni Japan is separate from Mikuni America and Mikuni America said they couldn t help me So far Suzuki of North America Mikuni America and all the dealers have talked to have said they can t help me Their stance is that the part is available you just have to spend 1500 for four carb bodies that s all No haven t contacted Mikuni of Japan and at this point do
117. bly a leaking exhaust gasket If you fixed the Pukin Petrol Syndrome and you were leaking gas before you were running rich and likely would not have the lean idle mixture backfiring By fixing that rich condition you have leaned out the fuel mixture and now have the minor popping due to the lean mixture Adjust your Idle Mix Screws as per the Carb Clean FAQ e 1 2 to 1 full turn richer may stop the backfiring Try that first before doing more complicated things That should also compensate for any altitude change however be aware you should isolate it to ensure you do not have another problem like blown Exhaust Gaskets or Worn Needles etc Or it simply may have not been set properly in the first place e Enrich the idle mix Now that you ve got more air your idle mix is lean which causes the backfire Turn them all the way in not tight and then back them out 3 5 turns each If that doesn t solve the problem completely turn them out another quarter to half turn Unless you have a new exhaust leak can almost guarantee this will cure 95 of the popping Feedback e The elevation of Phoenix is 1112 feet Yep 10k is a pretty big gain Pack light over the passes think the loss of power will be very noticeable but it won t stop you it IS a motorcycle Going down a tooth on the front sprocket is an option but it harms your gas mileage and maximum potential cruising speed say don t change anything and tough it out Stick in the
118. cal volume is about 4 2 r 3 smaller drops ignite better by a factor of three times the difference in the radii Producing these small drops at idle as well as wide open WFO requires more than one method of atomisation Hence your carb has three distinct fuel circuits The simplified view has one single air circuit If you look at a carb you ll see that it is a fancy glorified pipe through which air passes When you twist the throttle a slide raises in the carb throat This may or may not happen with the engine NOT running due to differences in design But anyway this slide controls the amount of air allowed to go into the intake manifold The intake manifold is whatever is between the carb and the hole in the head containing the intake valve s The float chamber is an area inside your carb filled with gasoline whose level is more or less carefully controlled There is a float in there sorta like in the back of your toilet You access the float by removing the float bowl The float is either solid or filled with air In any case it floats in gasoline and is made of material impermeable to that solvent When the fuel level rises so does the float At a certain level the float pushes a conically shaped round thing float needle into a conically shaped hole seat and shuts off the flow of gas This needle and seat is the valve that controls gas flow into the bowl Float level is important and so is a good seal here If the level is too low t
119. cceleration pump e The stock cable doesn t fit you have to make a cable Yes the stock choke cable fits and works e Minimum 2 3hp more and the throttle response you can t compare this all with stock cams Gottfried Team Pami PAMI Performance Kits by Mtbiero Cugino Pegaso don t have the entire kit won t work with my Pegaso but do have a set of team Pami 36mm Mikuni radial slide race carbs for a F650 on my Pegaso Just the carbs alone gave me a very noticeable power boost more top end and allows me to cruise the bike at the 2000 to 3000 rpm range without any lurchiness When first put them in used my stock airbox when finally removed it and went to Uni filters the bike really woke up Right now I m still trying to get the idle right messed up assumed the idle mix screws should have been at 2 turns out nominally finally got a tuning manual from mikuni com that says unlike every other carb Mikuni makes the RS idle mix screws range is 1 8 to 1 2 turns MAX Been wrongly going to leaner idle jets to compensate and causing other issues l m back on track and expect to have them idling perfect after about one or two more iterations The nice thing about removing the airbox is can have the carb out and on the bench in 6 minutes as opposed to 1 hour before Alternative Carb Parts OEM Parts List OEM Carb is a Dual Mikuni BST33 B316 CV carb http fag f650 com FAQS CarbMiscFAQ htm 18 of 23 18 02 200
120. ce until after this procedure you need steady hands Notes 1 Flash notes the manual says to put the seam in the float parallel to the joint where the bowl meets the carb Gasket Surface For him that was WRONG The float level was too low once the carbs were back right side up It wouldn t sustain a speed over 80 mph The manual doesn t actually say that ed 2 Float Height discussed this with Flash at the time Setting the float parallel to the Gasket surface is a rough measurement From what understand it s what he interpreted as the approximately correct setting from the Maint Manual tried to pin him down but he said he adjusted it following that approach and when it didn t allow him top speed he took them out again and bent the tang a little When asked what height he says I dunno bent it a little http faq f650 com FAQS Carb_Clean htm 14 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ Anyway there is a correct measurement and a correct WAY of measuring it If you re like me not too comfy with a little you measure it the right way put mine at 14 6 Several times It worked FINE At the end of the day what Flash did was right because he bent it just enough to get fuel delivery all the way across the board without flooding at low roms when the demand was not too high and with no overflow of gas because it could never shut off when switched off It s a TRICKY measurement as you
121. cept in the middle of this picture Main Jet Removed there is an aluminium stalk with a hole in it where I ve already removed the Main Jet The Main Jet screws through the hole in the Aluminium Stalk which pokes up through the Float Frame The Main Jet looks like this Stock vs DJ Jets to the bottom left is the Stock Jet to the right is my Dynojet Jet Using the Large Screwdriver Make sure it is good and WIDE so it just fits in the groove undo the Main Jet and remove it It should be stamped 132 5 if it is the stock jet Check there is nothing blocked in the hole and if so use a stiff PLASTIC rod or Bristle NOT a wire Brush Stalk to dislodge the blockage Put this aside Inspecting and replacing the Float Frame O Rings When you look down on the Float Frame close to the idle mix screw location Top of picture you will see a plastic Stalk about 5mm in diameter which connects the Float Frame to the Carb Body Grasp this stalk as low down as your fingers will allow and wiggling it a little bit pull it gently vertically upwards It is quite tight until the O ring comes out of the hole When you pull it out you will also pull out the Float Valve which hangs off a Metal Tang by a thin wire The location of the Metal Tang it hangs off is marked up in this picture Metal Tang It s O K for the Float Valve to fall off the Tang and it probably will when you remove the frame and don t think it makes too much difference which way around the w
122. ck on pinching both diaphragms in the process Looking from above either diaphragm would protrude from under its cover for maybe a fifth of the total circumference this can t be good Has anyone else experienced this problem Could it be that whoever replaced the diaphragms before me got the wrong size In your experience is the diaphragm exactly or at least almost exactly the same diameter as the groove it s supposed to sit in mean this was NOT a case of the rubber trying to pop out can t see how anyone could have managed to get the entire edge down there let alone keeping it down while reaching for the cover Last question could this be part of the reason why my mpg is low I m imagining that pinched diaphragm edges could be fairly equivalent to rips in the rubber No there was nothing sprayed on them Also they were already pinched before even started unscrewing the covers so the previous attempt to get it right apparently failed too called the dealer today It appears to be a well known issue with older diaphragms they simply grow larger with age due to contact with gas fumes The mechanic spoke to thought my diaphragms are the original ones which would make them almost nine years old They are approximately three millimeters too large across He also said getting older diaphragms back in the slot is a major PITA They wanted 18 per diaphragm must have remembered the price of some other part so called the local
123. ckrest pad 51667 98 mounted to the low sissy bar upright complements the Sundowner seat and makes life more comfortable for passengers Choose the standard size top stitched backrest pad 5261 2 95 if you plan to use the sissy bar mount Ultra Bags mentioned below The easily removed nylon Ultra Overnight Bag 94736 98 or Ultra Touring Bag 94744 98 slip over a low sissy bar with a standard size backrest pad and rest on the rack They strap to the motorcycle with quick release buckles and take only a minute to attach or remove Both provide useful storage space for light items like clothes A crash bar 49007 90 makes it easier to right a heavy bike that falls off its side stand and is also a convenient place to mount Halogen fog lamps 6891 3 98 Additional lighting is very nice at night and can be used to dramatically increase conspicuity in daytime http www chuckhawks com super_glide_sport htm 4 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT Forward mounted highway footpegs 49019 95 work with the engine guards and give the rider an alternative foot position on long rides The new Dyna passenger footboard kit 50877 01 replaces the standard passenger footpegs and can increase passenger comfort So equipped an FXDX can take a couple for a weekend jaunt or across the country Commuting accessories The Dyna Custom Pillow Look seat 52159 96A is comfortable and works well for commuting and weekend
124. copes better with Altitude Air temperature What does constant velocity mean When you open the throttle the engine draws more air through the carb A large quantity of air must move faster being drawn through the same diameter Venturi than a smaller quantity of air does In a non CV carb the air would be speeding up and slowing down in the Venturi depending on the demand of the engine In a constant velocity carb the Venturi automatically gets smaller when the engine isn t drawing much air and gets larger when the engine draws more air this keeps the velocity speed of the air close to the same at all throttle openings and provides a more consistent metering of fuel in the Venturi It is supposed to give better fuel economy cleaner emissions and adjust itself to altitude changes Most tuners dislike constant velocity carbs and use round or flat slide carbs in which the slide is raised directly by the throttle cable instead of indirectly by airflow as in a CV carb From http www sonic net blaineh xs1icarb html Going from Low to High Altitude Possible Symptoms You may experience rich running stalling hard starting and irregular idling at slow engine rpms at high altitude The bike will also run rich at full throttle because too much fuel will flow through the main jet So do need to adjust it Yes amp No The carb vacuum diaphragm will adjust the mixture for you when running on the throttle http faq f650 com FAQS Carb
125. d replaced all the rubber bits inside the lil face plate screws are as loose as they can be without it leaking and still it s difficult just wanna know if there are any other Chain Gang Geezers out there with this same problem and if so what did you do to fix it or did you just decide to live with it did you replace it with a billet unobtanium carbon fibre one from Slow By Sarducci or did you just stuff a big hose in there and the hell with a reserve or what I m getting desperate here my left hand hurts and not for the usual obvious reasons Shank NYC USA Take it apart Remove and grease the o rings Reassemble in reverse order Gotta do that every now and again Consider doing it as part of the 6k interval circus It sure helps if the tank is empty OR you remove it as the sidestand is on the left and you have to lean the bike to the right to make the gas go away find that doing it while have the tank off for something else is easiest But others have reported that it IS possible without removing the tank Flash 412 CO So has anybody had a fuel petcock that is REALLY hard to turn Mine must really need cleaning or something special Do I have to take it apart to make it easy to turn looked in my BMW manual and couldn t find anything nor could find anything on this site basically have to stop the bike at the side of the road and take my glove off to turn it because need such a tight grip Omnikron Try using one of those ha
126. d 230 Shank NYC Teddco 1192 JAMES We did it yesterday with the exception of Dyno jet springs and it runs really great now No flat spots or roughness in the acceleration curve We screwed up on the springs but we can probably pull the diaphragm cover and switch out springs without pulling the carbs Somebody tell me that can be done Pulling the carbs was not that hard but certainly not easy XtreemLEE 1188 e Carb removal experiences removed the carbs today using the mild force method described in the carb cleaning FAQ i e no airbox removal Everything went ok except that wasted one of the float bowl screws Had to get a screw extractor to fix it d mn that screw was hard to undo Anyway when reinstalling the carbs ran into a problem It wasn t that hard to get them into the engine side rubbers but then found the airbox side rubbers were suddenly way too short there was a 2 mm gap between rubber and port on the airbox side when the carbs were http faq f650 com FAQS Carb_Clean htm 21 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ fully seated in the engine side rubbers Apparently the rubbers had been pushed into the airbox when struggled with getting the carbs out It was NOT easy to pry the rubbers back out of the airbox Just a small warning and a note to self to take it a bit more easy next time veggie deluxe Sweden Yep changed both my diaphragms out last fall both had failed Bike exhibite
127. d rough running Done so far 1 Lowered the needles which made the bike able to run at lower rpm in the same gear and only a little bit of carbon fouling on the spark plugs 2 Changed the chain and sprockets which made the bike run at a stable speed on a constant throttle position Smooth is the word 3 Changed the Spark Plug Caps to OEM 1kOhm had NGK 5kOhm this made the bike run at even lower rpms in the same gear and perhaps a little bit smoother measured the Resistance before the change to 14kKOhm and after to 10kKOhm which means that the current is now 40 higher at the spark plug cap took the bike out for a 50 miles spin this afternoon and the bike runs pretty good now no rough running good rpm range in gears and easier starting Could it run even better have no idea since have no other bike to compare it to Problem left The needles are 1 position lower than they are supposed to and the bike is still a little rich not much though Solution Next thing up is to remove the carbs and change the emulsion tube and while I m at it I ll change the main and idle jets all parts laying on my desk I m going to try to measure the float height also If ain t mistaken mine Idle mix screws are set to 3 0 or somewhere near did a major overhaul of the carbs last spring which included new Venturis 135 main jets and new OEM spark plug caps Since then the bike is consuming approx 15 less fuel and the spark plugs are no longer
128. d that couldn t be the right price In fact that is price of the cast piece that bolts to the tank They then looked further and a found a price of 130 for a lock and key But must give them my key code There must be another source for such a small piece seem to remember others inmates mentioning European car repair shops a possible source Does any one have specifics on this That is a car model that uses the same lock or better yet an actual part number Adrian 668 97 Funduro 01 Dakar A Nope Not yet Sorry Removing the Gas Tank Restriction for easier filling NOTE Appears to ONLY apply to US Models and WILL VOID your WARRANTY Filling a classic from a gas can or at a station is not pleasant The small hole keeps you from seeing how much you put in and at the station the spring thing that surrounds the hose nozzle at least here in NJ doesn t fit into the larger opening just scratches whatever it contacts A while back someone mentioned that they cut off the small hole with a hacksaw thereby eliminating most of the unpleasant part of filling up It enables you to see better and the spring thing can be held back so no contact is made with the tank I m sure doing this is easy but thought many of us would like to as well and any additional comments and or suggestions would be appreciated It s really a good idea and the thought of not struggling each time fill up makes this surgery a must did the same with the F650
129. d that there are no sources of ignition like open flames etc There are two common methods used to set the float height FII go through both They both work well so the choice of which one to use is yours Getting Started Step One Turn the fuel tap to the off position and remove the carburetor That s an overly long word so from now on lets just call it the carb Drain the fuel from the carb hold it upside down and remove the float bowl Just remove the four Phillips head screws and that step is done A word of caution you ll be playing with some fairly small parts so would strongly suggest doing this job over a clean work surface so if some thing does fall you ll have a hope of finding it and so it doesn t get all dirty A smart trick is to use a couple layers of paper toweling or a clean rag on the surface That way if some thing does fall it won t jump away and hide Step Two The second step is common to both methods Before setting the fuel level you first need to confirm that the plastic tip of the float valve needle is in good condition Both procedures assume it is Over time the tip of the needle http justkdx dirtrider net floatlevel html 1 of 4 18 02 2007 12 30 31 Float Level Adjustment wears doesn t seat properly and alters the fuel level That s normally why your fuel level is out of whack To get at the needle you first need to remove the floats pivot pin Before you do take a look at the car
130. d the same drastic drop in gas mileage Marty 436 Chicago 97 F650F Numerous problems this month blown fork seals poor pick up worn head races but all easily resolved with the help of the Technical FAQ s God Bless You All The poor pick up has been traced to the carb mounted inline fuel filter but whilst had the carbs out decided to clean them anyway and have the following snippets to add to the FAQ Firstly as with many others found the float bowl screws difficult to budge solution get an impact driver it does the job Secondly as someone else complained once came to refit the diaphragms they wouldn t go at least 3mm too big Don t worry they will still fit The secret is lots of fine Sewing machine lubricating oil If you lube the grove on the carb body and the lip of the diaphragm Working with both hands from a point on the circumference feed the diaphragm lip into the grove Then moving your hands in opposite directions around the circle keep feeding the lip and press each section lightly back towards your original starting point The idea is you are compressing the rubber lip to a smaller circumference The oil will help the already seated material slide in the groove Once did this my impossibly large diaphragms went back on without any problem The oil helps hold them in place whilst you reach for the cover as well Hope it doesn t rot the rubber Just the new head bearings left to install My wife hasn t found the steeri
131. d via this link Performance Mods Section Carbs for Dummies Pulling the Carbs Puking Petrol All About Floats e Proper Choke Use Do I need a Carburettor Adjustment for High Altitude Dol need to Synchronise the Carbs Fast Idle Problems What is the Effect of Dropping the Needles Flat spot in carburetion What are the Holes in the Bottom of the Slides for Slide Barrel Wear Carb Alternatives Alternative Carb Parts Water in Float Bowls How do I drain them Fuel Line Replacement Straight to the Carb Clean FAQ For Aftermarket Fuel Filter Q s and the OEM In line Fuel Filter For Petcock Q s For Idle Q s For Canister Q s Carb Primer by Flash 412 Please read the Disclaimer before attempting any work in this FAQ October 01 This is a carb primer for those with little or no understanding of this device If you re carburettor literate move on If you re carburettor ignorant you might like this Carburettor is NOT Latin for don t mess with it http fag f650 com FAQS CarbMiscFAQ htm 1 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ Fuel and air need to be mixed in the proper proportions in order for your engine to run The device that atomises the fuel is your carburettor unless your motor is fuel injected Due to the relationship between the volume of a sphere and it s surface area spherical surface area is about 12 6 r 2 while spheri
132. d with the kit to make this upgrade the easiest youA ve ever done Our work and products are guaranteed for one year For an estimate on your particular application contact us directly by telephone at 805 481 6300 You can e mail us We also offer a 24 hour fax line at 805 481 6341 http www floheadworks com Products keihin_carburetors htm 1 of 2 18 02 2007 12 30 44 Keihin Carburetors Request Order Links Keihin Hi Flow Air Filter Kit Keihin CV Carb with Hi Flow Air Filter Related Articles Carburetor Tuning Tips Fun to Ride Guide 2000 2003 FLO Headworks Contact Perry Kime at 805 481 6300 or via e mail FLO Headworks 1150 Pike Lane 2 Oceano CA 93445 All rights reserved All prices subject to change without notice This site has no affiliation with Harley Davidson Trademarks and model names are the property of the trademark holders http www floheadworks com Products keihin_carburetors htm 2 of 2 18 02 2007 12 30 44 HARLEY DAVIDSON SUPER GLIDE SPORT THE Y2K HARLEY DAVIDSON SUPER GLIDE SPORT By Chuck Hawks Harley calls it a sport model motorcycle magazines call it a sport cruiser and call it a big standard Whatever you call it the FXDX which is H D s shorthand designation for the Dyna Super Glide Sport is a very versatile motorcycle It can carve a pretty mean canyon road take a friend for a ride negotiate city traffic with aplomb fly down th
133. ddenly Did it start after a long trip Have you done any maintenance lately Have you heard it before 5 Under what conditions does it occur Tell us more about when you hear the noise a Temperature Does it happen only when the bike is cold or when it is hot Does the noise change with the ambient air temperature b Engine Speed or Bike Speed Does it only happen between certain engine speeds eg between 3500rpm and 4500rpm or does it occur only at certain road speeds eg below 30mph 50kph c In all gears Neutral clutch engaged Does it only occur when in neutral etc Note Just because you can not hear it in 5th gear does not mean it is there when you are in 5th gear d Frequency Does it happen when you turn the key on off Does it happen just after you start the bike Does it happen once a minute once a second e Load Does it occur under heavy load or is it just under a normal load f Road Conditions On road or off road Uphill downhill 6 Anything else Is there anything else you think might help identify the noise But please please please DON T FORGET to tell us how you fixed the problem Because then you help others Send some more Noises http faq f650 com FAQS StrangeNoises htm 22 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ You know the hardest thing about working on the Noises FAQ You spend the next 1000kms listening for every little tick clonk and thunk http faq f65
134. e It was a fairly new bike with only 3000Km on the clock and was the second oil change since new All was well for about 500km then started to notice that the engine was making a bit more noise than usual In my case it was loudest from about 2500rpm through to 5000rpm Slowly over the next 500km the noise increased in intensity and sounded a little bit like bad bottom end bearings did another oil change just to satisfy myself that all was OK Opened up the filter and it seemed pretty much normal for a new bike with only 4000km on it Nothing improved with the new oil change Over the next 200km the noise got even louder and was the worst when the engine was cold My dealer guessed at the cam chain tensioner and replaced it It actually did seem better when picked it up but the noise was back the next day Probably it was just really well warmed up when got it back and the noise was less pronounced The next morning it was real cold and real loud Dealer took it back yet again and this time they open the engine to hunt down the problem It took most of the day as all looked OK at first Then on a whim the tech decided to actually mic the bores as well as the pistons and rings PROBLEM FOUND Bario o Answer The cylinder bore was well outside the maximum spec Not by premature wear the bore was quite nice It was simply not right from day one at the factory Although it was news to me the tech told me there is actually an A cylinder and rings
135. e end of the PVC pipe and a screw on cap on the other It was big enough to fit his tool kit Seth 972 Springfield MO http faq f650 com FAQS Canisterectomy htm 6 of 6 18 02 2007 12 30 27 http fagq f650 com FAQS Photos Carbn etPhotos CarbOutScrews jpg http fagq f650 com FAQS Photos Carbn etPhotos CarbOutScrews jpg 18 02 2007 12 30 28 http faq f650 com FAQS Photos CarbnJ etPhotos CarbI ntakeRubbers jpg E http faq f650 com FAQS Photos Carbnj etPhotos Carbl ntakeRubbers jpg 18 02 2007 12 30 29 Float Level Adjustment Float Level Adjustment By Canadian Dave Before you consider rejetting your carburetor you need to insure you don t have any mechanical problems that are mimicking poor jetting Float level problems are common so checking the float bowl fuel level is a great place to start You might suspect that the fuel level is out a whack but wouldn t it be great to be able to confirm it before making any adjustment A fuel level gauge can be installed on the carburetor and the fuel level visually checked You can order a fuel level gauge from Kawasaki The part number for 1989 to 2000 KDX200 220s is M18 x 1 0 5701 122 The factory service manual does a good job of explaining how to use it If you need some help just post your question on the JustKDX Forum Before we go any further remember that gasoline is extremely flammable and explosive Make sure the area you re working in is well ventilated an
136. e screws weren t stuck had used 10 different sizes of small screwdrivers and none of them worked Then in an overnight revelation decided to look in the BMW tool kit for a special tool even though adjusting carbs probably isn t considered a routine thing to do There was a bent bobby pin in the kit I m sure it wasn t from BMW and it worked perfectly Fit right in the hole and in the slot exactly Turned the screws with no problem think it would be worthwhile to put the bobby pin idea in the FAQs Thanks again for your help will look for some rubber plugs so the screws don t get gummed up in time William USA What s that Bobby pins were used by women to keep their hair in place They sort of look like thin black paper clips They were sold in 5 amp Dime stores for about a penny each and tended to end up at the bottom of every drawer ever accessed by a woman believe that they started losing favor as hair holding devices in the 1960 s However as willing to be corrected by the actual users of such devices Richard 230 Pacifica CA Geez It s bad enough admit to using a girlie item but it s worse when find out I m old enough that hardly anybody knows what am talking about Richard got it right However the more expensive high tech bobby pins were brass in color and stronger than the black ones Evidently am lucky enough to have the high tech variety went by a bike shop today and they had an Keihin FCR Carb Wrenc
137. e Calculations Main J et Correction Copyright 1997 2006 Stephen Mullen Oldsmar FL http www nightrider com biketech main_jet_correction htm 4 of 4 18 02 2007 12 30 51 Estimate Horsepower Estimate 1 4 Mile Time Estimate Top Speed Engine Displacement Exhaust Length Gear Ratios The Nightrider Diaries The ramblings of a genius a a madman and something in between Whereis Sifton Cams Autocom Active 7 tested Harley Davidson EFI EFl basics explained EFI modifications explained 183 HP 2 carbs 2680cc The Backfiring FAQ THE BACKFIRING FAQ compiled amp edited by Kristian 562 Please read the Disclaimer before attempting any work in this FAQ Mike in SC BCWIill Flash 412 HSN Randy 748 Lyndon Kristian 562 22 11 01 There are quite a number of different causes for backfiring What this FAQ will try and do is to help you isolate the cause of it There are a number of solutions for the Classic F which cannot be used on the GS Dakar simply because the GS Dakar doesn t HAVE a carburettor So that means if you have a GS Dakar you re lucky because there are fewer causes It doesn t mean it ll be any cheaper to fix though What causes Backfiring Deceleration Backfiring is the most common backfiring that occurs when you change down and throttle off This extract from the Virago Site explains it succinctly In g
138. e Rubber Diaphragm NOTE Do NOT spray the Rubber Diaphragm or indeed any Rubber Parts you wish to re use with strong solvent Some Carb Cleaners contain strong Solvents Use a gentle soap like Dishwashing Liquid After you ve cleaned it you can leave it attached to the barrel with your thumb holding the bottom lip of the Diaphragm hold the Rubber of the Diaphragm up to strong light and stretch it by pulling upwards It can take a fair amount of pulling Work your way around the full circle of the rubber If there are any splits or holes you should be able to see these fairly quickly and the Diaphragms should be replaced Inspecting the Slides If the Air Filter lets any gunk through or somehow dirt gets trapped in the Carb the Carb Barrels can wear at the front curved face and at the Wings on the side which results in their becoming scored so check for scoring on these surfaces They are fairly robust mine are actually quite scored but still function adequately so you don t need to replace them for a bit of scoring Don t forget there s fair amount of Air Pressure against the back of the Slide even if it doesn t go up and down that fast It s rate of rise and fall is controlled by a mixture of the Airflow through the Butterfly valve the spring stiffness the size of the little hole off centre in the base oft the Slide and to some extent the friction caused by wear at the wing and front faces There is no external mechanic
139. e a little further back not from rear of chain Chain is original Any ideas anyone Thanks UPDATE Kristian guessed that maybe the chain was hitting from the slack being taken out in a hurry think that is what it was as we just replaced the chain and sprockets See the Chain Sprockets FAQ and the popping is gone Thanks Kristian DaveJ 888 Hannibal MO Noise 18 01 Dakar 650 clunk clunk clunk Front end noise have developed a front end noise about 4k mostly offroad miles it sounds like my whole headlight assembly is about to fall off but nothing can find is loose Could this be from the forks themselves Try checking for play in the steering head bearings Also are you running an ABS machine People describe the ABS activation reset as a clunk Maybe you re hearing that Advrider e Noise 19 A while back posted about this rattle that had It seemed to be up front and only at certain load vibration conditions This sound went away when slid the front forks down and took off the lowering kit did not notice any bolts that were loose when did this but the sound none the less is gone Don Rochester NY Noise 20 Transmission rattle 2001F650GS Dakar 4500 miles It sounds like there is a lose set of jingling keys in my transmission The is very subtle and only occurs when am in gear and moving Anyone have any ideas At first thought the front disc or caliper was lose but that was not it Michael 1045
140. e highway for hours on end and even look pretty good cruising down main street Like all Harleys it is very easy to personalize very easy to hop up and retains its value better than any other brand of motorcycle It may not be the best bike in the world for any single purpose but it would be hard to find a better big general purpose motorcycle Ergonomics The basic ergonomics of the bike are moderate and comfortable The wide black 1 diameter handlebars have a normal rise and bend the forks are raked at a standard 28 degrees and the footpegs are located comfortably beneath the riders thighs neither forward nor rearset All controls fall easily to hand or foot and the tach and speedo are mounted on the handlebars facing the rider where they are most easily seen The black rectangular mirrors give the rider a decent view astern All in all a comfortable standard riding position Clearly this motorcycle was designed to be ridden fast and for long distances if http www chuckhawks com super_glide_sport htm 1 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT desired Ergonomically the only flaw is the seat which looks good but positions the rider too close to the tank and in any case is poorly shaped and inadequately padded It is even worse for a passenger than for the rider suggest replacing the stock seat with whichever of the many available H D accessory seats that best fits the owners needs Fea
141. e is a bronze piece which is or contains the SEAT 5 This bronze piece also has an o ring However BOTH of the seats just plain fell out when turned the carbs upside down 6 figured that if the o ring did not have enough interference to hold the thing in then it would not do much of a job keeping gas from getting by 7 replaced the o rings with some slightly larger non metric standard ones had in an o ring assortment box which fit better than the ones took out After putting it all back together it started right up like it s supposed to full choke amp zero throttle rode around the block When got back put it on the sidestand and a few drops of gas came out one of the hoses on the opposite side from where it HAD been leaking Being an optimist put a coffee can http fag f650 com FAQS CarbMiscFAQ htm 4 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ under there turned the petcock off and left it overnight All was well this morning BTW I also installed the fuel filter while was at it There are four carb screws which replaced with Allen s They are 5M0 8 x 12 But if you try to use ones that are too long they won t go in the front holes only the rear ones See the Carb Cleaning FAQ for details and pictures of the Carbs Q What are the Symptoms My bike a 95 F came to a halt as if had run out of fuel will add that hadn t Anyway the bike came to a stop and found the pip
142. e proper proportions in order for your engine to run The device that atomises the fuel is your carburettor unless your motor is fuel injected Due to the relationship between the volume of a sphere and it s surface area spherical surface area is about 12 6 r 2 while spherical volume is about 4 2 r 3 smaller drops ignite better by a factor of three times the difference in the radii Producing these small drops at idle as well as wide open WFO requires more than one method of atomisation Hence your carb has three distinct fuel circuits The simplified view has one single air circuit If you look at a carb you ll see that it is a fancy glorified pipe through which air passes When you twist the throttle a slide raises in the carb throat This may or may not happen with the engine NOT running due to differences in design But anyway this slide controls the amount of air allowed to go into the intake manifold The intake manifold is whatever is between the carb and the hole in the head containing the intake valve s The float chamber is an area inside your carb filled with gasoline whose level is more or less carefully controlled There is a float in there sorta like in the back of your toilet You access the float by removing the float bowl The float is either solid or filled with air In any case it floats in gasoline and is made of material impermeable to that solvent When the fuel level rises so does the float At a certain level the f
143. e running from out of the top of the carb was pumping petrol out and onto the engine It will turn over with no problem but doesn t want to know about catching know this isn t a huge amount of info but until Monday when I m off can t give you any more Any ideas as too what could have gone wrong The bike has 70K on it and normally runs well with no major problems other than a bit of oil in the airbox It MUST be a float or FUEL VALVE problem The fuel is gravity fed from the gas tank to the carbs The carbs is design to work with a certain height of fuel inside If this level is a bit too height it is like running with the choke on and if it is far too high it will overflow by the small pipe s The device to keep this level right is called a float and resides in the float chamber at the bottom of carbs It works like the device that you might find in your toilet bowl When it drops a bit it opens a valve to let more fuel in and when the fuel raises it it will close the valve If the valve gets stuck partly open by some small impurity in the fuel or the float does not rise due to it being punctured or stuck the fuel level will rise until it overflows Haakon 626 Norway 12 1999 F650GS Read the FAQ on how to get the carbs out Take them out Take the float bowl off Remove the floats Spray some carb cleaner through where the fuel normally goes IN to knock out any impurities You should probably change the little fuel filter in the T whil
144. e turns were very mild The sound seemed as if it came from the upper right side of the front wheel but this is very speculative have not experienced this when driving solo and could see nothing impinging on the front wheel A2Trak o Answer I m with Motoplaner especially if you have a factory lowered model There s a service bulletin to explain how to fix the dragging side centerstand for the lowered model Marty 436 Ed See also the Classic Lowering Kit FAQ or the GS Lowering Kit FAQ For the service bulletin see page 1 and page 2 Noise 32 when your bike stalls does it make a loud noise Where does it originate from Is it the decompression release stalled mine in a mud hole with a passenger and that noise was much louder than normal Now it makes kind of a crunch crunch sound when under load and a low http faq f650 com FAQS StrangeNoises htm 11 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ rpm starting from a stop went over all of the external parts of the bike and found nothing loose except the retaining clip for the sidestand but that wasn t the origination of the noise Hard for me to narrow down where the noise is coming from because need to be moving to here it gsatlanta o Solution 1 Oops it was a very sloppily adjusted chain Last time adjusted the lightbulb in the garage was out gsatlanta o Solution 2 I d wager it s the compression release trigger mine a lot off road
145. e up from the basement where pulled the petcock apart and put it back together didn t pull it off the tank just disassembled cleaned lubed a touch of white grease on the spring washer and o ring and re assembled Operates much smoother now As for able to ride for miles with it closed occasionally have found the bike will go about 3 4 mile on dead closed Rand 1111 Close the Fuel Tap http faq f650 com FAQS Gas_Tank_Removal Replacement htm 7 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank Q In the BMW owners manual it says to ALWAYS CLOSE the fuel tap when the engine is switched off I ve never heard that I ve only thought to turn the fuel tap off when I m storing it long term Yes Keeps it loose Chris in Santa Cruz CA 782 If either carb s float needle fails to seat possible to drain fuel tank into cylinders or floor see puking petrol syndrome at least on some bikes Cranking on cylinders full of fuel can damage engine bent conn rods While not likely just easier to turn off the tap Marty 436 Chicago 97 And if you park inside near a fridge water pump or heater you might save your house from burning down if the carbs leak Todd 389 I ve been riding bikes for 37 years and never turn the gas off unless am gone for a few days or more Never had anything happen But as mentioned above it will probably not hurt to do it occasionally so the valve doesn t get stuck Colorado Bob
146. e way older ones and some newer ones may be made of copper but that s another story Floats that are less buoyant will allow the fuel level in the bowl to become too high before they shut off the flow even if they are properly adjusted This in turn will permit more fuel to be sucked up which will enrich the air fuel mixture which will affect fuel economy Floats are cheap and relatively easy to replace As someone said it makes sense to replace them now and then 13 years seems a long time to me The post about weighing the floats was very interesting and this should permit a very precise determination of their condition ouoyancy However a visual examination can also help If they re heavily stained porous looking or just plain cruddy change em See also e htto www airheads org contrib fuel html e htto justkdx dirtrider net floatlevel html Proper Choke Use Q Ok here is my question Is the choke supposed to move by itself have found that when the bike is cold and have the choke fully on and ride aggressively read rev to 7000 then shift then wide open again the choke closes and often time the bike will stall going down the off ramp when declutch Is it supposed to move like this If pull the choke back it runs fine again It can be a pain staling like that Is this indicative of another problem do know you are supposed to let it warm up a bit before opening up but it seems to be warming up slower Is that a symptom
147. e you have them out If you don t have an inline filter installed between the petcock and the T you d be advised to add one Flash 412 CO Q Can not should you still drive with Puking Petrol syndrome e You should try to shut the fuel off 1 4 mile or so BEFORE you shut it off That way you have partially drained the fuel line amp carbs just in case fuel expands when heated and may find its way out when it does If the gasoline fills up the cylinder is that even possible on the F6507 you may get hydraulic lock and bent connecting rod or other parts when starting Fuel dilution of the oil may give you MUCH lower oil viscosity and the higher wear that goes with it Also be aware that the F650 petcocks have been known to fail Running the bike should not present a problem unless possibly during an extended period of gridlock YMMV Marty 436 Chicago 97 F650F All about Floats by A Watson http faq f650 com FAQS CarbMiscFAQ htm 5 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ 12 12 01 Floats serve 2 purposes First they keep the carb bowl from overflowing by floating up against the float valve and shutting off the gravity feed flow of fuel Second properly adjusted they maintain the fuel level in the bowl at the right height This is important because the height of the fuel in the bowl determines how much fuel gets sucked up through the main jet for a given RPM which in turn has a direct affect
148. echanic said that was normal but wonder TexasArmadillo o You won t know how far your valves are out of adjustment until YOU check Either that or else something silly is going on like your cam chain tensioner in backwards or summat Flash 412 CO o have 24k km on my 2004 GS have found on cold mornings for the first 1000km after an oil change sometimes get the compression release mechanism clicking listen for the sound when you kill the engine sometimes you will hear it It sometimes lasts 5 10 seconds as the engine comes up to speed and the oil starts warming up Each time have checked the valve clearances have also checked the compression release is okay and there appears to be no other strange behaviour Winter 1935 o Cold oil 5 to 10 seconds That would seem to fit my symptoms Lately as the weather has gotten warmer don t here it so much TexasArmadillo Noise 55 BMW Service Bulletin 23 001 06 061 from October 2006 identifies a possible gearbox transmission rattle With the engine running in neutral place the bike on the sidestand If there is a rattle on the sidestand but not on the center stand then it is likely you have this problem The other check is to engage pull in the clutch while the bike is on the sidestand If the noise goes away then this service bulletin applies to you Please check the Service Bulletins for relevant VINs and contact your local dealer to have the work performed Noise 5
149. ection of each Carb Bowl This way when goes go in it goes directly into the filter and out through the netting fabric to each carb Butterfly Valves When you first get the carb out you will see this on one side This is the Engine Side of the Carb The two Brass circular Discs are the Butterfly Valves which rotate about a Central Pivot and open when you open your throttle The more you open your throttle the more and faster air passes through and creates a vacuum sucking up the Petrol from the Float Bowl through the Carb Venturis These parts hardly ever need removal or replacement and should be left alone unless they are obviously sticking i e when you manually turn the throttle against the return spring you can feel they Jam for a moment before they open If there is any dirt stuck in the pivot give it a bit of a squirt with carb cleaner and clean it with a brush Inspecting the Carb Needles Take the Carbs and stand them up in your work bench Float http faq f650 com FAQS Carb_Clean htm 9 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ Bowls down Try to let the Idle Adjustment screw hang over one edge of the bench so you don t bend it On one of the Carb Diaphragm Caps undo the two Philips head screws and remove the Diaphragm Cap They can be pretty tight so use some good downward pressure so you don t mangle the screws You may even need to gently tap the end of the screwdriver or get to work wit
150. ed by Solvents e g Carb Cleaner Petrol Do NOT use wire brushes or bristles from wire brushes to clean the jets you will damage them 2 You need a Large Thick and Fairly wide Flat Blade Screwdriver for removing the Main Jets 3 You need a Small thin Flat Blade screwdriver for removing the Pilot Jets 4 You need a Medium Sized fairly Blunt Phillips Screwdriver for removing the Float Bowl and Diaphragm Cover Screws 5 The Tools should be fairly new should NOT be worn and must FIT properly or you will damage the Screws or the Jets especially the soft Metal of the Jets 6 If you want to measure the Float Bowl Height which is very tricky but important nevertheless a pair of callipers is recommended as a minimum Factory Pro make a Float Bowl Height Measuring Tool which in my opinion is not very well made and not worth the money but is useful If you can make one yourself go for it 7 Rags Fire Extinguisher in case you have an accident 8 Patience But don t open it up and then leave it lying around for weeks the O Rings and Gaskets can become dry and brittle and you might lose some of your parts or forget where they go But you may use the pictures here as a mnemonic if you wish J Q How do I undo those Float Bowl Screws A This is a good place to discuss the 2 Screws holding on each Float Bowl o The Phillips head screws holding the bowls were INCREDIBLY difficult to remove on my 97 ended up borrowing a friends cord
151. ed me to completely tear down the carbs for some direct inspection of my own After getting the carbs apart and taking some careful measurements finally found the true problem which is the plastic pieces that the slide mates with This piece eventually develops an uneven mating surface with the slide which leads to needle and emulsion tube wear and inaccurate air and fuel metering at idle and low speeds also noted that the problem can cause sticking of the slide if the wear is severe enough since the wear results in such a misalignment of the needle and the emulsion tube that the side load on the slide from intake vacuum binds the needle in the emulsion tube The original needles removed from Ellen s bike had two steps worn into them causing the slides to not fully lower as well had always thought the Bandit carbs would work on the 1100G so called American Suzuki and one of their reps said he had both a Bandit and an 1100G and had put Bandit carbs on the 1100G He said needed the Bandit intake boots and had to use pod type air filters It turns out he was incorrect it s a direct bolt on The used carbs put on Ellen s bike supposedly had about 4K on them and they looked like that was accurate mileage There is always the unconscious expectation when you work on your bike that it will run better since you have just expended so much effort and think this can sometimes create false expectations Before putting the used carbs on her
152. ems to have done the trick Noise 3 Rattling from Engine at Idle Possibly Compression Releaser Turn up your idle a notch If its occurs at low rpm especially when not fully warmed up it is the centrifugal de compressor It s a fairly regular click means it s about to engage because the engine is turning over too slowly If it is happening above 1500 rpm there s a problem If it s just the de compressor assuming it s had basic maintenance and oil changes unless you are going to get the valve clearances checked while you are in there don t bother to open up the engine at all If it s an OLD Bike Could be Cam Chain Rattle most probably caused by a fragged chain tensioner rather than a worn timing chain Refer the Cam Chain FAQ Noise 4 Brake Squeal See the Brake Squeal FAQ Noise 5 Buzzing sound from the front of bike 1997 F The ignition and cable guide assembly maybe loose and missing one of the two bolts that attaches it to the under side of the triple clamp upper Check that your ignition switch assembly isn t loose Makes a really annoying rev dependent rattle that sounds like something loose in the valve train Pete Ignition Switch FAQ Noise 6 A very noisy cam chain will be the sound of the plink plink of the chain smacking it s housing during trailing throttle and after throttle blips while idling But the F has a hydraulically tensioned cam chain it would be very unlikely for it to be loose Noise 7 Igni
153. eneral backfiring on deceleration as opposed to acceleration is generally caused by a lean condition in the pilot circuit What happens is that the mixture leans out enough to where is fails to ignite consistently This in turn allows some un burnt fuel to get into the exhaust pipes Then when the engine does fire these un burnt gasses are ignited in the exhaust pipe causing the backfire Newer Virago carbs have an enricher circuit which cuts in on deceleration to help this problem Earlier carbs do not have this would say check the pilot circuits and set them a bit richer It is hard to do this right without some equipment to test where you are Aftermarket pipes often increase backfiring probably because they may the bike run leaner A more detailed explanation can be found below Some riders have also experienced Backfiring on Up shifting An exhaust gasket item 3 below is the most likely culprit rather than items 1 2 or 4 5 So how do fix it 1 Idle Screw Can be Adjusted Classic F only Some folks cure backfiring by turning up the idle slightly This is the brass knob on the end of the black flexible thing hanging out the bottom of the carb set If you just have mild backfiring you can try this Many bikes never run at the low end of the recommended 1200 1400 Idle rom range in BMWs Manual Refer the Idle Mix Screw FAQ 2 Idle Mixture Can be Adjusted Classic F only No this is NOT the same thing
154. ening the Tighten Steering Head Nut in Middle or Handlebar Riser Mount Bolts o Feedback 1 had the same problem two years ago too thought that it was the steering bearings It turned out to be loose mounting bolts under the upper triple clamps which fasten the handlebar mounts to the clamp When they loosen in addition to letting the bars wiggle a bit too much they can make a clicking noise when you brake to a stop There are two bolts a jam bolt and a tightening bolt They are hard to reach without a deep socket or using a tool that is not supposed to be used on bolts The torque value is low only about 14 NM think to keep the rubber mounts from compressing too much o Feedback 2 Check the main nut for the head bearing shaft It is on top of the triple clamp and under the handle bars put up with this sound for months after the dealer adjusted the steering head Although couldn t move the nut with my hands as soon as put a socket 1 1 8 26mm on it could turn it with my hand After tightening the nut with lots of force on a 1 2 drive socket wrench the sound went away It was loose http faq f650 com FAQS StrangeNoises htm 5 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ o Feedback 3 also put up with the clicking for a while until tightened the steering head lock nut On my 97 the nut is 30mm was told to torque it down to 30ft lb but it loosened up again so went for 50 ft lb and that se
155. ep or that it cannot be done My intention was to remove the plastic so as to modify paint it was hoping it would just pop off with minimal hassle Robert in Texas 959 Black 97 Classic A You can pull the color part off the tank without removing the tank Take all the screws out between the cover and the fairing Take all the screws out between the cover and the engine covers Take the rear bolt out Removing the CAP is a bit tricky You need to be especially careful not to over tighten anything when you reinstall it Feedback e Leaving the plastic on the tank is just a short cut believe that the BMW method of removing the tank calls for removing the entire plastic fairing and then removing the tank Richard 230 e You will STILL need to remove all those fairing bolts panels and likely the BIG mounting bolt at the rear of the tank in order to slide it rearward enough to get the tabs out from underneath the fairing You ll still have to unscrew all those screws holding on the gas cap assembly to remove the beauty cover You might save having to disconnect the fuel line and cannister and vent line if still applicable If it s a matter of having a FULL gas tank perhaps it might make sense to drain it through the petcock into a large or several small gas can s first You could conceivably leave it resting on the bike but just slid rearward a coupla inches but very precarious especially if unattended with no gas cap If you ha
156. er than the mark then you might have a leaking float or bad float needle valve http faq f650 com FAQS Carb_Clean htm 18 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ You know the original Kawasaki Z 1 s had a tap on the bottom of the float bowls and you used a device just as you described to check the float level don t know where you would tap the float bowls on a Classic or if you would have small enough hands to connect it but this is a tried and true method that has been around for a long time F650GS Dakar Oregon Steve 1130 Or e lt lt My question is once you can see the fuel level from the outside of the carbs how do you know it s the correct level Is there a reference mark outside the carb gt gt Nope The only real way to measure it is from INSIDE See here http faq f650 com FAQs Carb_ Clean htm e Only a few carburettor makers and then mostly for racing carbs give fuel level info The most common tech info is the height of the bottom of the float s relative to the bottom of the carb body with the carb upside down BUT when the float height is absolute right upside down reassemble the carb and take an accurate measurement of the fuel level hose attached make your own mark s on the carb body and then you use that marking s the next time you want to check the float height Whenever something being it a piece of machinery boy girlfriend or whatever works near perfection ALWAYS make a note of ALL info
157. ers Manual the Harley Davidson Motorcycles Model Year 2000 brochure and the Standard amp Sport Cruiser Comparison Chart which can be found on my Motorcycle web page Wheelbase 63 88 inches Rake trail 28 degrees 4 1 inches Overall length 92 88 inches Overall width 33 inches Road clearance 5 75 inches Overall height 51 25 inches Seat height 27 inches Dry weight 619 pounds Wet weight 651 pounds GVWR 1085 pounds Fuel Tank 4 9 U S gallons inc 1 1 gal reserve Engine type 4 cycle air cooled 45 degree V twin Displacement 88 cu in 1450cc Bore 3 75 inches Stroke 4 inches Compression ratio 9 0 to 1 Carburetor 40mm constant velocity CV type Torque 82 ft lbs at 3500 rpm at the crankshaft Transmission constant mesh 5 speed Frame steel double cradle Front forks 39mm diameter 3 way adjustable cartridge type Rear shocks gas charged adj for preload and compression damping Front tire 100 90V 19 H D Dunlop K 591 sport Rear tire 150 90V 16 H D Dunlop K 591 sport Wheels 13 spoke black cast aluminum alloy Front brake dual 11 5 inch 292mm discs with 4 piston calipers Rear brake single 11 5 inch 292mm disc with 4 piston caliper Lean angles right left 33 5 34 5 degrees Miles per gallon EPA 50 hwy 42 city 1 4 mile 13 54 seconds at 96 48 mph Top speed 115 mph approximate http www chuckhawks com super_glide_sport htm 3 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUP
158. es that the bike was stored with carbs full of gas and hadn t run since last year have had the float needles stuck into the off position by varnish as the volatile portion of the fuel evaporates A few good raps with the end of a screwdriver handle can sometimes dislodge them and get things flowing again YMMV wield that screwdriver with caution carbs have been known to crack This also assumes that the problem is fuel related Marty 436 Chicago 97 F650F Last summer while riding on a rough dirt road at slow speed in high gear the engine died because of fuel starvation 2000 F Classic with Acerbis tank The fuel line was empty the tank half full disconnected the line at the pet cock filled it from the tank to let air out reconnected the line and the bike started again immediately Five minutes later same thing and so on opened the filler cap suspecting vacuum because of a faulty cap No improvement used a long spare fuel hose to make a bypass outside of the fairing to eliminate high heat from engine near auxiliary fuel filter Some improvement but no total cure Next day no problem put short hose back inside fairing No problem for a few days A week later riding slowly in stop and go traffic in city the same problem It always seems to happen when tank is half full or half empty suspect vapor lock because of high heat beside auxiliary fuel filter Werner 547 00 http faq f650 com FAQS Gas_Tank_Removal Repl
159. et because of the spooge that comes out so don t go replacing your head Gasket Until you re sure 2 Also this junction is right below the temp sensor that turns on the fan The hot air blowing out of there Can heat up the thermostat and fan sensor turning the fan on prematurely And when the fan comes on it will blow the hot exhaust gasses on your leg 3 My 98 F650 appears to display defective behavior The symptoms are as fallows an unusual gargle sound after downshifting after clutch release rapid acceleration or rapid deceleration the sound appears to originate and or surface in the exhaust have also noticed a slight decrease in overall power performance Jacek Refer also the Backfiring FAQ and the Strange Noises FAQ for more Symptoms of a Failed Exhaust Gasket B Where are the Clamp Nuts VERY often you can fix the problem by simply tightening the Exhaust Header Cylinder Clamp Nuts Do not overtighten The nuts are as soft as cheese Here is the RHS Upper One RHS Lower one LHS Lower One You can also try tightening the Exhaust Collector Clamp If you need to replace the studs refer What about those Rusty Exhaust Nuts below C So how do test if they are leaking You can check these with a bit of smoke like from a cigarette in a still area wafting around the joints Headers also crack and split sometimes Watch for the smoke being blown away by leaking exhaust gases or Take an old tired doll
160. ether if you wish Conclusion The Super Glide Sport is a two wheeled jack of all trades A big smooth well made and versatile motorcycle that can pretty much hold its own in any company It is not cheap in any sense but it delivers excellent value for the price Click here to return to Motorcycles amp Riding Online Copyright 2000 2005 by Chuck Hawks All rights reserved HOME PHOTOGRAPHY amp ASTRONOMY INFORMATION GUIDE GUNS amp SHOOTING ONLINE NAVAL AVIATION amp MILITARY HISTORY TRAVEL amp FISHING INFORMATION GUIDE MOTORCYCLES amp RIDING ONLINE http www chuckhawks com super_glide_sport htm 12 of 12 18 02 2007 12 30 48 Main J et Correction Motorcycle Performance Gu i d e www nightrider com biketech m j imne FA Henn matAarerisclac perrormance marie aviason motorcycies Rammer Performance Air Cleaners TC Performance Heads 100 HP Here is the way for your favorite lady to share your passion for motorcycles Preferred Links Reach 60 000 bikers a month Unique Parts and Used Parts Accessories for for Sal Sale 0 ters I s Step 1 Assume Nothing Check your carburetor s to verify the jetting installed in the carburetor s Step 2 Because air density varies with temperature and altitude changes a main jet correction may be necessary This chart was calculated at sea level with an air temperature of 60F
161. etimes gets 3x loud for 10 seconds then subsides Noise 45 sporadic grating the tranny on the RHS http faq f650 com FAQS StrangeNoises htm 4 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ from idle to about 2000rpm after 2000rpm it fades noise engine to normal piston noise Noise 46 replaced cam chain tensioner noise reduced moderately pitched MP clunk valve cylinder area vnen wurang o ol Noise 47 engine running Whirring of gears hum ooo gA ant Noise 48 inconsistent something electromechanical shutting off injector s area electrical antenna going down So what does it sound like and where does it come from For Engine Noises To help you identify WHERE it is coming from grab a good solid screwdriver put the tip on the Engine where you THINK the noise is coming from and the handle against your ear like stethoscope Move the tip around until you determine the source location Noise 1 Clicking from mid lower Front Forks As yet unidentified When replacing the fork gaskets you have to remove the spring in the fork And you can put in the spring upside down one end of it is thicker than the other and this end has to be up into direction of the upper fork bridge or better the driver Maybe someone didn t know that fact even the man who assembled it somewhere in Italy Noise 2 Clicking when Steering Turned see the Steering Head Bearings FAQ or Handlebar Clamps BUT try first tight
162. f a guy that misunderstood the choke on his veteran bike and was starting without it and when the engine got warm he applied full choke He did this for several years Pelle Sweden 02 GSDA The choke is not a choke air restriction its an enricher jet control more fuel hence it runs the engine rich carbons up plugs etc and uses more fuel If you run the cold starting device for long enough the plugs will foul the carbs will maybe overflow and the engine will flood and stall at idle If you don t have a temp gauge you should maybe get one the screw in type tells you when to close the choke Imagine setting up the bike with the choke on full You get the idle at 1100 rom by moving the idle screw in or out so the air and fuel match up and burn You then move the choke to the normal run position the engine will stall However run until the engine is hot and then move the choke lever The engine is so hot it ll burn pretty much anything lean rich whatever at least for a time and with the right throttle setting However the plugs will show what the mixture was like I ve had this on the dreaded Ural The Ural choke opens an additional fuel jet With the crappy sponge cake seals the Russians use the choke is always letting some fuel in You set up the carbs like this and get idle and some sort of balance You actually close up the main chamber a bit to allow for the extra fuel that s sneaking in via the choke On a Ural the seals then
163. f650 com FAQS CarbMiscFAQ htm 9 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ If it is idling high just Check the Cables BOTH Choke Cable and Throttle cables If you don t normally use the choke fully when the weather is warmer suspect that the cable isn t running freely and it s not going back all the way to the closed position In that situation would lubricate the choke cable with a very light oil and if you can just keep opening and closing it to work the oil along the length of the cable When the lever is closed is the end piece on the cable sat nicely in its socket or is there a pit of play there If there is a bit of play or you can see a small bit of the inner cable then it just needs that lubricant to get it working again Trevor 999 UK 01 GS Do need a Carburettor Adjustment for High Altitude by Kristian 562 Dick 420 Mark 403 HsN Richard 230 amp Unknown Generally the F650 Classic can cope with MOST Altitude changes with no changes to the Carbs Any Changes should normally only constitute MINOR adjustments to the idle mix screws The F650 CV carb provides crisp throttle response and lessens jetting sensitivity to temperature and altitude changes All constant velocity CV carburettors are designed to compensate for changes in altitude and barometric pressure From http www floheadworks com Products keihin_carburetors htm The FI should have no problem at all as it has lots of sensors and
164. ffect proper idle and starting not to mention sucking dirt and water directly into the carb The vent hose to the gas tank which was previously attached to the Canister is now used as a drain vent and is routed to the hose bundle by either footpeg I used the same side as the carb the right footpeg hose bundle There is a brass orifice in the rear carb vacuum line going to the canister It is actually a pinhole restrictive orifice which can clog It should be replaced or the tank may experience vacuum problems Some people replace it with the smallest size plastic fuel filters some people use a similar plastic nylon connector which is not restricted that is leftover from the removal of the other canister hoses Removing the CANISTER will not affect the catalytic converter Removing or plugging the AIR INJECTOR will kill the cat The canister is NOT the same thing as the air injection system The canister is an over glorified poorly engineered gas tank vent The air injector is used to inject fresh air into the exhaust stream with good success for over twenty years Some Euro bikes 95 96 may have the catalytic converter but not the vacuum actuated valve and the air injector system for the cat These bikes MAY not have ANY vacuum ports on the right carb nor any connecting hoses there Stock Configuration http faq f650 com FAQS Canisterectomy htm 3 of 6 18 02 2007 12 30 27 The Canisterectomy FAQ 2 3 exhaust Right side flow
165. firmly because they vibrate a bit although damped by the intake rubbers but not so tight you kill the head of the Screws Now you can turn the Carb over to stand on the Diaphragm Caps and work on the Floats For Problems reseating the Diaphragms see Diaphragm Trouble below Replacing the Main Jet This Parts easy You will see the needle where the main jet goes so Screw the Main Jet into the hole by hand making sure the Needle stays Central to the Jet When it is fully in Tighten it up firmly with your LARGE WIDE Screwdriver Do NOT over tighten it s soft Brass Just Firmly i e so it seats and then a little more Remember you will initially be compressing the new O Ring you just put on the Slide Carrier Replacing the Valve Seat Again fairly simple just push it back in place but put a little oil on the O Ring first so you don t ruin the Dry Rubber against the Metal Sides Replacing the Float Frame Replacing the Frame is fairly simple First smear the O Ring with a little oil Then feed the wire loop of the Float Valve over the Metal Tang and position the frame over the Carb Body with the Float Valve positioned over the Float Valve Seat and the Rubber O Ring on the Plastic Frame Stalk over it s hole Push it into position The Float Valve http faq f650 com FAQS Carb_Clean htm 13 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ likes to fall off the Tang during this procedure so either tip the Carb Body and
166. g back about 5 10mm then back and upward OFF the Frame Tank Lifting Have a Saw Horse ready or better still a railing with a cloth over it and place the Entire Tank over that Temp Tank Storage Lift with one hand under the rear of the Tank and one down from the top into one of the fork wells Tank Lifting Up They are flat Tabs on the Classic no locking devices The Tabs on the Tank just push in pull out the ones on the grey side pieces tank you have to slightly bend the grey pieces out at the bottom to disengage the tab which has a small kink in it With the Tank off it is a good time to Consider a Petcock Filter Clean and free up your Petcock Tank Replacement 1 Holding the tank with one hand under the rear of the Tank and one down from the top into one of the fork wells recesses Feed the tank onto the front round rubber Mounts Feed it on by lifting the rear of the Tank pushing forward then gently lowering the rear Do NOT push it all the way at this stage Leave a couple of inches from the from fairing Now go around the front of the bike and check all three of the plastic locating Tabs on each side line up with the holes in the front fairing Check the Breather Pipe on the LHS of the Tanks hasn t jammed under the Tank Major PITA to remove it again just because of that For US Models do up BOTH Vent Lines Go round the back again and push it forward until all the Tabs slide into place If you left the lower Gray fai
167. gether when the carbs go back in place but can anyone provide me with the BMW part number for the airbox rubber Also what is the BMW part number for the engine rubber My engine rubber had a lot of fine racks in it which were especially noticeable when pushed bent around to the extremes possible during a carby install removal The engine rubber is pretty thick so I m not too worried yet have since filed wet n dried the sharp edges off the carby intake output openings to avoid any further wear and tear on the rubbers carOtene Here are the Part No s Intake manifold 11 61 2 343 131 I think this is the Engine side http fag f650 com FAQS CarbMiscFAQ htm 3 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ Rubber grommet 11 61 2 345 007 I think this is the Airbox side e About the small cracks You could use some RTV silicone to seal it Just put a thin layer over it and let it dry over the night About the cut As long as it is at the airbox side it shouldn t make to much difference unless it is that big so that dust can enter It is more serious for the performance and the engine if it is leaking at the engine side because that would lean out the fuel mix Spakur 1117 Icelander in Malm Sweden 1995 Classic Red F650 with 60 000 KM PUKING PETROL by Flash 412 October 01 Last night stopped and filled up 0 8 miles from home was careful not to overfill NO gas escaped into the well below the metal
168. gi Wh i ld Noe at Khat Kha ngine Engine en engine co Noise 54 4200 4500 RPMs in 4th and 5th gear occaisionally when decelerate more noise after warming up Around 3000kms mic the cylinder bore out of spec something releasing tension big NE carter Sometimes when Noise 42 CLICK turning off At very low rom On start up without enough choke engine knock chain rattle keys in the cylinder Noise 35 Engine Noise 37 lightning storm cylinder Noise 43 starting in 1st gear with a bit of a load and starting up a slope Transmission Noise 53 grinding noise http faq f650 com FAQS StrangeNoises htm 3 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ Pate o ih Hs Rear R a 14 Hs Rear cere 16 after downshifting after gargle sound exhaust eeu TOES Noise 23 rapid acceleration or soe deceleration werd woodi ee ae ee M ail rear Noise10 Noise 10 M ail Under load Lower rpms upward slopes on for half a second off for another half second A E E ee after stalled loud grinding squeal shifting down coming to stop While on sidestand Goes away when clutch pulled in humming feline purring Noise 26 Noise 39 playing card clothespinned to my wheel knocking sounds from bottom end slows down as slow Noise 41 down right side lasting for a few minutes follows engine RPMs more at lower speeds Som
169. go 97 F650F http faq f650 com FAQS CarbMiscFAQ htm 23 of 23 18 02 2007 12 29 59 Disclaimer When you have read the following please continue with your visit to the FAQ section of the Chain Gang website The FAQs like much of the rest of the Chain Gang website is made up of contributions from many people Some are Chain Gang members some are not The Chain Gang is an open forum that allows individuals to post information that are open to discussion In such a forum The Chain Gang Staff does not endorse or advocate for any particular side or any issue The Chain Gang promotes safe responsible motorcycling and charitable works involving children s issues The information offered in the FAQ section often involves ideas concerning wrenching or doing mechanical work on the F650 as well as information of a technical nature and riding tips The Chain Gang in no way advocates modifications to the F650 which go against the policy of safe motorcycling Further The Chain Gang cautions anyone doing mechanical work on the F650 does so at their own risk Anyone who does not have the proper training or background in wrenching should not undertake any mechanical project without proper supervision and instruction Each piece in the FAQ section is a description of what has been done by another If a reader is not completely familiar with the processes involved in these descriptions the project should not be undertaken Keep in mind 1 The C
170. guys factually got here before 10AM to finish are AWESOME they really helped me out when bunged fthe project While this might seem up my float screws and went the extra mile for me to get common to you have had some replacements photos of the jets and screws below _ SQQOOOOOO many supposedly http www factorypro com go there and spend money overnighted parts show up a week later Nicely packed Jet Kit w decent data sheet Tasty new SS fasteners being the coal to Newcastle kinda guy ordered 2 sets 5 16 and 5 12 for those who This is the flexi gas spigot that is a pain in the you know what to get a line on when your old stiff factory gas line Sporty Stainless decides that it wants a new home Diaphragm screws Unless you are a hampster you cannot with liberal get under the carbs easily to put it back smearings of Anti on My fix was NEW line with a REAL screw type hose clamp no photos sorry but get a close fitting clamp to fit Looks purty now See the gold anodized bar that holds the carbs together Be sure http faq f650 com FAQS Carb_Clean htm 24 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ Why can t I get the Airbox rubber intakes to fit over the carbs after jiggling it for 20 minutes Do this you did remove the snorkel right you did loosen My hand and tool is well hidden but the clamps right you also lubed the rubbers right am pushing up on the left side carb 1
171. h Anybody know what that would be echo o Answer MAYBE itis the sprague clutch on the back of the flywheel The starter spins the flywheel to start the motor There is no mechanical solenoid to engage the starter with the flywheel Instead the gear on the back of the flywheel is attached with a one way drive The starter can spin the flywheel but once the bike is running that gear remains stationary as does the starter Perhaps when your motor stops sometimes it stops as it comes up on compression and then counter rotates for a bit If it did that the motor WOULD be driving the starter for a quarter turn or so at the crank Flash 412 Noise 43 Is it just my bike or can anyone else audibly hear the dual spark ignition firing at idle only notice it on start up if I m not using enough choke It s sounds like there is a lightning storm going on the cylinder until add some more fuel to the mixture via additional choke It must be too lean of a mixture combined with a cold combustion chamber can honestly audibly hear the snaps crackle and pops going on have never heard this before on any other vehicle Yes have brand new plugs NGK D8EA Yes they are gapped properly Yes the caps look great with no carbon buildup Yes the wires are even new Yes have premium 91 octane fuel in the tank too Yes would say the idle is quite low probably under 1 000 RPM when hear this The noise I m hearing certainly doesn t sound mechanica
172. h Kit distributed by Motion Pro Quality Tools and Controls made in Taiwan of course Model is MP 08 0181 for a whopping 13 00 US It has a carrying case and 3 adapters that can be inserted into a knob for easier carb adjusting It only has 1 size of screw driver adapter but bought it anyway and if it fits at all may have to grind it a little will keep it William USA Just took my carbs off to replace cracked inlet manifolds today Thought I d follow the advice of the FAQ and check the idle mix screws but they won t turn at all Has anyone else come across this problem I m trying to cure excessive backfiring and have already tried increasing idle speed but to no effect know the idle mix screws are supposed to be 3 1 2 turns out from closed but can t check this Does anyone know the depth the screw should be in the threaded recess Not sure whether to just refit the carbs and see if the inlet manifolds have cured the problem Ed UK don t now the depth but last year couldn t turn one of the screws either After trying myself left it to a MC garage who worked on the screw for 30 minutes before it came out bought a new one and installed it Nowadays try to work them out once in a while every 3 months or so If its http faq f650 com FAQS Idle_Mix_Screw htm 2 of 3 18 02 2007 12 30 25 F650 Idle Mix Screw FAQ stuck it probably means that it has been so for a long time so if your problem has been noticed recen
173. h a bit of WD 40 recommend once you ve undone one of the two screws to hold the cap down with your thumb while you undo the other otherwise the slide springs will try and push the Cap up and skew it making it more difficult to undo the other screw Lift the Cap off and gently extract the Spring putting both to one side You do not generally ever need to replace the springs Now gently pinching the Black Rubber Diaphragm with thumb amp forefinger and working your way around the edge lift it up off the Carb Seat out of the little Groove in which it s in Then using two hands again thumb and forefinger extract the Diaphragm vertically upwards It will come out with the Black Plastic Slide attached and the Needle hanging out the bottom When it s free grab the Plastic Slide and tip it over pouring the Plastic Washer Needle with E Clip and Lower White Spacer all into your hand The needle E Clips Lower Spacer Upper Left of Picture should all come out as one unit the upper washer separately If you don t know whether your bike needles have been altered they should stamped 5E94 and the clip should be in the 4th groove from the TOP Blunt End of the Needle The Stock Needles are on the Left of this Needle Picture Dynojet Needles on the Right Check the needle for wear score marks or an easily rotating e clip in accordance with Factory s Worn Needles guide If all is O K Put them all in a little box for safekeeping Inspecting th
174. h the engine when put the bike in gear and ride off The noise has been there for the last 6 months and 3 4000km or so The problem was evident before the last time changed the oil and at that time didn t find anything strange in the drain plug The noise only appears once in a while and then only for a minute or two before the bike gets hot spakur 1117 o Feedback cam chain or it s tensioner Trevor 999 Starter soraque clutch Flash 412 automatic decompressor Richard 230 o Answer Unknown not provided Noise 30 My 4 year old 16 000 mile F650 GS has suddenly and inexplicably started making an odd noise a tick tick tick tick that s louder than the engine at tickover but gets drowned out at around 3000rpm My friendly local bike courier says it s the tappets ed the F650 has shims not tappets which makes vague sense to me o dben o Answer 1 Thanks for the advice Guide rail tensioner was the official verdict from the garage oldben ed See also the Cam Chain FAQ o Answer 2 It could just be a fragged tensioner Flash 412 CO Noise 31 Between us we are around 330 pounds my 210 driving and his 120 as GIB Guy In Back We went through a left hand traffic circle 15 MPH and something in the front scraped A little while later turning left from a dead stop at a traffic signal another scraping sound from the front tire area Both turns were accompanied by a slight amount of suspension travel but not a lot and th
175. hain Gang does not advocate unsafe wrenching 2 The Chain Gang does not advocate any modifications to any motorcycle which are unsafe to proper motorcycle operation or maintenance 3 The Chain Gang does not advocate any modifications to any motorcycle which will negate any vehicle warranty 4 The Chain Gang cautions and reminds visitors and readers that each is responsible for their own actions 5 The Chain Gang urges anyone having any doubts or concerns about any of the presentations in the FAQ section to consult a qualified mechanic 6 The presentations offered in the FAQ section are by individuals not by The Chain Gang 7 No responsibility or liability is accepted by The Chain Gang for incorrect part numbers torque values riding tips or any other information in the FAQs It is advised that any information presented should be verified with official or expert sources have read this information understand the intent agree with the principles as stated and wish to http faq f650 com 1 of 2 18 02 2007 12 30 00 Disclaimer continue to the FAQs there is also an unofficial framed version http faq f650 com 2 of 2 18 02 2007 12 30 00 Miscellaneous Carb Questions FAQ Miscellaneous Carb Questions FAQ compiled amp edited by Kristian 562 Please read the Disclaimer before attempting any work in this FAQ If you are looking for performance related carb information See the Rejetting Spreadsheet accesse
176. he Diaphragm the Needles Complete with E Clips and Spacers the Slides and also but ONLY when you have unscrewed the MAIN JET INSIDE THE FLOAT BOWL the Slide Carrier Slide O Ring and the Carb Venturi All these parts come out the TOP of the Carb The sealing gasket for the Diaphragm Cap is also the Diaphragm itself Access BOTTOM The Silver Bowl at the bottom left of the Intake Side picture is the Float Bowl also held in place by two Philips Screws Once removed you have access to the Float Frame Floats Float Frame O ring Float Valve Float Valve Seat Float Valve Seat O Ring Float Bowl Gasket Main Jet and the Pilot Jet As mentioned above you will NOT be able to disassemble the Slide Carrier out the Top nor gain access to the Venturi without first removing the Main Jet Inline Filter When you pull the Carbs out the Fuel Line to the Petcock come with it So it doesn t get in the way while you are Cleaning the rest of your Carbs undo the spring clip to where the Fuel Line meets the Carbs in between the Two Carbs When you pull off the Fuel Line Do it gently the T Piece is only Plastic there is a brown T Piece which holds the In line Fuel Filter Gently pull out this filter by hand and clean it with a little petrol blowing on the outside to dislodge any particles on the INSIDE Then put it back in again so it doesn t get lost or squashed When you reinsert it try and line it up so that each of the two flat sides faces the dir
177. he carb won t get as much gas as it should lean Too high and it can run rich or leak The idle circuit is made by drilling some holes from the float bowl to the area on the motor side of the throttle slide There is ambient air pressure on the air filter side of the carb There is vacuum on the motor side This vacuum is used to draw fuel through this little hole the diameter of which is normally controlled by an orifice or pilot jet installed in that hole More vacuum at wider throttle opening draws more fuel This is from idle through off idle to about 1 8 throttle Normally idle SPEED is set by a screw that opens the slide a little more or a little less Idle MIX is set by a screw that sticks a pointy tip into the little fuel passage or a similar air passage used to draw the fuel At about 1 8 throttle the effect of the next circuit swamps out the effects of the idle circuit There is a bigger hole that goes straight up from the float chamber into the bottom of the carb throat This hole has two precision fittings one at either end both removable The one at the bowl end is the main jet More on that later The one at the top is the needle jet Hanging off the bottom of the slide is the jet needle The jet needle is a tapered needle that moves in and out of the needle jet Normally both the needle jet and jet needle can be changed Needle jets have different size holes in them Jet needles have different lengths and tapers Usually they
178. he fact that the petcock is at the front of the tank and going uphill would drain the fuel to the back of the tank away from the http faq f650 com FAQS Gas_Tank_Removal Replacement htm 13 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank petcock would think that going downhill would have the opposite effect but what do know James 523 CT USA 99 e My 97ST with 53 000 miles will sometime give warning and sometimes die right out At 150 miles start watching my see through gas filter have noticed under higher speeds the warning is less than at lower speeds Scott 264 Remember that when you re going downhill even with the throttle totally closed against the stop some fuel is still going into the cylinder so it s quite likely if it was a long downhill that the float bowl would have been sucked completely dry If as you say the wheel locked up then it seem you were in a lowish gear using engine braking which would leave you with no fuel in the float bowl once you tried to open the throttle hence the lock up Trevor 999 Bristol UK 01GS e While riding along turn off your petcock to find out how it dies Flash 412 CO e That s typical you do get SOME warning a slight loss of power and change in engine tone about 30 60 seconds I ve had the same happen to me in the middle lane of a three lane freeway All can suggest is watch that mileage Pete Broken Tank Support Bracket Not a common Breakage
179. he new gasket is not easy with all the other hardware getting in the way You have to pull the pipe flares open with a pair of pliers but getting a bead on it is tough just pulled the lowest one open as much as possible because there were no http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 4 of 8 18 02 2007 12 30 55 Exhaust Gasket Replacement FAQ obstructions Another method is to stick a long screwdriver in the slot between the ears angled from the inside of the hole as close to the open end as you can get it and then smack it with a hammer iii If your think your main exhaust gaskets have disappeared you will swear on your mother s grave you have no exhaust gaskets They are there really iv Collector gasket 11 clams They wear out quickly They wear out quickly WHEN THEY START TO GO But if the clamp is tight that isn t a problem This is NOT a normal wear item v Exhaust gasket 1 50 that s a BMW shock They are durable think you can probably get the same gasket at lots of other motorcycle stores for half as much But do not KNOW this Gasket Replacement at the Collector Header Pipe Junction by Francois December 01 My exhaust collector neader pipe gasket end of the U tube went 99F650 26 000km and was leaking gas am not happy about the lifespan of this piece which is way too short and am especially unhappy about BMW s explanation that it was destroyed by an excess of heat thought
180. he vacuum http faq f650 com FAQS Canisterectomy htm 1 of 6 18 02 2007 12 30 27 The Canisterectomy FAQ charcoal canister at the top rear fitting When the hoses are incorrectly reversed there can be excessive suction into the canister This can cause problems in wet weather when the vent hose near the RIGHT footpeg sucks up water into the canister and the carbs Check with your dealer for more information So which way around SHOULD the vacuum lines go e The US Spec F650 has two vacuum lines connected to the right side of the right carburettor looking down from a seated position You might have to remove a plastic panel to get to these but you can see them without removing anything The front vacuum line should go into the airbox It operates the vacuum actuated valve for the air injector for the Catalytic Converter inside the exhaust system More on that below in the last section The rear vacuum line should go to the charcoal canister if you have one or it may just be plugged with a screw or something if the canister has been removed If you have these ports and the vacuum lines have been removed or disconnected they must be plugged or capped to close them off for proper operation e The European spec bikes do not have an EPA canister So why Does the Bike feel like it is out of Gas e There are two vent hoses attached to the gas tank One is a vent and the other is an overflow drain connecting to a small drain ho
181. hen using the larger see through filters but no problems since switching to the tiny ones The theory is the smaller quantity of fuel in there produces less vapour and cycles through fast enough not to cause a problem Smaller within reason have heard of tiny ones supplying insufficient fuel flow as they start to get plugged up a good reason to get a spare one to carry in the saddlebag If you get 40 miles per US gallon at 80 mph you are flowing 2 0 US gallons per hour which is 126 cm 3 minute You could check your fuel filter s performance by sticking a filter on a piece of fuel line attaching it to the petcock of a nearly empty tank catching the flow in a 12 ounce cup and timing the exercise til the cup is full 12 fluid ounces is 354 cm 3 so it should take 354 126 354 cm 3 cm 43 minute about two minutes to fill the cup if your burn rate is 40 mpg MORE time is Bad Less time is GOOD Because your filter should be able to handle the flow that the Engine needs Great a new field event Petcock Races Flash 412 CO e There are of course people who have two very large in line filters on the bike and have never had a vapour lock problem YMMV e You want to make sure that the final placement of the filter allows you to see it and keeps it away from the heat of the motor Start long and trim the hose down until it looks right Don t install the inline filter until you have completely put the bike back together including
182. his is not that common The Float Valve Tips and or Springs can also wear but take a bit longer than other parts AND Don t forget to check the rubber intake manifold for cracks as well as the rubber Air intake boot One thing you might also want to watch out for If you ve been using Coolant with Silicates in it which you should NOT as it will destroy your water pump you might accidentally spill some into the intake snorkel when you fill your coolant and the fine Silicates that may pass through the Air Filter will quickly http faq f650 com FAQS Carb_Clean htm 5 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ wear your Carb Venturis and Needles The sizes of the Four Replaceable O Rings 4 in EACH Carb i e Total 8 available from any bearing shop are Smallest to Largest e Idle Mix Screw O ring 1 x 2 5 or 1 x 3 found that the 1 x 3mm O ring was the closest fit for the idle mix screw vs the 2 5 in the FAQ Actually the 1 x 2 5 is closer on the ID and the 1 x 3 is exact for the OD Marty 436 Idle Mix Screw O ring 1 x 2 5 BMW Part 13 11 234 3 412 Float Frame O ring 1 5x5 e Float Valve Seat O ring 1 5 x 7 e Slide O ring 1 5 x 10 e Where the first number is the O Ring thickness and the second is the internal diameter both in mm Buy atleast two of each but get even more say 4 of each as they are really cheap and you might even break or lose one putting them back e Seriously
183. ht it was a design feature Maybe it is If ride with respect until the engine is warm then the choke is fully off when it needs to be This is fine with me J mes had have this problem too The choke closes on its own i e the lever moves away from me I m going to try Richard s suggestion re the screw In my case my bike was stalling unless kept the choke on even when the bike was warm but I ve adjusted the idle and it runs fine now Idle is 1300 100 rom and can be adjusted with the brass knob on the left hand side of the bike just above the foot peg It hangs loose from a cable you can t miss it Hope this helps Johnny Canada 1088 98F Q Which way is the Choke on A The Choke is on when the Lever is BACK toward you It often goes off by itself rotating AWAY from you when you are sitting one the bike Q How long should I leave the Choke On A Do not leave it on TOO LONG You will foul your plugs carbon your cylinder and head and and stuff up your fuel economy Most folks can switch it off after half a mile to a mile depending on the weather Same as Wamer use the choke only to start it when it s completely cold Turn it off immediately and drive away Mason 631 97ST in PA am curious how long people run before they turn the choke completely off Even on a 80 degree day am still at 1 2 choke when get to work any less and it stalls have a 15 minute commute much of which do at 80 have also n
184. ier is an O Ring which gets compressed when you do up the main jet which pulls the Carb Venturi Down and hence the Slide Carrier O Ring onto the Carb Body At the bottom of the Slide Carrier you will see the O Ring which can be http faq f650 com FAQS Carb_Clean htm 12 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ replaced Size given above Now check the Carb Venturi The main hole down the middle is large enough that it should never get blocked However on the sides as you can see in the picture are a number of small holes Clean these in the same way as the other Jets with a small NON Metallic bristle Replacing the Slide Carrier and Carb Venturis Note that the Carb Venturi has a Flat Surface on one side at the bottom This flat surface sits against a Pin in the Carb Body which you can see if you look down the well that the Venturi came out of This surface sits against the pin so that the Venturi doesn t keep turning when you screw up the Main Jet Once you ve cleaned the Venturi Jet and have replaced the O Ring put the Venturi Jet back into the Slide Carrier and press it into the small wall so the flange seats Note also for Slide Carrier replacement that the curved part of the Slide Carrier is at the FRONT or Engine Side of the Carb Then turn the Venturi so that the flat surface lines up with the Pin Smear the O ring with a little oil and press the whole Slide Carrier Venturi combo back into position so
185. ihin CV carburetor on the bench to the requirements of your specific engine The result is greater power smoother running and better gas nalitere e om All constant velocity CV carburetors are designed to compensate for changes in altitude and barometric pressure But even a slight modification to increase engine performance will require retuning of your CV carburetor Our blueprinting process harmonizes your carb perfectly with your engineA s type and modification level When ordering our blueprinting process be sure to ask for the accompanying High Flow Air Filter Kit for your Keihin CV carbs It gives the increased air flow your big inch V twin needs Hi Flow Air Filter Kit for Keihin Carbs We are pleased to offer the highest flow air filter kit ever manufactured for Harley Davidson motorcycles K amp N has been helpful in the development of a filter element that effectively cleans incoming air but will flow in excess of 700 CFM This is a must for big inch engines because they need a lot of air Maintained properly this filter has a lifetime guarantee The air filter backing plate is made of 125 inch thick steel with welded mounting fixtures for all Harley Davidson V Twin models from 1937 to present including the Twin Cam 88 The High Flow Air Filter Kit comes complete with all required mounting hardware for your Hog including a radius venturi ring Detailed installation instructions with photos are supplie
186. improvement Ran good up to 9 000 10 000 after that but still coughed and spit and was problem child Although it ran poorly at lower rom and slower speeds it wasn t enough to make me want to cut short my 2 000 mile trip I d say don t change anything worst case you ll run a little rough and get poor fuel mileage It ll be a blast I m taking my new DAKAR to Colorado next week I m hoping Fall River Pass is open so can see how this fancy fuel injection works at 12 000 feet guzzimike e I have ridden my 01 GS two up around the same areas you are talking about and was fine Sure there was power loss but like it was said before it is not a race Besides power loss means slower speeds more time to take in the amazing scenery Have fun and ride safe facito 2001 F650GSA Las Vegas Nevada Do I need to Synchronise the Carbs Randy 748 Synchronization is possible with anything more than one carb Two as in F650 s case can be synched and may not be noticeable to rider other than less HP am assuming a bit here because the 650 carbs may have no adjustment ability I ve not looked individually but my experience with other bikes has always been that the individual carbs can be adjusted separately Usually a screw on the actuating bar for each carb Factory set these are rarely off but possible Most Japanese bikes with multiple carbs have single cable bar actuating all four as unit and they are synch d as a regular service item Single cyl
187. inder has no input here except acting as a single the input to rider will be less obvious in rough running vs less HP The domes on F650 carbs do have access ports Two 33mm throats feed the 650 and less than two equally opened butterflies will mean less HP imagine the settings are very close to perfect from factory Comparison My R100 only has two 32mm carbs The 650 has 4mm more feeding power than the 1000cc bike A lot going through a 650 and thus the 48HP it delivers and the somewhat equal mpg to the R100 The R100 7 delivers 58 60HP as recall but with one more cylinder and very close to same carb size total The 650 breathes better with 4 valves which creates more power where the old boxer has two valves per hole Anyhow the 650 rams a lot through one cylinder with two 33 s behind the intake and imagine without water cooling high tech metallurgy etc the engine would burn up One fun bike Fast Idle Problems http fag f650 com FAQS CarbMiscFAQ htm 13 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ Bob 550 October 01 This is to share a possible fix for your pre fuel injection F if the idle suddenly or unexpectedly refuses to drop down to normal Tonight took the tank off my 99 F650 to see what was causing the throttle to hang up What found was that one of the electrical wire connectors located near the left carob had worked its way down to where it was rubbing against the throttle cable and had
188. ing weird Anyone have a clue to what it is Or if need to stay 50 feet back for that first minute after parking heymarz o Solution 1 Is the tach or speedo needle twitching with the tick Totally normal Don t fret you are probably overly sensitve to instrument cluster anomolies right now notice mine doing it from time to time right after shutdown jetdocs 1546 o Solution 2 This is normal it s the gage needles resetting to zero If you were to rotate a needle it will stay in the incorrect position until you turn off the key At that point it will tick back to a park position and reset itself to zero roamer e Noise 52 Every time turn the bike on my tach rattles makes a buzzing sound like it does when you reconnect the battery after servicing the bike it only lasts for a few seconds However can not get it to stop buzzing How do stop it Winter 1935 o Solution Have you recently removed fuses from the bike In what order did you put the fuses back in The solution is to remove the 10A fuse ONLY wait 15mins or so then re insert the fuse also did the twist the throttle three times but have no idea if this is part of the solution Winter 1935 Noise 53 My new to me F650GS with 65 000km has a grinding noise from the gearbox region although that s hard to tell for sure when you are riding that you can only hear when starting off in 1st gear with a bit of a load aboard and starting up a slope Any ideas on where to star
189. ing a bit corroded am concerned that if need to remove the exhaust in the future might have some difficulty Any advice on how to get around this problem would be appreciated Skidmark A Replace the studs now Use ant seize Q Can you please advise how to remove the studs A Pull whatever it is you need to pull to have access to the area See above Remove the nuts A clamp plate will pull out of the way Shoot a little Liquid Wrench around the base of the studs and follow the instructions on the container Use Vise Grips to twist the studs out If you need to pull the headers to do the job so be it The absolute worst case is that you will break one or more off in the head and need to drill it to remove it There is no point in using any Loc Tite on reassembly because of the temperature where the studs live To screw in the new studs put two exhaust nuts on one stud and jamb them together using two spanners Then put the wrench on the outboard nut to drive the stud home in the head Yes hi temp anti seize on the threads where the nuts go just before you install the nuts Preventative Maintenance 1 Soak with WD 40 http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 7 of 8 18 02 2007 12 30 55 Exhaust Gasket Replacement FAQ 2 Remove one at atime Clean with wire brush Glop on anti seize Retorque Unless they look like the corrosion is more than surface wouldn t try to remove them unless they come out
190. ire goes because it s centralised over the Float Valve though you can make a note of it before you pull out the Float Frame if you wish WATCH out the Float Valve doesn t drop down the drain If it didn t fall off tip the frame to one side and take it off and put it aside When you get the Frame out you will see something like this Float Frame The Float Valve is still hanging off the Tang in this picture The O ring will look this Float Frame O Ring This is the first of the two culprits of Flash s Pukin Petrol Syndrome You can easily replace this O ring Get a blunt needle and gently prise it off then roll on a new one Size given above The Carb Body minus the Float Frame and Main Jet looks like this Float Frame Hole Location The marked hole is the Float Frame Connection location Shake the Floats gently to see if they have any petrol in them if they do then they are leaking and need to be replaced Some Web Sites reckon if the Floats are discoloured they should be replaced but think they can be discoloured and work just fine Inspecting and replacing the Float Valve Seat O Ring With the Float Frame removed you will see the Float Valve Seat which is where the Float Valve that you just pulled out with the Frame sits into It is a Dark Brown Brass Cylinder In the same way you just took out the Float Frame Grab the cylinder and wiggle it out At the bottom you will see the O Ring which can also be replaced Size g
191. iven above This is the second of the two possible culprits of Flash s Pukin Petrol Syndrome Inspecting the Float Valve The Float Valve itself is tipped with a Rubber Pointy End which does the sealing into the Float Valve Seat Inspect the tip to make sure it is not worn with a severe groove or the tip broken At the TOP of the float valve under the wire which is bent into a loop is a small piston Underneath this piston is a VERY fine spring which gets compressed http faq f650 com FAQS Carb_Clean htm 11 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ when the Fuel Level push the Floats Up Check by tapping very very gently that this spring can be compressed and doesn t stick This piston and spring is discussed in more detail below for checking the Float Heights once you replace the frame One member said he fixed a problem by replacing the little cutoff valves AND the seats for the Float Valve as they weren t shutting properly which means that even with the floats at the right height he was getting too much gas Removing and inspecting the Pilot Jet With the Float Frame removed and the Float Valve Seat removed all that is left to take out and clean is the Pilot Jet which is the small brass screw in the well just visible in the photo needs RED Circle Unscrew this with your small thin screwdriver taking extreme care with the soft brass You can easily ruin Screwdriver Slot Tip the Carb over
192. ized exhaust pipes Reason am asking is that was installing new ones to replace the old ones OK at 25K miles while the muffler was off and the new ones were 1 2 mm too big in diameter to fit into the bores in the head As they are soft crushable material made them fit but as they are calling for snow this week and likely the season s first de icing salt probably won t know until next spring if they actually seal or not Marty 436 Actually had the same problem Kristian 562 MADE them fit which is why in this close up of one of them it looks all squashed Don t know WHY BMW do that But it looks like it s normal You might have more luck with a set of Gaskets from Aprilia The Pegaso Gaskets will fit the Classic G If you need to replace the studs refer What about those Rusty Exhaust Nuts below otherwise H Reassemble In reverse order It REALLY helps to have someone over on the left side feeding the left pipe into the head while you re dealing with the other three joints all at once on the right side Tighten it all up Torques are in the Torque Table Fire it up Test again as above Notes Justin843 Flash 412 There is no way to get socket wrench or torque wrench on the main exhaust pipe nuts without removing the radiator The tool to use is a 18mm box end wrench You won t have to mess with the radiator and it works quite well ll Get the collector pipe flare pieces to open up to accept t
193. k 2 Sometimes hear the decompression device clunk just as the engine stops rotating If that s it no worries mark1305 1495 o Answer think you re describing what I m hearing The moderately pitched clunk sound hear is just as the engine stops rotating the clunk is the last sound the bike makes before the engine stops That s the only time the MP clunk happens meribona Noise 48 Whirring of gears or at least that s what it sounds like It s not a knocking noise more of a hum My engine developed this noise it s persistent but inconsistent happens at idle and at speed thought maybe it was the cam chain tensioner gone bad allowing the chain to rub against the case but replaced that with no seeming affect Earplugs have helped but haven t totally eliminated it Got any idears SScratch 1082 o Feedback 1 Are you sure it s based on engine speed and not wheel rotation My new chain whizzed not peed for awhile after changed sprockets and chain It would most likely be the actual timing chain but it s a little soon for that to die justin843 o Feedback 2 Oil pump water pump drive gears going south Doubt you could hear that WITHOUT the earplugs as they re plastic Marty 436 Noise 49 On rough dirt every now and again at different roms different speeds would end up with a strange rattle Not a regular sound and only happened going down hill on some dirt roads Turns out every now and again had a rock that was so
194. k all electrical connections in the ignition system The connection in the line to the side stand cut off switch is one place to check Another is the fuse box under the seat There are three fused lines in a rubber mounting One BMW mechanic has specifically cited the middle fuse line as the culprit Wherever there is a slide male female slide connector there is a possibility that there is a poor or intermittent contact which can mean that electrical current is not present when it needs to be e Others have indicated that the vacuum charcoal canister is to blame Check the lines for kinks and bends and that all connections are tight to the gas tank and carburettor One owner even suggested checking the drain tubes that something may be clogging the tube at the opening and not allowing the vacuum canister to not get sufficient air in or out But then again others have cited that the canister has mysteriously fallen off while driving which has fixed their problem Please note the EPA in the United States likes the canisters and if you live in California make sure it is securely attached so it won t mysteriously fall off A BMW service bulletin has said most 1999 F650 s came with the vacuum hoses on the carburettors installed backwards The forward port on the right side of the right carb should have a vacuum hose going into the bottom front right side of the airbox air filter housing The rear carb port vacuum hose should be connected to t
195. l It really sounds like electrical arcing going on would think the compression relase would be more of a mechanical sound Powder Blue o Feedback Is the idle speed really low when you re not using enough choke think you re hearing the compression release lever whacking around in the head It s quite disconcerting to hear this thing As for hearing the spark I d have to hear it myself to believe it ed Idle should be around 1300 1400 anything lower is NOT GOOD for the engine Yep the compression release has a resounding smack to it could sound electrical and it occurs at less than 1000rpm Either way get the idle up and try not to do stupid things to your engine Shank o Answer rode in the frost again this morning and started to hear the noise as reduced the amount of choke think the first respondant was right and it probably is the decompressor Powder Blue Noise 44 the persistance of what can only describe as a mystery rattle noise coming from somewhere in the front end of the motorcycle at speeds beween 30 50 mph Regardless of whether I m accelerating hard or just moseying on up the road starting at right around 30 mph start to hear what sounds like some sort of mechanically induced fairly consistent rattling noise which seems to emmanate from somewhere within the instrument cluster windshield area It s sorta hard to describe the noise accurately as I m always hearing it through my full coverage helmet and
196. le Steering is light and predictable and it reverses direction lean easily At speeds below triple digits the bike feels well planted in sweeping turns I have no personal experience at higher speeds would rather ride an FXDX aggressively than a Sportster Triumph Thunderbird Sport or Kawasaki W650 to name three popular standard style motorcycles even though the FXDX is much heavier and has a longer wheelbase than those middleweights Anyone needing a motorcycle sportier than an FXDX should probably buy a sport bike rather than a standard motorcycle As they say you have to try it to believe it http www chuckhawks com super_glide_sport htm 11 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT Riding with a passenger The Sport s long wheelbase sophisticated suspension powerful engine and comfortable riding position make it a natural for riding double For those who don t want to ride half a car i e a full dress touring bike but enjoy the pleasures of motorcycling with their spouse or significant other an FXDX equipped with a decent dual seat is an excellent choice Set the rear shocks preload to the maximum position inflate the rear tire to 40 psi and off you go in comfort and style The bike still handles well and looks good In fact when riding two up performance and handling are only slightly compromised You can still have fun on winding back roads In fact you can ride them into the next state tog
197. le in the left side of the tank cap filler well under the gas cap It s the hose running on the left side of the gas tank under the tank cover which ends as one of the drain tubes by the left hand footpeg When you overfill your tank it drains straight out the overflow onto the ground Note that when you close the gas cap the space this hose reaches is SEALED OFF from the interior of the tank The OTHER hose on the right side of the gas tank under the tank cover is the vent hose This vent hose connects to the interior of the gas tank thru a series of check valves contained inside the filler cap The other end of this vent hose runs to the charcoal canister at its center rear fitting The front lower fitting on the canister goes to a drain hose which ends by the right footpeg This can cause problems in wet weather when the canister drain hose near the RIGHT footpeg sucks up water into the carbs The vent hose goes to a stupid charcoal canister There are two other hoses connected to this canister When the tank develops overpressure the liquid fumes go into the canister and are collected by the charcoal There is a big hose that leaves the canister and goes to the air by your right footpeg This is for fresh air INPUT to the canister The little tiny hose goes to the carb The carb draws a vacuum which sucks on the little hose which sucks all the nasty hydrocarbons out of the canister to be replaced by fresh air in a limited quantity If it
198. less impact driver to remove them Use anti seize on the threads when reassembling or at least a little grease Chris in Santa Cruz CA 782 o Better yet replace them with Allen s aka Socket Head Cap Screws SHCS Flash 412 CO On with the Cleaning http faq f650 com FAQS Carb_Clean htm 8 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ Outside of Carb Body First off give the outside of the Carb a good clean with your brush and Petrol including the springs and all the nooks and crannies Clean it and rub it dry with a Rag Not only will it look good when you put it back it will stop getting dirt everywhere inside the Carb and it will stop it being a slippery sucker when you work on it Orientation For purposes of orientation in this picture Intake Side the Black Dome at the TOP Left is the Diaphragm Cap held in place by two Philips Screws One of the Float Bowls the Jets the Float Frame the Slides Slide Carrier and the Diaphragm Caps have already been removed in this picture RHS You can see the back of the Slide through the left Carb and you can see through the right Carb because the Slide has been removed recommend you work on ONE Carb at a time clean it thoroughly adjust and replace what you need to and then button it back up again This way you won t damage any parts in the adjoining Carb nor will you lose any Access TOP When you take the Diaphragm Cap off you have access to the Slide Springs t
199. loat pushes a conically shaped round thing float needle into a conically shaped hole seat and shuts off the flow of gas This needle and seat is the valve that controls gas flow into the bowl Float level is important and so is a good seal here If the level is too low the carb won t get as much gas as it should lean Too high and it can run rich or leak The idle circuit is made by drilling some holes from the float bowl to the area on the motor side of the throttle slide There is ambient air pressure on the air filter side of the carb There is vacuum on the motor side This vacuum is used to draw fuel through this little hole the diameter of which is normally controlled by an orifice or pilot jet installed in that hole More vacuum at wider throttle opening draws more fuel This is from idle through off idle to about 1 8 throttle Normally idle SPEED is set by a screw that opens the slide a little more or a little less Idle MIX is set by a screw that sticks a pointy tip into the little fuel passage or a similar air passage used to draw the fuel At about 1 8 throttle the effect of the next circuit swamps out the effects of the idle circuit There is a bigger hole that goes straight up from the float chamber into the bottom of the carb throat This hole has two precision fittings one at either end both removable The one at the bowl end is the main jet More on that later The one at the top is the needle jet Hanging off the bottom
200. look for a sad big end bearing these can make a very terminal sounding noise at low revs with open throttle loaded engine If it higher up in the middle of the motor with not so much of a heavy clonk it could be piston slap loose piston to bore clearance If is more of a rattle then look at the cam chain tensioner setup IT MAY also be a balancer shaft problem too would start with doing an oil pressure check with a master gauge that is remove the pressure sensor and connect a separate mechanics test pressure gauge Run the bike on road and make sure that pressures are in spec Next drain the oil and check for metal pieces on the drain plug and also metallic sparkle in the oil itself wash the oil filter out in clean petrol and look for residue from the filter Remove the cam cover and check the chain for slack look down inside to see if you can see any wear broken cam chain guides etc Jack F650GS Australia Other things to try consider For plastic type rattles find a street were you can safely press parts of the fairing with your hand to try and find what is rattling Swap bikes with another F650 owner see if they can identify the noise Have you checked your helmet ie Borrow someone elses helmet for a quick test ride DON T ride without one e Check everything is tightened to spec including engine mounting bolts bash plate fairing etc And check a second time If you have just done so
201. lower gears up the hills and prepare for a significant drop in gas mileage Aurora CO chppdlvvr e Itis a common misconception that a trip to the mountains requires that you to rejet the carburettors There will be a slight loss of power nothing more The time you spend at 11 000 feet will probably be about an hour What you really need to do is make sure the engine is tuned up and running properly before leaving A climb to altitude will expose any flaws in the engine and when people have trouble with their vehicles on a trip to the mountains that s why they have trouble So forget about rejetting the engine F650GS Dakar Camden New Jersey echo e A clean air filter is pretty important if you re not going to rejet for altitude If you re only going to be at altitude for a few days you probably shouldn t worry about rejetting If you are comfortable removing your carbs going one size smaller on the main jet is a good idea BMW dealers will be useless when it comes to supplying alternate jets But the jets are the same as run of the mill Japanese bike Mikuni carbs Mikuni BST B316 CV carbs to be exact available wherever Japanese bikes or parts are sold According to the FAQ your stock mains should be 132 5 believe the next smaller size in that numbering scheme is 130 If you plan to change main jets get two one for each carb See Performance Mods Flash 412 CO Inthe good old days in order to lean out the mixture for a few hours of high
202. ls If you happen to strip your petcock screws undoing them the petcock for the Aprilia Pegaso appears identical to the Funduro classic s with one major plus it has a big plastic handle instead of the lame o lever we ve got Costs about a buck more for the pleasure NormJ 473 Hard to turn Petcock Experiences e I m having a problem with the petcock fuel flows even when shut off Know that there is a rebuild kit for it Anybody else have this problem If so were you able to fix it with a rebuild kit or did you have to replace the petcock Any ideas about the cost of the kit VS a new petcock checked the http faq f650 com FAQS Gas_Tank_Removal Replacement htm 4 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank FAQ s but couldn t find much about the petcock Tom in Tallahassee Is it just me or do any of the rest of youse guys and gals have problems with the fuel petcock mean mine is so difficult to turn with my big hairy sweaty arthritic hands And going from on to reserve is brutally painful My fuel petcock is so difficult to move that I m actually considering paying the 23 for a new one that my dealer doesn t have in stock Either that or I m gonna perform some surgery and attach a huge honkin piece of metal rustified to my specifications to make it easier to turn that dang thang Yes made many sacrifices to the gods of lube and sprayed it profusely with a plethora of spray on slippery stuff Nothing has worke
203. ltitude The bike will also run rich at full throttle because too much fuel will flow through the main jet So do need to adjust it Yes amp No The carb vacuum diaphragm will adjust the mixture for you when running on the throttle http fag f650 com FAQS CarbMiscFAQ htm 10 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ CV carbs tend to be self compensating at high altitudes the flat slide carb does not From http www chuckhawks com super glide _sport htm e Carbs are tuned to provide a certain A F ratio based upon the ambient atmospheric pressure If the pressure changes so does the A F ratio But if you are actually measuring the A F ratio the carb is more immune to pressure variance What does that mean It means a CV doesn t go rich at altitude the way a fixed jet carb does It is altitude compensating So at 10 000 feet a CV equipped bike only looses power from the loss of available air pressure while a fixed jet carb will loose power from less air and lower combustion temp from being overly rich From http www easternillinoisabate org tech_talk htm If you were moving to altitude you might consider the following Try ONE at a time depending on the Altitude e Screw in the idle air screws and or Lower the needle position and or e Possibly reduce the size of the main jet Refer http Awww nightrider com biketech main jet _correction htm for Jet Multiplication Factors for Temper
204. m think is most often noticed Spakur o Answer 1 My 97 F650 had a mechanical noise at low rpm from the time it was new The noise was a sort of rattling and seemed to quiet as roms increased wrote it off as a characteristic of the engine The first time had to replace a valve ship at 20 000 miles found that the spacer in the cam spring lightener was installed backwards from what was shown in the service manual When installed the spacer as shown in the manual the noise disappeared My theory is that the shape of the spacer results in slightly more cam chain slack if it s installed backwards Traverse City John Refer the Cam Chain FAQ It was the Cam Chain Tensioner o Answer 2 Check that your ignition switch assembly isn t loose Makes a really annoying rev dependent rattle that sounds like something loose in the valve train Pete Noise 23 Unusual sound My 98 F650 appears to display defective behavior The symptoms are as fallows an unusual gargle sound after downshifting after clutch release rapid acceleration or rapid deceleration the sound appears to originate and or surface in the exhaust have also noticed a slight decrease in overall power performance Jacek See the Exhaust Gasket Replacement FAQ Noise 24 Knocking when in neutral clutch engaged Gets Faster as Idle Raised Actual cause unknown but it could be the Compression Releaser Turn up your idle a notch or the Cam Chain Refer the Cam Chain FA
205. mance Modifications FAQ for details of how others got on 5 Carb Intake Rubbers Can be Replaced Classic F only Testing For the carb intake rubbers you can an unlit propane torch just barely cracked open and see if the idle changes when the gas gets sucked in Don t get carried away or you will flame the bike Less messy than using WD 40 See the Carb Cleaning FAQ for details on removing your carbs The extra air from the split boot will cause the popping 6 The Airbox to Exhaust Header Line Can be Fixed Permanently Classic F only Remove the line from the bottom of your airbox to the right exhaust header This is the steel rubber steel piece that follows the right header pipe rearward Plug the airbox better yet pull the air filter and pull out the exhaust re circulation valve cut the pipe behind the exhaust end connection and replace it on the threaded piece it came off of with a 3 8 ball bearing inside it That ended my backfiring Check your Air Injection Hose Routing if you ve done a Canisterectomy The mis connected carb vacuum hoses can also encourage backfiring the right side carb is sucking too much air thru the canister and up the drain tube right That means the carb fuel mixture is also slightly leaner more prone to backfiring Putting the hoses back correctly may help with the backfiring without having to adjust the idle mixture screws richer The mis connected hoses can also degrade low end respo
206. me work on the bike retrace your steps For noises up the front of the bike around the dash area Noise 44 is a really good place to start Noises from 40 onwards tend to get a little long and can help in trouble shooting http faq f650 com FAQS StrangeNoises htm 21 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ After you have done some work on the bike you are more likely to pay attention to strange noises some noises are normal some are not What Should I Mention in the Forums If you can not find your noise or a similar noise in the list and the other suggestions do not help identify the noise ask in the Forums When you do provide the following information 1 What model year bike do you have Most people forget to tell us this Is ita Classic GS Dakar CS and what year was it made in Also tell us if it has ABS this could help the diagnosis 2 What does it sound like Does it sound metalic or like plastic Is it a deep knock like a clonk clock or more of a tap tap Is it a heavy clonk clonk or a lighter plink plink 3 Where does it sound like it is coming from Is it coming from the engine Left or right side Front forks Rear of the bike If you can safely get off the bike to hear the sound where does it come from Have you tried the mechanics stethoscope Where abouts in the engine is it coming from 4 When did it start So when did the noise start Has it been gradual or did it start su
207. mehow bouncing up under the engine in bouncing around on the engine guard bash plate Winter o Solution Not sure may be add the additional aftermarket guard and hope it fixes the problem Winter Noise 50 This one has been a puzzle for the last 1000 kms Between 4500 and 5000 rpm http faq f650 com FAQS StrangeNoises htm 18 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ usually in 2nd and 3rd gear had a rattle Was not metallic sounded like the fairing on my old ZZR 250 would have to replace one of the grommits regularly because the fairing would begin to rattle After much investigation applying pressure to certain parts of the faux tank kinda gave up Could not find anything that was loose and it did not sound like the engine This morning found it on the diagnostic connector was a small sticker that would flap like a ruler when you twang it on a bench That flapping did not normally cause any noise but between 4500 and 5000rpm it was probably synchronised with the engine speed or something result noise Winter o Solution Turn sticker cable around so sticker is pinned down or cut the sticker off Winter Noise 51 When turn OFF the key there are three tick tick ticks then a one second pause then it starts over again It is very faint but can hear it with my helmut off It does this for a minute or so then stops took the cluster back off and reinstalled still there Bike seems fine noth
208. n t expect a different answer from them either Since the supply of good used carbs is finite have developed an inexpensive way to correct the worn plastic pieces by re facing it with brass and at this writing will have the first prototypes installed in a bike in about two weeks It is a rather labour intensive undertaking but it sure beats 1500 for some plastic pieces that should cost 10 each So far have found about seven different types of bikes that use carbs with this same configuration mainly big Suzuki s and the fix is applicable to all of them as well Pretty much any bike with 36 38mm Mikuni s Please post this ASAP welcome correspondence from other Worshippers Happy Trails Morgan Carb Alternatives Complete by Mtbiero Cugino Pegaso http fag f650 com FAQS CarbMiscFAQ htm 17 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ found a pair of 39mm Keihins here http www rotax net BMW_F650 htm for 760 and more cheaply here http www pro flo com proflo keihin fcr carb _kits htm BMW for 625 However think dual 39 s is best for all out racers and feel the dual 36mm Mikunis offered here http www team pami de ENGLISCH index htm for 448 euros 392 would work best Since the F650 and Pegaso share dual Mikuni BST33 s think the F650 carbs would work on my Pegaso Info got from Team Pami The Mikuni flat slides have both 36mm diameter both open together the carbs have an a
209. nd exerciser things Just kidding have the same trouble not quite as bad have taken mine apart and found that there s nothing you can do I think Very minimalist inside no opportunities to adjust the tension An o ring and a spring washer You can t lubricate it gasoline right When you put it back together with the screws appropriately tightened it goes to it s natural state of tension Bummer Then again there might be a narrow sliver around the spring washer where a little grease could go Anyway it s easy to open and put back together so have a look Aleksander Try silicone spray It doesn t rot rubber and it s largely petrol repellent Pete Managed to strip the threads on the small petcock screw the one nearest the on setting whilst taking it apart to free it up it was very sticky and hard to turn to reserve It looks like there is not enough of the very soft metal to go to a wider screw but perhaps enough to tap another 1 8 or 3 16 deeper on the same hole just went to home depot and bought 2 6 x 1 2 self drilling hex heads Bored right through the soft metal and seated everything well Not leaking yet NormJ 473 Ruined my petcock I ve put in a longer screw can t recall how much longer and used a tiny lock washer so would be less tempted to over tighten plan to re tap the holes with a coarser thread if ever get around to it Very very soft material if ever have to replace it will definitely no
210. ng more fuel than normal or limit choke hence the name the air supply Your bike will consume more fuel on choke sometimes it will also run badly on low revs and probably pollute more Not having to remember the choke is one of the nice things about fuel injection know of a guy that misunderstood the choke on his veteran bike and was starting without it and when the engine got warm he applied full choke He did this for several years Pelle Sweden 02 GSDA The choke is not a choke air restriction its an enricher jet control more fuel hence it runs the engine rich carbons up plugs etc and uses more fuel If you run the cold starting device for long enough the plugs will foul the carbs will maybe overflow and the engine will flood and stall at idle If you don t have a temp gauge you should maybe get one the screw in type tells you when to close the choke Imagine setting up the bike with the choke on full You get the idle at 1100 rom by moving the idle screw in or out so the air and fuel match up and burn You then move the choke to the normal run position the engine will stall However run until the engine is hot and then move the choke lever The engine is so hot it ll burn pretty much anything lean rich whatever at least for a time and with the right throttle setting However the plugs will show what the mixture was like I ve had this on the dreaded Ural The Ural choke opens an additional fuel jet With the crappy sp
211. ng stem in the freezer just yet but am not sure how will heat the new bearings in our oven without her noticing Simon 98 F650 Ireland To make along story short am moving and all my tools are packed have a 2 month old new to me 1998 f650 with 22k It started running poorly died in the middle of a ride dropped it off at the BMW shop and they immediately want to rejet it as the plugs were fouled No attempt or offer at idle mixture etc Re jet was their only offered option The bike is from the same altitude as my current town admit my ignorance as have never owned a BMW and don t really get this two carb hi low with the F650 Are those guys trying to pull a fast on me Flash That sounds like one of two things you probably have either ripped carb diaphragms or else bad spark plug caps Oh might you have gotten some bad gasoline Rejetting it is horseshit You can check and or fix either the diaphragms or plug caps yourself by using the FAQ Sante Fe BMW treated us well clogged idle jet was all it took Chicken little 98 F650 Albuquerque e Next Detailed Feedback on Carb Reconditioning Feedback 1 Feedback 1 Rejet of the 97 F650 Carb with Tech Tips Problems Tools General Whining by Langlois http faq f650 com FAQS Carb_Clean htm 22 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ First Get your airbox out see the F650 Fag remember to take the muffler off much easier with it out of the way str
212. ng surface with the slide which leads to needle and emulsion tube wear and inaccurate air and fuel metering at idle and low speeds also noted that the problem can cause sticking of the slide if the wear is severe enough since the wear results in such a misalignment of the needle and the emulsion tube that the side load on the slide from intake vacuum binds the needle in the emulsion tube The original needles removed from Ellen s bike had two steps worn into them causing the slides to not fully lower as well had always thought the Bandit carbs would work on the 1100G so called American Suzuki and one of their reps said he had both a Bandit and an 1100G and had put Bandit carbs on the 1100G He said needed the Bandit intake boots and had to use pod type air filters It turns out he was incorrect it s a direct bolt on The used carbs put on Ellen s bike supposedly had about 4K on them and they looked like that was accurate mileage There is always the unconscious expectation when you work on your bike that it will run better since you have just expended so much effort and think this can sometimes create false expectations Before putting the used carbs on her bike opened up the mixture screws a bit and raised the needles about 040 After getting her bike all buttoned up anxiously started it and it idled perfectly was so relieved was nearly beside myself with disbelief Of course when buying anything used you are at
213. ng to try Richard s suggestion re the screw In my case my bike was stalling unless kept the choke on even when the bike was warm but I ve adjusted the idle and it runs fine now Idle is 1300 100 rom and can be adjusted with the brass knob on the left hand side of the bike just above the foot peg It hangs loose from a cable you can t miss it Hope this helps Johnny Canada 1088 98F Q Which way is the Choke on A The Choke is on when the Lever is BACK toward you It often goes off by itself rotating AWAY from you when you are sitting one the bike Q How long should I leave the Choke On A Do not leave it on TOO LONG You will foul your plugs carbon your cylinder and head and and stuff up your fuel economy Most folks can switch it off after half a mile to a mile depending on the weather Same as Wamer use the choke only to start it when it s completely cold Turn it off immediately and drive away Mason 631 97ST in PA am curious how long people run before they turn the choke completely off Even on a 80 degree day am still at 1 2 choke when get to work any less and it stalls have a 15 minute commute much of which do at 80 have also noticed very poor fuel mileage 33 mpg am wondering if maybe my thermostat is stuck open Any way to test this without taking it out of the bike and putting it in a pan of hot water am going to go through the poor mileage faq and take off the lowering kit since got my o
214. noise have now is not nearly as loud as prior to the change When replaced it checked the travel of the tensioner and it was right on the 9mm limit This is why am going to replace the cam chain know the 9mm limit may be reached because of worn guides but since the bike was probably ridden for a while with the tensioner problem by me and possibly the previous owner figure the chain could be worn so don t want to take any chances Anyway the engine is still distinctly noisy up to 2000rpm Even thought the 9mm tensioner limit of effectiveness is almost used up figure it should still be doing its job Around 2000rpm the noise fades until it disappears and you just have normal piston noise Perhaps it is just a worn timing chain but the decompression mechanism makes sense to me dnd o Feedback 1 My suggestion and this is coverered in the FAQs is take a good long hard look at the Hydraulically Operated Chain tensioner and replace that Chances are it is your noise culprit not the Decompression lever Either that or the idle is too low but on the FI you cannot really change it yourself although someone reckon s he tried unless a s w upgrade lowered it somewhat On mine and others classic when had one that noise would disappear at the correct idle Seems odd must say about the noise Have you compared it to another s GS wonder if you have gunk in your Oil feed which is stuffing up the Hydraulic Tensioner Kristian 562
215. notch physically Matthew CV carbs operate of the velocity of the air passing through them Removing the snorkel or opening up an airbox will slow the speed the slide raises It will have no effect on the distance the slide rises Can anyone enlighten us on Practical Observation vs the Theory ed What are the Holes in the Bottom of the Slides for Curt Martin October 01 http faq f650 com FAQS CarbMiscFAQ htm 14 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ While I m not even close to being a guru I ll take a crack at answering your question The vent holes bleed off vacuum that operates the needle slides Ok you probably figured that out already So why change the hole diameter To change the ratio of vacuum to slide position You ve had your carbs apart so you have seen the slide return springs and know that the slides carry the needles as they move With that in mind the chamber amp diaphragm at the top of the slides gets a supply of intake vacuum fed through the little hole at the lip of the cover The vacuum pulls the slides up exposing more of the needle That vacuum is pulling against the return spring and also being bled off by the vent hole at the other end of the chamber If that makes sense so far then you ll realize that there are three ways to alter the needle position vs engine load vacuum 1 Change the diameter of the vent hole A larger will bleed the vacuum off quicker smaller
216. nse slightly Hang on a minute all but one those fixes are for the Classic F Sorry if you have checked your Exhaust Gaskets and NOT modified anything else like your Intake Snorkel or your Exhaust Pipe you ll have to ask your Dealer for a Newer Version of the FI Software to fix your bike There are no idle mix screws or idle adjustment knobs on the GS Dakar More Details on Carb Related Backfiring By Ted Harris From the Virago Site When it comes to machinery am a perfectionist A machine must be carefully maintained and assembled in order to perform to its full design potential own a 1983 Virago XV920K with which had an annoying and persistent backfire every time decelerated Other motorcyclists and mechanics with whom spoke were most sympathetic when discussing this problem but invariably dismissed the problem as something to be expected when using low restriction after market pipes Now an engine is not supposed to backfire and when it is persistent am not convinced it is harmless to the engine If there is an explosion in the exhaust pipe when the cylinder is trying to exhaust its spent combustion products a back pressure is created which interferes with the next cycle This could result in incomplete extraction irregular charging with the fresh mixture and overheating In addition valves are not designed to seal against pressure from their backsides and a broken valve head rattling around in the http fag f650 c
217. nture pipe The noise follows the RPMs As I rev the motor with the clutch engaged or disengaged the grating noise increases with the spin It happens moving or standing still when the motor is cold warm and more at lower speeds But it will also disappear for awhile only to return Sometimes it gets triple loud for ten seconds then subsides When it happens it clicks on like a compressor when flipping on the AC in a car and stops the same way strikingviking o Feedback 1 Of course you ve eliminated the chain sprockets and chain roller as possible suspects right Mine did that Also although it s on the left side the cam chain tensioner and guides can allow the cam chain to make the same kind of noise when they wear out SScratch 1082 o Feedback 2 Remove the front sprocket cover and see if the chain has been rubbing on the inside of it once heard a ticking grating sound and it turned out the drive chain was too loose Scott 1244 o Feedback 3 l m betting the countershaft sprocket nut is loose and the front sprocket sliding in out on the shaft YMMV Marty 436 o Answer None provided Noise 46 plan to replace my timing chain and guides in a few weeks when do a valve clearance check At the same time was hoping to do something about my decompression mechanism It makes the engine sound very average from idle to about 2000rpm About a month or so ago replaced the cam chain tensioner and it certainly reduced the noise The
218. o Cugino Pegaso don t have the entire kit won t work with my Pegaso but do have a set of team Pami 36mm Mikuni radial slide race carbs for a F650 on my Pegaso Just the carbs alone gave me a very noticeable power boost more top end and allows me to cruise the bike at the 2000 to 3000 rpm range without any lurchiness When first put them in used my stock airbox when finally removed it and went to Uni filters the bike really woke up Right now I m still trying to get the idle right messed up assumed the idle mix screws should have been at 2 turns out nominally finally got a tuning manual from mikuni com that says unlike every other carb Mikuni makes the RS idle mix screws range is 1 8 to 1 2 turns MAX Been wrongly going to leaner idle jets to compensate and causing other issues l m back on track and expect to have them idling perfect after about one or two more iterations The nice thing about removing the airbox is can have the carb out and on the bench in 6 minutes as opposed to 1 hour before Alternative Carb Parts OEM Parts List OEM Carb is a Dual Mikuni BST33 B316 CV carb http faq f650 com FAQS CarbMiscFAQ htm 18 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ FCarbParts1 FCarbPartsList1 FCarbParts2 FCarbPartsList2 FCarbParts3 FCarbPartsList2 For the diaphragm try one from a Suzuki GS500 part number 13507 17c01 don t know if the other parts are the same or not
219. o turn your idle mixture http fag f650 com FAQS CarbMiscFAQ htm 12 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ screws in a turn Just remember to turn them back out to 3 5 4 turns out when you get below 5000 feet Richard 230 e would and did do nothing you will lose some power but hey its not a race anyway Lance 1303 01 F650GS 96 G650ST y_kiwi e live at 1400 feet have had two different experiences in Colorado and Utah at elevation 1998 Triumph Sprint Three Keihin Carbs Factory stock probably a little lean Ran SMOOTH and perfect all the way to over 12 100 feet on the road to Fall River Pass Noticeable loss in power over 9 000 feet Smooth and comfortable at 12 000 feet but way down on power Really a non issue was loaded for a solo 10 day trip and had a blast Didn t use sixth gear much 1996 Moto Guzzi Sport 1100 Two Del Ortos with accelerator pumps Aftermarket exhaust and jetting mods probably runs a little rich Ran like shite at anything over 6 000 feet Had to keep it at 5000rpm or more the whole friggin way from Colorado Springs to Park City the long way Had it rejetted and dyno d at Salt Lake City with some improvement Ran good up to 9 000 10 000 after that but still coughed and spit and was problem child Although it ran poorly at lower rom and slower speeds it wasn t enough to make me want to cut short my 2 000 mile trip I d say don t change anything worst case you ll run a
220. ockets FAQ My missing chain tension roller caused a sort of rattling This was on a 01 though Sean STL Noise 12 Rattling from the Front of the Bike I ve had a rattle from the from end of my F for the past couple of months Very annoying and couldn t locate the source went for a ride this morning on the way back stopped to fill up the bike Stop put bike in neutral reach forward to turn the ignition off That s odd could have sworn there was an ignition switch there when started the ride grin Well at least found my rattle The switch assembly hadn t fallen very far and no damage was done 1 20 and a couple of new Allen screws and it was all back together Pete Noise 13 Front of Bike Rattle For six weeks rode half leaning out of the seat because it really sounded as though the rattle was coming from under me Poked around everywhere Then finally one day getting on it turned the handlebars while they were still locked and noticed the whole ignition assembly jump around Looked underneath only one bolt left of two and it was just about out as well Six weeks for new bolts still waiting Likewise a grin because felt silly spending all the time looking completely the wrong place Aleksander in Dubai Noise 14 LHS Side Rear Rattle At one point the aluminum foil under the left rear plastic piece it protects against heat from the muffler it was loose and made a little noise as it moved around Bill No
221. of some other problem and if so what Thanks for all your help A No this is not normal When the choke is off it is supposed to stay off It should have a spring near the choke mechanism on the carbs that must be overcome to activate the choke It this spring missing The reverse problem is more typical with the choke refusing to stay on because the tension is too loose at the choke lever on the handlebar Usually it is not too hard to increase the friction of the plastic choke lever by placing some heavy grease or rubber cement between the choke lever and the adjacent housing If that doesn t work try using a small plastic shim between the choke lever ring and the mirror clutch handle mount to provide some additional drag on the ring Looking at my bike don t believe that there is a screw http faq f650 com FAQS CarbMiscFAQ htm 6 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ to tighten would just loosen the mirror lever mount and move it over closer to the choke ring and see if you can put a little more friction on the ring don t have an answer about your idle just turn it up to 1400 rpm and see what happens Richard 230 Pacifica CA thought it was a design feature Maybe it is If ride with respect until the engine is warm then the choke is fully off when it needs to be This is fine with me J mes had have this problem too The choke closes on its own i e the lever moves away from me I m goi
222. ollector e Loosen the Allen screw on the clamp that holds the collector to the muffler e Geta 13mm box end wrench A socket won t work An open end won t work Get a BOX end wrench An open end will round off the corners of the cream cheese material used to make the fasteners The stock stud nuts are made of cream cheese and extraordinarily cheesy You may want to replace them with some Japanese exhaust nuts that you have lying around Perhaps slather everything with Aunti Sieze she didn t mind That s Anti Sieze to non native English Speakers You NEED a box end wrench That is the one that is NOT in the Official BMW POS Tool Kit e Loosen all four 18mm nuts at the header clamps until you can remove the nuts with your fingers e When removing the Lex pipe suggest removing the frame bolt just below it to make it easier If a stud wants to come out of the head give it some Vice Grippian persuasion to make it stay in the head e Itis much easier if the radiator has been removed and if you have four arms e Remove them and then remove the clamps that hold the headers in Pull the headers out There is some wiggling that needs to be done to get the headers out at the same time you re removing the u pipe You might need to pull the collector out of the muffler at the same time Make sure you hold your mouth just so e Replace your vaporized gasket Pull out or lever out the Old Gaskets with a Screwdriver The Exha
223. om FAQS BackfiringFAQ htm 3 of 4 18 02 2007 12 30 52 The Backfiring FAQ combustion chamber at 7000rpm engine speed is not something am desirous of experiencing As a side note got a real appreciation for the forces involved in the internal combustion process one day when had removed one of the spark plugs in order to clear raw gas from the cylinder had forgotten to disconnect the igniter and to my very great surprise the engine started and began to run WOW the forces involved can only be described as awesome And remember the open cylinder was not even firing The force of the exhaust pressure alone at idle speed was responsible for this incredible display am still disquieted by the act of straddling this beast A man named Daniel Bernoulli 1700 1782 was the first one to describe the effects of a Venturi Basically stated it is this As the speed of a fluid increases its pressure decreases And a fluid exhaust gas is a fluid when forced through a restricting orifice Venturi an exhaust pipe is a restricting orifice increases its speed and creates a vacuum This principle has a dramatic demonstration any one can perform Grasp an ordinary sheet of paper by two contiguous corners and let it droop down in front of your mouth Now blow across the top of the paper and the paper will rise toward the vacuum created This effect is what makes airplanes fly and motorcycles backfire It application is truly profound and if you have
224. om the left of the bike The other one of two is accessible from the RHS of the bike The Manual says of turns OUT from LIGHTLY bottomed out i e screw in clockwise until just seats is 3 5 The Screws Circled RED are the Float Bowl Drain Screws for emptying Crud Water out of the Carbs A SkewDriver or similar tool is highly recommended to access these screws Let s face it the screws http faq f650 com FAQS Idle_Mix_Screw htm 1 of 3 18 02 2007 12 30 25 F650 Idle Mix Screw FAQ aren t exactly hard to turn just hard to get to Actually have the Weekend Pro Model DSK 1200 I didn t buy the 12 Pack btw just the one You really don t need anything else and the little handle thingy under the SC 1600 just gets in the way and leaves you LESS room in what s already a tight spot Especially on my Ohlins Preload Handle Side The SC 1600 might fit but I m happy with the Standard Bevel 10 95 too if you can find it a Hardware Store See SkewDriver Alternatives to the SkewDriver SkewDriver Feedback Another alternative to Spectools is a tool from Harbor Freight Cost is 8 haven t used it haven t received it yet but you can see a picture and the contents of the kit at www harborfreight com enter the number below in the find item number box Part number is 34273 3VGA If you order 50 or more from HF you get free shipping Unknown At a pinch you can use a bent Bobby pin My rubber plugs are missing but found that th
225. ome free Unscrew the Plastic 12mm Nut to the Choke Cable and pull it out gently You can only use an open ended spanner Do NOT turn it the wrong way and screw it up tight now or later it s just a PLASTIC Nut and will Break Give the Choke Cable Barrel a bit of clean with some Jif or some other polishing fluid If you want to lubricate the choke cable this is a good time to do it Recommendations for lubricating cables run from a It s not required because it s ion a plastic Sheath I subscribe to this notion especially for Choke Cable to b Tape a SMALL STRONG plastic bag of cable lubricant around the cable then hang it up higher than your handlebars leaving it overnight The Carb is now free for you to work with in a nice warm comfortable and CLEAN environment all of which are highly recommended Bear in mind the Carb Bowls are still full of GAS so undo the Float Bowl Screws Circled Red a few turns and rotate the Carbs around until all the GAS you can get out of it comes out DON T SMOKE Removal of the Diaphragm Cap only on the Bike DON T SMOKE Remove the Seat Remove the Tank See the Gas Tank Removal Replacement FAQ Remove the Seating Plate at the Rear of the Tank held in Place by two 10mm Bolts You now have access to the Diaphragm Caps which after removal allow you to check and replace The Diaphragm Slides But NOT the Slide Carriers The Needles Springs Needle E Clips
226. on Steve 1130 e went to pick up my bike from the shop yesterday not a BMW dealer after a major service and the bike started up okay It ran 1 2 minutes put it in gear and it stalled It would just about catch then stall 2 3 times couldn t see any gas in the fuel filter We added gas to the tank still no gas showing in the fuel filter The shop had the tank off cleaned the screen lubed the petcock etc Any ideas as to why gas apparently isn t getting through The bike is a 97 Funduro w 48 000 miles stock Answer The shop evidently took the in line filter off and put it back on after reinstalling the tank etc There was an air pocket in the hose that had to work out The bike started right up not long after left guess the lesson is patience Plus realize it may take longer to start It did take longer to start than when you switch to reserve Yeah the in line filter was on backwards for a year the shop discovered it and turned it around guess it worked fine as far as gas flow went but wasn t filtering anything details Muriel 582 e Split the problem in two Unhook the fuel line at the petcock Put a container under the petcock Turn on the petcock does gasoline come out at a decent flow rate If not the problem is with the tank petcock filter screen vent If so the problem lies with the in line fuel filter OEM and or aftermarket fuel line or carbs floats needles To venture a wild guess this assum
227. on of the canister My tank has been venting just fine for almost 5 years now Richard 230 This worked perfectly for me and should be all you need to do 1 Remove canister from the bracket 2 Unhook all three hoses from the canister One drains by the right foot peg one goes to the carb and one goes to the gas tank 3 Discard the canister and hose that drains by the footpeg Bye bye 4 Plug the hose going to the carb plugged mine with one of the bracket bolts from the canister 5 Reroute the hose from the gas tank to where the old drain hose was by right foot peg Cut it to an acceptable length 6 Done Grady Aus TX 13 Aug 02 also found a metal restrictor in the vacuum line running from the rear connection on the carb to the cannister simply removed it and the rest of the line running back to the cannister and screwed a suitable sized bolt into the remaining vacuum line to plug it The other vent tube running from the tank to the cannister just tucked up under the seat behind the latch mechanism Instead of a filter covered the end of this tube with a small swatch of cotton cut from an old t shirt and held in place by the stock spring clamp Works just fine and keeps out the bugs When was performing the Canisterectomy noticed that the vent line from the tank had an accumulation of oily gunk in it There was enough so that when blew through it it gurgled and dribbled out the other end wonder if this
228. onge cake seals the Russians use the choke is always letting some fuel in You set up the carbs like this and get idle and some sort of balance You actually close up the main chamber a bit to allow for the extra fuel that s sneaking in via the choke On a Ural the seals then leak gunk into the carb by reacting with the petrol and give a proper seal and or block the start jet The engine runs lean and hot You then retune and all is well until the main jets block and you hit them with carb cleaner The choke jet seal de gunks and its sooty plugs time again At this point you sell the bike and buy one with FI if you have any sense The F carb doesn t have this exact problem because the rubber bits are petrol proof but am wondering if something similar is possible guess you ve already checked the choke cable for tightness Andy Leeds UK 982 e Less air in mixture than usual This results in the engine running a little hotter which is never a great thing normally ride to the second stop street with my choke on about 2 3 Classic By this stage the engine is warm enough to tick over smoothly by itself do however frequently check my choke turn signal and low beam switches while ride just a habit really Bernard http fag f650 com FAQS CarbMiscFAQ htm 8 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ Make sure the choke is off check at the carb not the bar lever are you sure your choke goes completely off
229. opped to 4V With started pressed it dropped to 3V Could have sworn tested it with key on last night and got 11 9V but it was late apostate 1618 Ed See also the Hard Starting and Poor Running FAQ Noise 34 The symptoms see Noise 3 Rattling from Engine at Idle are similar in that there is no noise above 1500 rom and when the engine is warm When the engine is cold and while it idles itself to warmth and 1500 rpm there is Khat Khat Khat sound than a click Once warm don t hear anything abnormal In a way it does sound like a solenoid heavy relay Seems to be coming from left side gear lever side of the engine The engines done about 2000 miles I ve not known the bike to have been raced arun o Answer That rattle rattle click IS the compression release If it does it at 1500 rpm maybe your chain tensioner is bad or going bad Maybe the plastic chain rails are worn Maybe the oil is too thin 3000 feet is nothing Before you start messing with the carbs give the bike a thorough service Without a GOOD baseline you can end up adjusting the thing into a horrible state Flash 412 Noise 35 My 97 F650ST makes a VERY strange noise when pull through 4200 4500 RPMs in 4th and 5th gear It also makes the noise occaisionally when decelerate from about 65 mph to 60 mph I m running the highest octane can find BP gas It seems to make the noise more http faq f650 com FAQS StrangeNoises htm 12 of 23 18 02 2007 12 31 03
230. or a Valve Check Carb Clean laying it down on its side on a wad of cloths with the petcock side UP will also allow you to remove it even with some gas in the Tank 5 Switching the Petcock to OFF won t help you 7 Remove the two screws holding the metal casing that surrounds the petcock and slowly and gently remove the cover and the copper looking washer NOTE The metal on the bolts and petcock housing is very soft and the threads can ruin easily 8 Now you are looking at the petcock from the cross view and you can turn it back and forth and watch it work but be careful because the force of the gas pushing against it will most likely push out the petcock and will spray gas all over the place Its what happened to me but just stuck my petcock back in where it came out of and it held After that sprayed silicon around the edges and all over it put it back together and it works wonderfully now Its SO much easier to turn I m not sure if it was the silicon or just the speed of the gas exiting the hole that perhaps cleaned it out but whatever it was it works a WHOLE lot better now 9 You can get Silicone Spray from most auto shops 10 There is nothing to it Just put the washer back on and if it gives you some trouble trying to get everything to go back properly just be patient and make sure the washer fits in the groove before you tighten those screws down 11 You may need to repeat this at your 10 000kms Service Interva
231. or popping due to the lean mixture Adjust your Idle Mix Screws as per the Carb Clean FAQ e 1 2 to 1 full turn richer may stop the backfiring Try that first before doing more complicated things That should also compensate for any altitude change however be aware you should isolate it to ensure you do not have another problem like blown Exhaust Gaskets or Worn Needles etc Or it simply may have not been set properly in the first place e Enrich the idle mix Now that you ve got more air your idle mix is lean which causes the backfire Turn them all the way in not tight and then back them out 3 5 turns each If that doesn t solve the problem completely turn them out another quarter to half turn Unless you have a new exhaust leak can almost guarantee this will cure 95 of the popping Feedback e The elevation of Phoenix is 1112 feet Yep 10k is a pretty big gain Pack light over the passes think the loss of power will be very noticeable but it won t stop you it IS a motorcycle Going down a tooth on the front sprocket is an option but it harms your gas mileage and maximum potential cruising speed say don t change anything and tough it out Stick in the lower gears up the hills and prepare for a significant drop in gas mileage Aurora CO chppdlvvr e Itis a common misconception that a trip to the mountains requires that you to rejet the carburettors There will be a slight loss of power nothing more The time you spend at 1
232. or something Guess this particular mod was is the brain cells torched rallying this summer As always proceed at your own judgement and risk YMMV Marty 436 Where does the Fuel Cap Drain Drain to Q have a 98 classic and seem to remember when first got it if spilled some gas when was fueling into the little black channel around where the nozzle goes that it would disappear This is no longer happening went to fill up the other day after a heavy rain and opened the cap to see all this liquid running from that channel into the gas tank This is not a good thing as it was water but the bike has run ok since anyway just don t want to make a habit of it My question is is there supposed to be a drain for this channel and if so where does it go What do need to do to check to see if this is clogged If anyone has some pictures that would be great e The well the filler cap fits into drains thru a small hole in the LEFT side thru the left side tank tubing The right side tubing is the internal tank vent that goes thru the check valve in the filler cap There is a detailed schematic drawing of the vent drain tubes in the FAQ s under reversed vacuum tubes routing or the Canisterectomy Diagram at the bottom Be careful when opening the filler cap when it s wet out the cap tends to collect a teaspoon of water between the top of the gasket and the filler cap body which drips into the tank completely un noticed when you open
233. ort in the cylinder head This is a photo of where it goes Refer to Exhaust Pipe to Collector Gasket below for details e One 1 where the exhaust collector meets the exhaust pipe that goes to the muffler just before the crossover pipe If the leak is right at the exhaust header where it connects to the engine the leak could cause valve damage over a period of time if it is anywhere else further down the exhaust system it will just make noise Gaskets Replacement at the Cylinder Head By Shank Flash 412 December 01 http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 1 of 8 18 02 2007 12 30 55 Exhaust Gasket Replacement FAQ What to check First Before you go replacing the Gasket try first tightening the nuts that clamp the Exhaust Headers to the Engine Ports The location of these nuts is shown below Replacing the gaskets should give you far less flatulence wish could say the same for me will be quieter and may give you more power Check also you actually have the nuts as sometimes they can come off A Symptoms of a Failed Exhaust Gasket As you increase revs you may get popping and perhaps in a darkened garage or at night a blue flame shooting out of a pipe on the front of the engine around the exhaust pipes The flame if any will come from around the clamp It may not have been assembled correctly at the Factory or it might just have got tired NOTE 1 It can also make it LOOK like a weeping head gask
234. orth some odd digging to see Note the 1994 Triumph Daytona 1200 has Mikunis BST 36mm CV carbs but the 36m is the horizontal opening size and Diaphragms MAY be the same as the F650 You CAN get some Carb parts from Sudco at www sudco com but they do not list our carb got my Pilot Jets from them Ron Wood offers dual 39mm flatslides for the F650 for 760 you can get them at www pro flo com for 625 mtiberio Dave 365 Thank you Dave got this precious Gem Dear Sir We checked your question Your F650 s BST33 B316 original slide springs are the following compatible part No s Please order Yamaha or Suzuki your local dealers It is faster than delivery when you order to BMW or Rotax engine maker o Suzuki genuine part no 13417 12D00 o Yamaha genuine part no 3LN 14933 00 Yours faithfully Mikuni Corp International Dept Next How do get Water in the Float Bowls Q How did I get water into my float bowls emptied the fuel tank replaced the green gasket under the filler cap but somehow still get water into my float bowls Also don t have a cannister Are there any other suspicious passages for water The problem arises only in wet weather under rain and cold Then the bike drops its idle and stalls or surges as if it runs out of gas http faq f650 com FAQS CarbMiscFAQ htm 21 of 23 18 02 2007 12 29 59 Miscellaneous Carb Questions FAQ e This is a common problem on the classic
235. ose See the Carb Misc FAQ GAS TANK REMOVAL amp REPLACEMENT by Kristian 562 01 11 01 Removing the Tank To do this you should first turn OFF the GAS petcock Also remove the SEAT Preferably done with an almost empty Gas Tank Then 1 Remove the fuel line at the Petcock Use a pair of Pliers to slide the Spring Clip back down the http faq f650 com FAQS Gas_Tank_Removal Replacement htm 1 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank line then use a screwdriver to prise off the line Some excess fuel will drain out of the carbs but it s not excessive so don t fret and don t SMOKE 2 On the LHS of the bike Just left of the Carbs there is a small Breather Pipe coming down between the Skin of the Gas Tank and the Tank joined together just beside the carbs with two smaller spring clips Use small pliers to loosen one then pull the hoses apart NOTE On the USA model bikes there are actually TWO vent lines between the tank and tank cover that must be disconnected one on each side 3 Undo the Large Bolt Just at the rear of the Tank Its a 10mm Use an Open Ended or Ring Spanner or Socket 4 Undo the Small Allen Key Bolts Each Side of the Tank that holding the tank to the front fairing You can also remove the bolts holding the side fairings to the tank but PERSONALLY leave these Grey Coloured parts of the side fairing attached amp remove the lot If you do it this way there are Classics up to and incl
236. ot my Pilot Jets from them Ron Wood offers dual 39mm flatslides for the F650 for 760 you can get them at www pro flo com for 625 mtiberio Dave 365 Thank you Dave got this precious Gem Dear Sir We checked your question Your F650 s BST33 B316 original slide springs are the following compatible part No s Please order Yamaha or Suzuki your local dealers It is faster than delivery when you order to BMW or Rotax engine maker o Suzuki genuine part no 13417 12D00 o Yamaha genuine part no 3LN 14933 00 Yours faithfully Mikuni Corp International Dept Next How do get Water in the Float Bowls Q How did I get water into my float bowls emptied the fuel tank replaced the green gasket under the filler cap but somehow still get water into my float bowls Also don t have a cannister Are there any other suspicious passages for water The problem arises only in wet weather under rain and cold Then the bike drops its idle and stalls or surges as if it runs out of gas http fag f650 com FAQS CarbMiscFAQ htm 21 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ e This is a common problem on the classic F The water goes in through the air filter You can empty the water of the carbs by unscrewing for a few seconds 2 or 3 are generally enough the two screws located below the carbs in horizontal position taking care you have the gasoline pass key in the off position Then the
237. oticed very poor fuel mileage 33 mpg am wondering if maybe my thermostat is stuck open Any way to test this without taking it out of the bike and putting it in a pan of hot water am going to go through the poor mileage faq and take off the lowering kit since got my other bike running am going to check the plugs and gap et all my impression is that something is wrong Don Don Rochester As soon as get to a road where can run for more than two blocks without a stoplight turn it off less than a mile Yes have to turn it on when the temperature is in the 80 s if the motor is stone cold Flash 412 CO It also only takes me a couple blocks before can turn the choke off Robert 959 in TX 97 F650 need the choke to start easily even when hot but it goes off within 1 mile and then the bike idles normally With the oil at 40 centigrade plus the choke goes on half the engine fires with no throttle and the choke goes straight off With cold oil on a normal UK day 10 15 centigrade half choke for 1 mile On a cold winter day minus 2 3 need full choke to start then half for 1 2 miles With a warm engine and choke on after the engine fires you get the trick where the engine stalls as soon as the throttle is opened am guessing that the passage in the carb is a bit on the big size and the rest of the carb setup might be critical Having the choke part on when the carb was set might give the result Don describes A plug
238. ou won t hear it It s too small If the exhaust pipes have ever been removed or replaced of if the exhaust gaskets have been stressed in any way replace the gaskets http fag f650 com FAQS BackfiringFAQ htm 4 of 4 18 02 2007 12 30 52 Exhaust Gasket Replacement FAQ Exhaust Gasket Exhaust Nuts Replacement FAQ Compiled by Kristian 562 Pictures by Kristian 562 Please read the Disclaimer before attempting any work in this FAQ Classic Exhaust Gaskets What about the GS Exhaust Gasket What about those Rusty Exhaust Nuts Studs Alternative Gasket Sources Note This might sound really dumb but do please wait for the bike to cool completely before replacing any Gaskets Classic Exhaust Gaskets Where are all these Gaskets Gasket Replacement at the Cylinder Head Gasket Replacement at the Collector Header Pipe Junction Where are all these Gaskets There are actually a total of FOUR Exhaust Gaskets on the Stock Exhaust Pipe Only three for a Staintune however the most common ones that fail are the two at the Engine Header pipe connection They are One on each total of 2 of the Exhaust manifold connections to the Cylinder Head which look like this This is a close up of one of them It is the Silver Ring which is very soft crushable metal sandwiching a Gasket Material e One 1 where one of the Exhaust Manifold U pipes meets the collector pipe that goes to the other exhaust p
239. our bike with a low or failing battery is a really bad idea because there is a real risk of the starter solenoid contacts welding closed due to low voltage arcing If this happens you will have to disconnect the battery because the permanently closed solenoid contacts will crank your battery dry and either replace or repair the starter solenoid Noise 9 Farting and a loud popping from the front of the bike Possibly Blown Exhaust Gaskets http faq f650 com FAQS StrangeNoises htm 6 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ Recently went to replace gasket where header pipe meets cylinder head After pulling left header pipe found culprit of noise blown out header pipe to collector gasket This was a corrugated sleeve that failed under the clamp Replacement gasket is no longer corrugated Added bonus was the commonly reported backfiring problem thought had to live with is now completely gone Try this 11 00 fix if your bike is backfiring See the Exhaust Gasket Replacement FAQ for details Noise 10 Making weird wooo noise when compressing the rear shock Culprit Humming rear brake calliper wheel moves slightly when compressing the rear shock o Solution Stop compressing the rear shock and listening for silly noises perhaps a little anti seize on the back of the pads Noise 11 Rattling from the Chain Area This could be poor Chain Tension a Loose c s Sprocket or a Chain Roller See the Chain Spr
240. ows the result Highway pegs are a convenience on long rides and usually fitted to cruisers The standard Dyna chrome highway pegs are 40919 95 These require purchasing the http www chuckhawks com super_glide_sport htm 6 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT actual footpegs separately and chose the cushion footpegs 91821 85 which have chrome end caps with bar and shield logos These same footpegs can also be used to replace the stock rider and passenger footpegs for a matched look Because the test bike was to wear saddlebags didn t add chrome parts that would have been largely covered by them To dress up the rear end on a bike without bags would add a chrome sprocket cover with holes 91346 00 and a chrome belt guard 60293 00 For a complete list of modifications and accessories added to the test bike click here to see the H D Super Glide Sport Accessory List The Twin Cam 88 engine Like all Harley big twins the Super Glide Sport is powered by the redoubtable Twin Cam 88 engine This modern air cooled OHV 45 degree V twin has hydraulically adjusted valves that never need attention The factory rates this engine as producing a peak of 86 ft lbs of torque at 3500 RPM at the crankshaft Independent dynamometer tests usually show 71 to 73 ft lbs of torque and 57 to 60 horsepower at the rear wheel for stock engines This is sufficient power to give the Super Glide Sport good street
241. performance and more than adequate highway passing power even riding double In fact stock performance is better than just about everything in its class except the dedicated power cruisers Modifying the TC 88 engine For those of us who want more power virtually 100 of Harley owners almost all dealers suggest replacing the stock air cleaner and mufflers with Screaming Eagle replacements and re jetting the carburetor These simple changes add the 5 10 horsepower stolen by the EPA Many owners have these changes made before their new bike leaves the dealership others have them done the first time the motorcycle is serviced Almost every Super Glide Sport you see on the street will have had at least these modest engine modifications which noticeably enhance throttle response and performance Many owners go farther with performance enhancements In addition to the SE air cleaner breather kit and mufflers mentioned above Harley s Stage 1450cc engine adds a SE Mikuni 42mm flatside carburetor replacing the stock 40mm CV carb and a SE 6200 rpm performance ignition system module plus coils to the above performance enhancements According to Harley s dyno tests a Stage motor produces about 81 ft lbs of torque and 71 hp at the rear wheel The test bike was taken to Stage equivalent specification before it left the dealership http www chuckhawks com super_glide_sport htm 7 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLID
242. r General FAQ s about the F650 Carbs Reduction in mileage Gas mileage Who makes the F650 Carb Another bike with the same carb Another supplier e Synchronise e STOCK Carb Settings Carb Parts Numbers Websites to tell me how to tune my Carb What Parts of the Carb get worn What about alternative Sources for the O Rings Adjust the Idle MIX Screws Q At what mileage can I expect to get a reduction in mileage due to worn Carb parts A This is an extremely difficult question to answer it depends on whether you ride in dirt road or at cruise revs or high revs Some inmates have noted a decrease in Gas Mileage around the 20 000 miles mark Q So what gas mileage should I expect to get A Again this is an extremely difficult question to answer it depends on whether you ride in dirt road or at cruise revs or high revs Some inmates get 45 50 some 50 55 some 55 60 If you get less than 45 50 with a stock bike normal around town riding on the road and you have a high mileage bike it s http faq f650 com FAQS Carb_Clean htm 2 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ probably time to check the Carbs Same goes if you get less than about 50 55 on the open road Refer the Poor Mileage FAQ for more details feedback Q Who makes the F650 Carb A Mikuni They are 2 x 36mm Mikuni BST B316 CV Constant Velocity Carburettors There are two on the F650 side by
243. read my earlier fixes on the Worship page little did know how wrong actually was My fixes were more of a band aid that made the bike run better but didn t cure the root cause A letter sent in to the November 2000 issue of Cycle World magazine s Service section by Sasha Shapiro of New Paltz New York describing the exact symptoms had experienced prompted me to finally get hot on the problem must note that Cycle World s response was way off target will be sending them a letter regarding the true cause of her troubles contacted her and she eventually replaced her carbs curing the bike finally got fed up enough to do some serious research and found a letter on the Web from a guy in England that said he had noted emulsion tube wear on his 1200 Bandit and after replacing them it cured his low speed mixture problem reasoned http faq f650 com FAQS CarbMiscFAQ htm 16 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ that with 56K on our bike we must have this problem as well rushed out and bought new needles emulsion tubes and slides confident that had solved the problem at last Wrong The bike ran no differently which prompted me to completely tear down the carbs for some direct inspection of my own After getting the carbs apart and taking some careful measurements finally found the true problem which is the plastic pieces that the slide mates with This piece eventually develops an uneven mati
244. ring bits attached to the tank lift them out a bit so they go past the front fairing Push the rear off the tank as far forward as you can place and tighten by hand then torque the Tank retaining Bolt Do up all your Allen Key Bolts NOT TOO TIGHT some Blue Loctite these closed but remove my tank quite a lot Reconnect the Breather pipe amp Clamps Reconnect the Fuel Line and Clamps Turn on the petcock FUEL PETCOCK FAQs e Sticky or Hard to turn Petcock Problem In Tank Fuel Filter Cleaning Close the Fuel Tap Sticky or Hard to turn Petcock Problem by Omnikron http faq f650 com FAQS Gas_Tank_Removal Replacement htm 3 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank 1 Well for me my fuel petcock was almost impossible to turn So took it outside on a day when knew wouldn t be riding the bike cause just knew was gonna get gas all over the place and unfortunately had a full tank 2 Please do this OUTSIDE in a well ventilated area and do NOT smoke Keep the Tank and any spilt gas away from Naked Flame sparks and children 3 So 1 recommendation is to have a near empty or empty tank If it s not been driven to empty you can simply undo the fuel line from the petcock Pull the clip back after squeezing with a pair of pliers drain the GAS into an approved container and refill it back into the Bike after cleaning if your Tank is still a bit full 4 If you have the Tank OFF the bike e g f
245. rmation you have and can get with regard to whatever it is Motorcycles Fuel level or pressure ignition timing or map valve timing valve movement relative to degrees of crank rotation compression pressure with info of battery voltage or rom of engine and so on The more info of the perfect machine you have the easier it is to find any fault WHEN it will not be perfect forever you want to restore it to it s former state Haakon 626 Norway F650GS Carburettor LINKS Some good resources for Jetting and Plug Reading Information Not F650 Specific FactoryPro SS I OO httpvTwww factorypro com eel Tuning CV Carbs Mikuni Sudco recommends tuning the circuit from the Pilot upwards as they say each circuit is additive Factory recommend starting with the main and going DOWN cannot put copies of the information on this Spreadsheet as Sudco has a copyright on this information It s about a 13 US Manual from Sudco http www factorypro com tech carbtun html http www nightrider com Note Actually for Harley V Twin with CV Carbs but general information is useful http www nightrider com biketech a i On Carb Circuit Ranges carb jet ranges htm http www nightrider com biketech carbadjust htm On adjusting the Carbs http www nightrider com biketech hd_cv_mods http faq f650 com FAQS Carb_Clean htm 19 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ http Awww nightrider com biketech hdcvcarb
246. rom the manufacturing process and sand and other junk blew fell into the tank during fueling 1 This really should be done with the tank removed for the reasons explained in step 5 below See the Tank Removal FAQ for details Also you should wear rubber vinyl gloves to prevent neurological damage from the gasoline 2 Drain as much fuel from the tank as you can by turning the petcock to reserve and tilting over a suitable container such as your oil collection pan You should theoretically NOT be able to completely empty the tank there is a slight sump wherein water can settle and thus not enter the reserve tube 3 Turn the tank on its right side and carefully remove the 2 hex head bolts securing the petcock it takes a 4mm wrench strongly suggest using your high quality T handle and taking your time The metal on the bolts and petcock housing is soft and threads can ruin easily 4 Gently remove the petcock by pulling straight out this would be down if the tank were on the bike 5 Gently place the petcock on a cloth Then work the tank around to slosh out the remaining gas into your collection pan You are likely to see more gas than you expected 1 15th or 1 10th of a Litre plus maybe some water and more particles than you thought you d see 6 Gently clean the gunk from the tubes screens and the joint where the tubes join the body of the petcock A soft toothbrush a little gas and med high pressure air are great tools The long
247. rs ago mc gas caps had a literal hole through them a vent hole to the air that became clogged This hole was generally under the cap outside the perimeter of the sealing surface of the tank Sometimes it was even on top in the middle of the gas cap It ain t like that no more Actually the interior of the cap is much more complex than most would realize with a couple flap type check valves Take it apart some winter just for fun Feedback e Acerbis tanks excepted mine vents through the keyhole in the lock Marty 436 Chicago 97 F650F How suddenly should the effects of running low on gas kick in Q Last week was riding downhill on a curvy dirt road when my engine sputtered once or twice and then very quickly shutdown So fast in fact that my rear wheel locked up and sent me high side before could engage the clutch Sure enough when dusted myself off and picked the bike back up it was at about 150 miles and wouldn t start back up until turned the fuel tap to reserve This is my first carburetted bike in a while but still tend to think should have a little more warning before running out of fuel Any advice would be great A Sudden engine death e On flat roads normally get a good amount of sputtering for 30 45 seconds guesstimate before it dies completely On a fairly long steep uphill section of Rte 2 in western Mass once had no warning whatsoever it just died suddenly in a corner attributed that to t
248. s to multi cylinder engines where individual Carbs feed individual Cylinders You do NOT need to Balance the carbs on the F650 if you set the Settings Needle Float Jet Size Mix Screw the same for each Carb It s a single cylinder engine For more information refer The Carb Misc FAQ Q What are the STOCK Carb Settings A The Stock Carb Settings are http faq f650 com FAQS Carb_Clean htm 3 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ 1996 Onward Models Main Fuel Jets 132 5 Pilot Jets 41 3 Idle Air Jets Needles 5E94 4th Clip from Top Blunt End Carb Venturi Emulsion Tube 58400 2 The first 2 stands for a rectangle with a small square inside the second o stands for a small rectangle Thanks to Marty 436 Float Height 14 6mm from the Gasket Surface Idle Mix Screws backed out 3 5 turns from LIGHTLY seated all the way in The Stock Organ Pipe s are sealed so if yours are open someone has probably re jetted your bike 1993 1995 Models Thanks to Spakur amp Fede Main Fuel Jets 140 Main Air Jet 0 6 Pilot Jets 41 3 Idle Fuel Jets Idle Air Jet 1 5 Needles 5E94 4th Clip from Top Blunt End Carb Venturi 584 0 2 Float Height 14 6mm from the Gasket Surface Idle Mix Screws backed out 3 5 turns from LIGHTLY seated all the way in The Stock Organ Pipe s are open so if yours are plugged someone has probably re jetted your bike Here s a
249. seating position that moves the hips farther from the gas tank 1 2 inch more width and a little more padding For the occasional passenger it incorporates a better shaped seating area with thicker padding while maintaining the 5 inch width of the stock seat This seat s carbon fiber inspired graphics look kind of trick The Screaming Eagle fork brace 46192 99 makes a nice addition to the front end http www chuckhawks com super_glide_sport htm 5 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT of a Sport destined to be ridden hard Also for the front of the bike stainless steel front brake lines 45287 99 are attractive and can firm up front brake lever feel The sleek color matched quarter fairing 57070 XX and chin spoiler 58593 XX add protection and a performance appearance Orange SE performance spark plug wires 319 44 deliver maximum spark voltage and look trick When you get your performance ignition system be sure to get the matching orange high performance coils Lighter than stock Thunderstar black alloy wheels front 43772 00 rear 43780 00 reduce unsprung weight and look great These are also available in chrome finish An oil cooler 62871 99 can help keep a hard working engine cool in hot climates The oil dipstick with digital temperature readout 62938 00 lets you monitor oil tank temperature Appearance cruising accessories There is an awful lot of black on a stock Super Glide Sport
250. servation vs the Theory ed What are the Holes in the Bottom of the Slides for Curt Martin October 01 http fag f650 com FAQS CarbMiscFAQ htm 14 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ While I m not even close to being a guru I ll take a crack at answering your question The vent holes bleed off vacuum that operates the needle slides Ok you probably figured that out already So why change the hole diameter To change the ratio of vacuum to slide position You ve had your carbs apart so you have seen the slide return springs and know that the slides carry the needles as they move With that in mind the chamber amp diaphragm at the top of the slides gets a supply of intake vacuum fed through the little hole at the lip of the cover The vacuum pulls the slides up exposing more of the needle That vacuum is pulling against the return spring and also being bled off by the vent hole at the other end of the chamber If that makes sense so far then you ll realize that there are three ways to alter the needle position vs engine load vacuum 1 Change the diameter of the vent hole A larger will bleed the vacuum off quicker smaller will bleed the vac off slower 2 Change the rate the return spring A heavier spring will have the same effect as a larger vent hole 3 Change the position and shape of the needle You can use any combination you wish provided it produces the results that you or
251. should say the engine wants I ve seen it done all three ways by different shops and kits know one successful race shop that prefers to use the stock needles straight taper and slides He only changes spring rates and jet sizes Others Dyno Jet kits included use custom needles stepped taper adjustable position and larger vent holes in combination with stock spring rates And some just alter the needle shape while leaving the vent and springs alone The results are all that matter btw this is usually a mid range adjustment Low range is still governed primarily by the pilot jets amp float height and top end by the jet size Flat spot in carburetion Refer the Canisterectomy FAQ Idle Mix Screws FAQ Poor Mileage FAQ Carb Clean FAQ The following responses are for PRIMARILY from people with Stock setup If you know or suspect you have a Jet Kit please also refer the Performance Modifications FAQ e figured out what the problem was On the air filter side at the bottom of the Venturi there are two orifices a small one and slightly larger one The smaller one was clogged big time used carb cleaner and a piece of stiff wire and finally got it cleared Took about 20 min Put them back together and the bike runs like a charm Thanks again for all your help and everyone here JAMES http fag f650 com FAQS CarbMiscFAQ htm 15 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ e Oh yes was talking about the
252. shut it off That way you have partially drained the fuel line amp carbs just in case fuel expands when heated and may find its way out when it does If the gasoline fills up the cylinder is that even possible on the F6507 you may get hydraulic lock and bent connecting rod or other parts when starting Fuel dilution of the oil may give you MUCH lower oil viscosity and the higher wear that goes with it Also be aware that the F650 petcocks have been known to fail Running the bike should not present a problem unless possibly during an extended period of gridlock YMMV Marty 436 Chicago 97 F650F All about Floats by A Watson http fag f650 com FAQS CarbMiscFAQ htm 5 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ 12 12 01 Floats serve 2 purposes First they keep the carb bowl from overflowing by floating up against the float valve and shutting off the gravity feed flow of fuel Second properly adjusted they maintain the fuel level in the bowl at the right height This is important because the height of the fuel in the bowl determines how much fuel gets sucked up through the main jet for a given RPM which in turn has a direct affect along with needle size and adjustment on the air fuel mixture that reaches the cylinder All the wisdom I ve heard is that floats which are made of plastic they appear to resemble extruded closed cell styrofoam can over time absorb fuel and become less buoyant Th
253. side Q Is there another bike with the same carb from which I can scavenge cheap Bike Parts A Yes the Aprilia Pegaso a 5 Valve Aprilia version of the bike made in the same factory in Italy It s not identical though You can also get SOME parts from the Suzuki GS500E Carb which is very similar Refer Alternative Carbs amp Carb Parts for details Q Is there another supplier that supplies parts A If it s just Main and Pilot Jets you are after you can probably get them from your local Bike Shop Ask for Mikuni Jets and show them your old ones as there are several different head Styles know you can get them from to Sudco Mikuni in the U S however Sudco do NOT supply the needles They say they were a special run for BMW and I ve found the only supplier to be BMW or a BMW Agent However Dave 365 Thank you Dave got this precious Gem Dear Sir We checked your question Your F650 s BST33 B316 original slide springs are the following compatible part No s Please order Yamaha or Suzuki your local dealers It is faster than delivery when you order to BMW or Rotax engine maker e Suzuki genuine part no 13417 12D00 e Yamaha genuine part no 3LN 14933 00 Yours faithfully Mikuni Corp International Dept See also Alternative Carbs amp Carb Parts for details Q Do I need to Balance Synchronise the Carbs A You have probably read somewhere about needing to balance the Carbs This really applie
254. t or is this fairly normal My 94 F650 has been a trouble free up to it s current 140 000km and was hoping this new one would be as reliable DancesWithPoultry Nigel in NZ o The clutch on my second F650GS made exactly the same noise in exactly the same circumstances realised it was bathed in oil it sounded dry like a coffe grinder so ignored it I m never sure if it ever went away cos ignored it Trevor 999 o Thanks Trevor and all who replied That makes sense to me It did used to be a hire bike so it was likely to have been hammered in the clutch region DancesWithPoultry Noise 54 Is this a bad thing when can here their slight click a click when the engine is cold Ed On a CS TexasArmadillo CG 1930 BBG 93 o What RPM Are you sure it s not just the compression release thingy going on and off if you re idling around 1k rom or so dinskeep o It s most noticable at idle 1400 rom but can still hear it up to 3000 rpm while it s http faq f650 com FAQS StrangeNoises htm 19 of 23 18 02 2007 12 31 03 The Very Strange Noises FAQ warming up TexasArmaadillo o Have you checked the valve clearances lately Flash 412 CO o Oh boy here comes the beating They should have at the BMW dealer in Plano TX when had the 6000mi It s at 8750mi now And didn t really notice much of a clicking before took it in then It was noticable only after got it back immediately asked them what was hearing and the m
255. t get the BMW OEM part Aleksander in Dubai 98ST You probably could go with a longer screw some sort of self tapping one would probably work The good news is if it doesn t a new petcock is only about 27 00 just replaced mine because it wouldn t shut off Just to warn you found out that the hex screws holding the petcock to the tank are made out of some incredibly soft piece of sh metal that my hex key basically destroyed removing it Be prepared to go to the hardware store or the dealer for replacements Tom in http faq f650 com FAQS Gas_Tank_Removal Replacement htm 5 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank Tallahassee e My fuel petcock is unreasonably stiff Almost impossible actually Not that it matters because even when switch to reserve the bike surges stalls and dies Once pulled over the engine restarts like nothing ever happened Does this happen to anyone else Thomas Stewart 97 f650st orange In Tank Fuel Filter Cleaning by Normd 473 Petcock Removal and Tank Screen Cleaning FAQ If you have never removed and cleaned your petcock and in tank screens you should And as discovered when doing my own 24k maintenance none of the 3 previous dealer 6k services had actually done the work When removed the petcock to clean the screens there was an amazing array of plastic shavings sand and unidentifiable particles collected on the reserve screen My guess is that the plastic shavings are remnants f
256. that they sound too big Marty 436 Chicago 97 F650F e Secondly as someone else complained once came to refit the diaphragms they wouldn t go at least 3mm too big Don t worry they will still fit The secret is lots of fine sewing machine lubricating oil If you lube the grove on the carb body and the lip of the diaphragm Working with both hands from a point on the circumference feed the diaphragm lip into the grove Then moving your hands in opposite directions around the circle keep feeding the lip and press each section lightly back towards your original starting point The idea is you are compressing the rubber lip to a smaller circumference The oil will help the already seated material slide in the groove Once did this my impossibly large diaphragms went back on without any problem The oil helps hold them in place whilst you reach for the cover as well Hope it doesn t rot the rubber Simon in Ireland Q How Do Replace the Carbs A With Difficulty Patience Cotton Gloves and Vaseline Putting them back can almost feel more gruesome than taking them out You think your ruining something but the rubbers are pretty hardy and with a bit of patience you ll get there suggest you use some of the lubricants Flash mentions on his removal procedure or coat the inside of the rubbers Both Airbox and Engine Side with Vaseline Reconnect the Choke Cable BEFORE you start pushing the Carbs in You can do it afterward but it s very hard
257. that the 4 Tabs are all the way down If the Venturi pin pops up when you press the Slide Carrier in you haven t lined it up properly so have a look at the pin flat side arrangement again It should stay down OK until you get the Main Jet in position Replacing the Needles Springs and Diaphragm Now s a good time to put back the Slide Diaphragm Needle Spring and Diaphragm Cap in that order See Needle Parts Install Sequence Before you start smear a little oil on the Diaphragm Seat and on the Sealing Ring of the Diaphragm where the Diaphragm Cap seals it to the Carb Body find it easier to install the Needle With E Clip and Spacer Below it on the Needle the Upper Washer IN the Slide Barrel keep the whole shebang in place with the spring and feed the lot into the Slide Carrier If the needle comes up a bit pull the Slide Barrel out a bit and try again keeping it as vertical as possible so that the Needle can drop into the Venturi Thread the Spring onto the little green Spring Guide under the Diaphragm Cap Press the Diaphragm into the Groove on the Carb Body and make sure it more or less stays in It might try to pop out but don t worry when you put the Cap on it will slip into the groove so to speak So put the Cap on and slide it around a little bit on the rubber just to make sure the rubber is down in that groove and you haven t pinched it somewhere Do up one bolt just seated then the other Then Tighten both nice and
258. the new fuel line and all body work You want to make sure that the final placement of the filter allows you to see it and keeps it away from the heat of the motor Start long and trim the hose down until it looks right Chris 782 e Also check the DIRECTION of the inline filter there should be an arrow showing the correct way of the fuel flow it should be pointed toward the carbs grin remember a thread or a FAQ that talked about inline filters etc use one of the those little Karcoma inline filters got from bing when was rebuilding the carbs for my other bike it works great am sure that there are others out there as well Nick 1085 Fuel Filter Vapor lock Q I installed an aftermarket filter on my 97F It s a glass one with replaceable element from Pep Boys 10 notice that it doesn t usually fill up with fuel Sometimes it does but more often it just has a little in the bottom and you can see it trickle in the top as the bike is running That s my first question why doesn t it fill up located under the tank as it is About 400 miles into my Saturday ride this weekend hit reserve Pulled off to go to a gas station about ten miles later Waiting at the stop light the bike dies and it won t restart push it off to the side pop the gas cap and shake the bike around to see if can hear any fuel in there do hear some sloshing then the filter starts filling up Then of course the bike started What w
259. the enrichener pulled all the way out the cold engine will idle at about 1500 RPM As the engine warms the idle speed will increase As this happens push the enrichener knob part way in like to keep the engine idling between 1200 1500 RPM as it warms up When fully warm it should idle at 900 1000 RPM with the enrichener off You can ride the bike about 30 seconds after starting the motor but like to let the engine warm up with no load until it will idle with the enrichener off or only slightly out If you start to ride with the enrichener pulled out don t forget to push it all the way in once the engine is at normal operating temperature Use of the enrichener when the motor is fully warm will cause poor fuel economy and may foul the spark plugs When you ride any Dyna Glide you will find that it requires more effort to pull in the http www chuckhawks com super_glide_sport htm 10 of 12 18 02 2007 12 30 48 HARLEY DAVIDSON SUPER GLIDE SPORT clutch lever than is typical today and the transmission has an industrial strength feel shifting with a slight clunk especially into first It does not shift as smoothly as most modern Japanese and British bikes But you will find that the transmission is very positive missed shifts are rare and there are no false neutrals The whole bike feels solid unperturbed by the vagaries of life on the road Vibration from the big V twin rumbling beneath you is quite noticeable at idle when you are
260. the mercy of the guy at the junkyard who usually has a different perspective To him if the donor bike was in good shape it must be low mileage but fortunately these carbs actually were suspect the wear problem with the plastic pieces starts to affect carburetion around the 15 20K point think not everybody notices how bad their bike has begun to run since it is a very gradual degradation and some people are not as particular about their vehicles as am Here s the arrangement with the carbs and why haven t had any luck getting the parts need Suzuki buys the carbs from Mikuni Japan and in order to get the part that wears out you have to buy the entire carb body for approximately 350 and of course you need four of them Dealer reps told me to contact Mikuni so did and it turns out that Mikuni Japan is separate from Mikuni America and Mikuni America said they couldn t help me So far Suzuki of North America Mikuni America and all the dealers have talked to have said they can t help me Their stance is that the part is available you just have to spend 1500 for four carb bodies that s all No haven t contacted Mikuni of Japan and at this point don t expect a different answer from them either Since the supply of good used carbs is finite have developed an inexpensive way to correct the worn plastic pieces by re facing it with brass and at this writing will have the first prototypes installed in a bike in about two
261. the time highly recommend a reading of the Bernoulli family biography No slackers in the brains department these people Its not the after market pipes causing the backfire you see Its the air leaks caused when the gaskets weren t replaced and other leaks sealed when they were installed Fresh air is drawn in through those tiny holes and provides sufficient oxygen to ignite the unburnt gases inside Recently removed the rear wheel from my motorcycle and had to exert pressure on the front pipe in order to extract the axle bolt Upon reassembly the backfire had returned though not to the outrageous extent as before Attempting to deny that my old problem was incurable after all tried to convince myself it was due to a heightened sensitivity on my part Yesterday received the new shock assembly had ordered and the rear wheel was removed again Upon close inspection the evidence was unmistakable Soot marks were present not At the front exhaust flange but on the 1 rear cylinder downpipe where the slot is cut for the pinch bolt Taking great care in the reassembly removed the old gaskets and sealed the slot with a paste made for the purpose and obtainable at any well stocked automobile parts store The backfire problem is cured and there is not the slightest bit of doubt in my mind that the cause was as have explained One caveat is in order here Do not waste time trying to listen for a leak in the exhaust pipe with the engine running Y
262. ther bike running am going to check the plugs and gap et all my impression is that something is wrong Don Don Rochester As soon as get to a road where can run for more than two blocks without a stoplight turn it off less than a mile Yes have to turn it on when the temperature is in the 80 s if the motor is stone cold Flash 412 CO It also only takes me a couple blocks before can turn the choke off Robert 959 in TX 97 F650 need the choke to start easily even when hot but it goes off within 1 mile and then the bike idles normally With the oil at 40 centigrade plus the choke goes on half the engine fires with no throttle and the choke goes straight off With cold oil on a normal UK day 10 15 centigrade half choke for 1 mile On a cold winter day minus 2 3 need full choke to start then half for 1 2 miles With a warm engine and choke on after the engine fires you get the trick where the engine stalls as soon as the throttle is opened am guessing that the passage in the carb is a bit on the big size and the rest of the carb setup might be critical Having the choke part on when the carb was set might give the result Don describes A plug chop test after a longish run would seem to be the order of the day to see if the choke is set to start even when the lever is http fag f650 com FAQS CarbMiscFAQ htm 7 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ set to off Andy Leeds UK 982 e
263. tings are very close to perfect from factory Comparison My R100 only has two 32mm carbs The 650 has 4mm more feeding power than the 1000cc bike A lot going through a 650 and thus the 48HP it delivers and the somewhat equal mpg to the R100 The R100 7 delivers 58 60HP as recall but with one more cylinder and very close to same carb size total The 650 breathes better with 4 valves which creates more power where the old boxer has two valves per hole Anyhow the 650 rams a lot through one cylinder with two 33 s behind the intake and imagine without water cooling high tech metallurgy etc the engine would burn up One fun bike Fast Idle Problems http faq f650 com FAQS CarbMiscFAQ htm 13 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ Bob 550 October 01 This is to share a possible fix for your pre fuel injection F if the idle suddenly or unexpectedly refuses to drop down to normal Tonight took the tank off my 99 F650 to see what was causing the throttle to hang up What found was that one of the electrical wire connectors located near the left carob had worked its way down to where it was rubbing against the throttle cable and had snagged the spring loaded linkage at the carb body moved the connector back and away from the carb and all was well until decided to check the diaphragms that control the needles in the carbs took the top off the right carb first and checked things out The rubber
264. tion Mount Cable Guide Just got back from lunch about a mile away On the way there heard a buzzing sound from the front of bike 1997 F When I stopped to look around found that the ignition and cable guide assembly was loose and missing one of the two bolts that attaches it to the under side of the triple clamp upper tightened the remaining bolt and now need to get a new bolt You might want to add this to your list of things to check occasionally Ignition Switch FAQ Noise 8 When try to start my bike there is a Tic Tic Tic sound coming from the Solenoid Large Round Object just Rear of the Battery on the Aijrfilter Cover with two big red wires coming out of it What is that See the Battery FAQ for details Read it carefully Your battery may just need water if you caught it in time but you might already have ruined it running it dry so first try and refill it with distilled water push start your bike and ride it for a good 20min 1 2 hour to recharge it If itis still dead after that your battery is probably fried On these bikes esp the Classics you need to check the battery water OFTEN The Starter solenoid clicks when it doesn t have enough power to turn the engine over OR if your Airbox fills with enough Gas or Oil that it can leak down into the cylinder and stop the engine turning over Your battery MAY also have died due to the charging system overcharging See the VR FAQ for more info Note Attempting to start y
265. tly Spakur in Sweden 1117 95F WD40 and patience should get the screws loose if you get them out undamaged would use anti seize on them mike410 lowa You also need the right size screwdriver One with too wide of a shank can get stuck in the tube leading to the screw and feel like the screw is not turning when it is really the screwdriver that is not turning had to take my small screwdriver and file its sides down before it would fit all the way into the recess without binding Richard 230 Pacifica CA e SkewDriver Forever and that may be how long need to keep it in order to get any more use out of it ordered a SkewDriver from Spectools com and it s perfect for adjusting the low speed carb jets on my 99 Classic What convinced me to buy this tool is trying to adjust these jets with a screwdriver well am kinda ham fisted Anyway the SkewDriver fit these screws perfectly and was able to back em out exactly 3 5 turns per FAQ recommendation in fact turned the left one out 3 5 and the right one just 3 turns The bike now idles perfectly and pulls much better at low rpms lt 4k and I m a happy camper Bob 550 Olympia WA am also sending a picture of my Carb Tools Last year there was talk of using a Bobby Pin to adjust the carbs Just snip it off and start adjusting It fits easily into the tool kit Also is a picture of a store bought carb tool This actually works the best of anything have used The ru
266. to the extremes possible during a carby install removal The engine rubber is pretty thick so I m not too worried yet have since filed wet n dried the sharp edges off the carby intake output openings to avoid any further wear and tear on the rubbers carOtene Here are the Part No s Intake manifold 11 61 2 343 131 I think this is the Engine side http faq f650 com FAQS CarbMiscFAQ htm 3 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ Rubber grommet 11 61 2 345 007 I think this is the Airbox side e About the small cracks You could use some RTV silicone to seal it Just put a thin layer over it and let it dry over the night About the cut As long as it is at the airbox side it shouldn t make to much difference unless it is that big so that dust can enter It is more serious for the performance and the engine if it is leaking at the engine side because that would lean out the fuel mix Spakur 1117 Icelander in Malm Sweden 1995 Classic Red F650 with 60 000 KM PUKING PETROL by Flash 412 October 01 Last night stopped and filled up 0 8 miles from home was careful not to overfill NO gas escaped into the well below the metal cap parked the bike in the garage At about 4AM my wife woke me up because she smelled gas There was a large puddle below my bike put a coffee can under the hose and mopped up the puddle Thinking to improve the situation put the bike on the centerstand When did
267. tp justkdx dirtrider net floatlevel html 2 of 4 18 02 2007 12 30 31 Float Level Adjustment Method One Measuring the Height of the Float This method requires a set of calipers With the carb upside down tilt the carb until the tang on the float just makes contact with the needle rod protruding from the float valve At this point the distance between the bottom of the float and the float bowl mating surface should be 16mm 1mm or 0 63 0 08 Remember the carb is upside down so the bottom of the float is facing you If the distance is out side of this range gently bend the tang and recheck Ideally you would reassemble the carb and recheck it with the fuel level gauge If you don t have a gauge you ll have to trust you set the height properly Measure the distance between the bottom of the float and the float bowl mating surface 1 The distance should equal 16 mm 1 mm or 63 0 08 fi lt lt Bottom of Float Method Two Setting them Parallel This method is similar to the first method It isn t quite as accurate but works fine if you don t have access to a set of calipers In method one when you measure the distance between the bottom of the float and the float bowl mating surface the two are parallel to each other If you use a straight edge for a reference a feeler gauge works well and place it on the float bowl s mating surface you can visually check to see that the two are parallel to each other
268. tra fuel when the throttle is open is not likely to cause a ring oiling problem However it might shorten the life of the spark plugs and the catalytic converter if you still have the stock muffler through fouling over a long period of time Richard 230 Pacifica CA My bike peed gasoline all over the garage floor cuz the petcock was left on and there were some tired o rings in the carbs Since then prefer to avoid the fire hazard and turn it off This isn t common But am not the only one it happened to See Pukin Petrol in the FAQ Flash 412 CO The fuel enrichment circuit of Mikuni carbs starts to work only when the cable is pulled about half way And I think that if you whack the throttle open it basically defeats the vacuum that the enrichment circuit relies upon so don t think riding with a partially open choke would result in any damage if it were open further the bike would just run poor lots of smoke and over the long term catcon damage maybe Shank NYC USA THIS is how much mpgs can drop with choke on Ok it s not a choke but fuel enrichment device wouldn t fit in the subject line Over the last 3 fills go 150 155 miles before getting fuel starvation symptoms which calculated out to 50 55 mpg at the fill ups During this last tankful left the fuel enrichment device aka choke on for about 10 miles on one trip My mileage to reserve dropped to 125 miles 1 don t know yet the gas mileage on this fill up h
269. tried adjusting and lubing the chain Didn t help but afaict it s pretty worn so it might get better if get a new one along with new sprockets haven t checked the front tire but the rear doesn t have any foreign objects stuck to it checked while lubing chain veggie_deluxe o Answer Maybe your chain has streched unevenly balam See the Chain and Sprockets FAQ More Details I m pretty sure it has I m going to replace it along with the sprockets as soon as my economy allows me to But would an unevenly stretched chain really cause such a low rate of change to the noise mean in 4th and 5th gear I m going gt 70 kph I m not going to do any mathematical calculations here that would just give me an even worse headache but I m guessing the chain would rotate quite quickly at that speed Perhaps it s a combination of unevenly worn sprockets and unevenly stretched chain o Answer agree And here s why if you assume that a 17 rim has a TIRE diameter of about 20 then multiplying by Pi gets you 62 8 which is 5 24 feet A mile is 5280 feet Let s just assume that the circumference of the tire is 5 28 feet or 1 1000 mile At 60 mph you re going one mile per minute or 1000 revolutions of the rear wheel per minute Divide by 60 to get about 17 revs per second If you have a hairlipped link getting caught ina combination of front and rear sprocket wear spots every 8 rotations that gives about a 2Hz repetition of SOMETHING Flash 412
270. tures and specifications have sung the praises of Harley s Dyna Glide line in my reviews of the Wide Glide and Convertible so will merely say that the Dynas are Harley s best performing big twins and the Super Glide Sport is the best performing of the Dynas The 2000 model tested here features a blacked out engine and exhaust system adjustable suspension triple disc brakes with four piston calipers cast wheels tubeless performance tires and a lot of black rather than chrome trim Almost all the parts are lovingly plated or painted metal there is no cheap plastic trim here The overall finish and quality of the motorcycle are extremely high it is clearly meant to be a lasting investment If the bike is maintained properly it should run at least 100 000 miles before any major engine work is required Harley Davidson has been making motorcycles longer than any other company in the world and they clearly have it down pat The Sport comes with a black ceramic coated staggered shorty dual exhaust system This system is EPA legal quiet but has a nice low pitched sound potato potato The mufflers themselves are a little larger than those on other Dyna models a little less restrictive and make a little more horsepower They are good looking mufflers although heavy Despite this virtually everyone immediately replaces them usually with slash cut Screaming Eagle SE slip ons These are lighter meaner looking make more power and have a
271. uding 96 4 Small Allen Bolts each side on Tank itself 8 Total Small on Tank 1 Small Allen Bolt each side attaching Gray Fairing piece to Tank 2 Total Small Tank Fairing 1 Large Allen Bolt each Side 2 Total Large Tank Frame Classics from 97 on 96 4 Small Allen Bolts each side on Tank itself 8 Total Small on Tank 2 Small Allen Bolt each side attaching Gray Fairing piece to Tank 4 Total Small Tank Fairing 1 Small Allen Bolt each side attaching Gray Fairing piece to Radiator Fairing 2 Total Small Gray Fairing Radiator Fairing 1 Large Allen Bolt Each Side 2 Total Large Tank Frame If the clips turn just stick your hand behind the tank fairing amp Hold them These Photos are for 970n Many Thanks to Nate for the Heads up OK That s all the Bolts Now if you LEFT the grey fairing bits below the Tank attached GENTLY disengage them from the FRONT fairing of the bike by pulling from the bottom and bending upwards Grey Side Fairing Removal Location 96 Classic Shown Do not try to lift off the Tank at this stage Note that the Skin of the Tank remains attached to the Tank i e on My Bike the Red skin on the http faq f650 com FAQS Gas_Tank_Removal Replacement htm 2 of 16 18 02 2007 12 30 23 HOW TO Remove the Tank Black Tank Do not try amp prise them apart OK now that the side units are free you can lift off the tank Do this by gently pulling the whole thin
272. uggled for a while and could not get the angle right to pop it out without the pipe removed the headers stay the muffler is removed with the cross over connector pipe NOTE You do NOT need to remove the Airbox Just pull the Carbs ed Second Have a cup of coffee am sure you just spent half an hour dicking with this and you will need your wits about you for the rest of the job Now see photos Plug the intakes with paper towel Ideally you will be able to use a Phillips keep the nuts Here is what you Screwdriver drop the float bowls bolts washers sometimes they are frozen birds from getting P in Carbs still hanging from Throttle Cable still attached there is a little room to mess with the carbs Then latch onto them with a mini Float Bowl Removal When that does vice grip and ruin for difficult screws fnot work soak them completely with your favorite see bottom of penetrating oil page for contact info on nice new stainless ones http faq f650 com FAQS Carb_Clean htm 23 of 25 18 02 2007 12 30 16 Carburettor Cleaning FAQ Note needle with lock ring and 2 Stubby one for the Diaphragm with plastic bushings Floats off note bubble wrap and Skinny screwdriver for genuine factory tool i slide spring 4th from the top Stainless Carb Screws from Factory these guys overnighted me the parts in the afternoon of one day and they Eurosport Jet Kit as sold by Factory Pro Tuning these
273. uld not do much of a job keeping gas from getting by 7 replaced the o rings with some slightly larger non metric standard ones had in an o ring assortment box which fit better than the ones took out After putting it all back together it started right up like it s supposed to full choke amp zero throttle rode around the block When got back put it on the sidestand and a few drops of gas came out one of the hoses on the opposite side from where it HAD been leaking Being an optimist put a coffee can http fag f650 com FAQS CarbMiscFAQ htm 4 of 23 18 02 2007 12 30 06 Miscellaneous Carb Questions FAQ under there turned the petcock off and left it overnight All was well this morning BTW I also installed the fuel filter while was at it There are four carb screws which replaced with Allen s They are 5M0 8 x 12 But if you try to use ones that are too long they won t go in the front holes only the rear ones See the Carb Cleaning FAQ for details and pictures of the Carbs Q What are the Symptoms My bike a 95 F came to a halt as if had run out of fuel will add that hadn t Anyway the bike came to a stop and found the pipe running from out of the top of the carb was pumping petrol out and onto the engine It will turn over with no problem but doesn t want to know about catching know this isn t a huge amount of info but until Monday when I m off can t give you any more Any ideas as too wh
274. ust Gaskets are slightly larger than the opening and very soft metal so it is http faq f650 com FAQS ExhaustGasketReplacementFAQ htm 3 of 8 18 02 2007 12 30 55 Exhaust Gasket Replacement FAQ difficult to get it in there so some persuasion with a screwdriver and hammer may be necessary and of course the radiator is in the way Getting the Gaskets in place and not mangling it can be very difficult E Gasp I m sure there is no gasket there There is Stick your finger in the port Feel for the EDGE of the gasket as your draw your finger out You might need to feel in several places 3 o clock 6 9 and 12 for instance If you go ahead and put a new Gasket in on top of your old one i e TWO gaskets in your exhaust system is more liable to leak and won t fit exactly right Besides that the nuts won t run down as far The gasket where the U pipe joins the collector is just asbestos or some sort of impregnated carbon as is the gasket where the collector joins the muffler With NO metal these can disappear gradually The gaskets where the pipes enter the heads have METAL in them They cannot disappear When first took my header pipes off thought those gaskets were missing too Keep looking F Gasp 2 think was given the wrong sized Exhaust Header Gaskets Sound Familiar Does the F650 have different size gaskets to go between the exhaust pipes and head I m thinking of certain models of BMW Airheads that had different s
275. ve no need intention to remove the beauty shell that covers the tank from the tank just remove the tank shell as a unit This assumes you re trying to get the tank out of the way to fill the radiator or something Just be sure to block up and support the removed tank so the weight of the tank isn t resting on the petcock Marty 436 Chicago 97 F650F Where s my Reserve Problem The problem is it doesn t seem like my bike has a reserve At about 180 miles classic F run out of gas Switching to reserve doesn t help What does help is leaning the bike over to get that last little bit out of the right side of the tank Could my reserve inlet be leaking into the on inlet Any help you can offer will greatly improve my marriage otherwise known as my wife is getting sick of standing around in the middle of nowhere while go off looking for some dirt bikers with extra gas 97 F650 1291 Solution Run it out of gas Lean it over to the right Remove the petcock Look at the petcock and see if there are two tubes of different lengths on it If not fish the missing tube s out of the tank and shove it them back in the hole s The LONGER tube is for the ON position The shorter or no tube is for the reserve position You can figure out which is which by blowing through the tube s Flash 412 If you are losing gas check the PUKING PETROL FAQ Feedback http faq f650 com FAQS Gas_Tank_Removal Replacement htm 15 of 16 18 02 2007
276. while trying to take the nut off If one breaks then what could have been a clean up and re lube job becomes a nightmare Alternative Gasket Sources Ring Gaskets Sleeve Gasket Ring Gaskets by Flash You might have more luck with a set of Gaskets from Aprilia The Aprilia Pegaso Gaskets will fit the Classic Sleeve Gasket by Steve F650001 was in Eastern Oklahoma when things started getting loud As neared Queen Wilhemina State Park the loud got louder and when backed off the throttle the engine backfired That may sound cool when you are 17 years old and driving your dad s vehicle but not when you are the owner who has to pay for repairs The gasket a cylindrical woven sleeve that fits on the end of the left side exhaust pipe just before it enters the Y had disappeared leaving quite a gap for exhaust gases The closer a leak of that type is to the exhaust port the greater the chances for a burned valve The connection is about 12 inches from the exhaust port At first thought it to be the ring gasket which fits inside the port and several Inmates helped by calling dealerships in their hometowns We planned to contact another Inmate who would be coming to the rally and could pick up the part and bring it to the rally Meanwhile drove to Mena looking for replacement parts Closer inspection showed that the ring gasket was not the problem it was the exhaust pipe gasket See photo raced back and forth across

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