I install a ProCycle jet kit on a DR650
Dino’s Tinker Shed, S2-Ep 4. Suzuki DR650 BST40, Procycle jet kit installation, part two
In this second of a two-part series, I will show you how to install a ProCycle Jet kit in a DR650. I will also show you how to set your float height, throttle free play and even lube the throttle cables.
As always, I have included time code chapters below for you to skip ahead or return to if you are following along.
The Suzuki DR650 is known to have been jetted extremely lean to meet emission laws and this creates not only performance issues but can lead to hard starting and even back firing at times.
The ProCycle jet kit includes an extended fuel mixture screw and stainless-steel Allen screws for the float bowl and top cap. Also included are new Viton o-rings for the float. Comes with easy-to-understand detailed instructions and diagrams. Includes a template for modifying the air box.
Benefits from this kit are, better cold starting, improved mid-range and some even claim better fuel economy, I hope these things turn out to be true. For me I really want to see better cold starting as my bike is cold blooded
Time code chapters:
00:00- Cold opening
01:42- Introduction
02:02- Overview of the project
05:03-Review of the kit
06:36- Installation of the Fuel Screw
10:04- Change float O-Rings and set float height
13:35- Install main jet
14:32-Install needle jet
17:11- Recording data
19:01-How to lube cables
22:15- Reinstall the carburetor
24:09- Setting throttle cable free play
25:46- Install choke cable and Vacuum lines
27:01- Starting the bike
29:00- Summary
MUSIC
Cantina Blues – Take the Lead by Kevin MacLeod is licensed under a Creative Commons Attribution 4.0 licence. https://creativecommons.org/licenses/by/4.0/
Source: http://incompetech.com/music/royalty-free/index.html?isrc=USUAN1100407
Artist: http://incompetech.com/
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Nice work! I just did this before the cold hit. Got 300 miles in but I didn't adjust anything yet from the install. It's an imrovement for sure.
You skipped over the needle placement part – with the D shaped spacer into the slide. I think it's key to get that in right.
Greetings! I was wondering if you have checked out the Smart Carb. Hope you can show us an install. I’m seriously considering one for my 2017 DR650. Thanks for all that you do. Subbed
Hi dino!
Thank you for the great video's.
Wanted to ask
why change the folat hight?
With the procycle kit in hand, the service manuel arrived yesterday…and now this video, I think I'm ready to start on my dr650. Thanks so much for taking the time to put this together.
Hello I m from London Ontario. I have a DR and would like this PRO CYCLE jet kit to go with my new aftermarket exhaust.I can t find who carry s this kit. Can you help? Thx Blair
Thanks Dino. Greeting from Maine. My new to me dr is benefiting from you experience.
Thanks for the instructions. I assume the EPA require a mixture so lean (likely an AFR 14.6: 1 or worse) that a stock engine misfires and has an excessive high combustion chamber temperature which could destroy the engine. I had that problem with my new yamaha Vstar 1300. I found the AFR was swing around 14.6 : 1 . The idiots required a 20 : 1 AFR at closed-almost closed throttle (I adjusted the throttle position sensor to eliminate that stupid dodo) so when riding in a parking lot my head was jerked about like the little toy figure with a spring for a neck. Yamaha Importers customer service advised me to not ride in shopping center parking lots. I thought that is sound advice. I used a resistor and diode to adjust the AFR to 14 : 1 and no more problems. Also the MPG increased from 45 mpg to 55 mpg. The problem turned out to be a defective O2 sensors on many of their lemons. To my knowledge they never fixed one of them.
My question, will backing out the factory fuel mix screw 2 turns from full closed will that stop the engine from misfiring? I wonder what the AFR is after backing the screw out two turns? I have a AFR gauge but it is a pain in the azz to install.
Why did you replace the two internal carb o rings?
I didn’t realize how many cads own these things my wife’s from Ontario and we visit often 🙂 love Canada
I lubricate cables with Teflon dry lube.
absolutely my favorite channel on YouTube
Wow, that was really well done. Thanks for sharing.
Love your channel, currently shopping for a DR and your videos are super helpful!
Thanks for putting the time into this video, it's been really great to watch!
Thank you! Fantastic. So well presented. I wish I had your calm demeanour…
big thanks for taking your time to teach us how to tinker on the DR :- 1
Hello, my carburetor is mikuni bst 33, very similar to this one, i have a problems with tuning Beta alp4.0 did not count turns on mix screw needle, and have no access to it when installed on bike, how can i preset settings on my mix screw before install carburetor on bike? There’s no accessible manual on how much turn, my bike sounds like it has lack of air, meanwhile overflow drain throws gas out, and i find gas in my airfilter.
Im concerned about gasoline in air filter, what could be the cause and next step?
I'm having a cold beer in low 30's C here …
@ 14:32 … measure for 2 pieces minimum 2-3 mm thick aluminium angle to the width of your vice … this is for soft jaw applications so as to not damage or leave jaw prints on your work as the aluminium will absorb the crush … there are "DIY soft jaw videos" to show different methods & using different materials & magnets etc etc to save me explaining …
Also follow the laws of gravity when flushing & lubing cables … & grip a rag around the entry point of spray tube & place a container under cables to catch what comes out & assess …
I have to say for someone who isn't a mechanic … you do a great job explaining & presenting with the camera work & editing … highlighting the most important factors to the less educated … there is a lot of work that go into these types of videos & arriving at the final product … cheers …
How would you solve a problem with warm weather dying if the choke or throttle isn’t kept slightly on idle?
Basically if the outdoor temps are above 70F the bike instantly dies anytime you let off the throttle. It drives awesome otherwise. I bought a 45 pilot to replace the 42 but am told the pilot doesn’t have anything to do with idle.
Another very informative, well detailed and professionally edited "How To Do" video. Great job Dino and always a bonus to see Karl.
I have an old small hair dryer I used to warm up the rubber before re-installing the carby.
Hey Dino! I installed this same kit this week (along with the Acerbis tank) and am unfortunately having some issues with starting the bike. Followed the instructions to the best of my ability.. 4th notch on needle, seated float assembly as best as I could, screw is loosened by two full turns, all of that. Since then, I have been able to get the bike to run four times with multiple failed start attempts in between. It will turn over all day but I just cant pinpoint whats missing. The last time I had it running, the air filter was removed, so it was idling away, I went to reinstall the air filter and as I replaced it, there was this strange tinging noise then the bike stalled as I seated the filter in place. Any tips? Seems to me it's lacking air but now it wont start at all with no filter in place!
Hey Dino, so I watched your video about 10 times and it really made my pro cycle carb mod install go very smoothly. I particularly noticed how you got the right side of the carb in the boot first to get it re installed..that made it very easy. A few things of note about my install. When i drilled out the cap to take out the old and install the new adjustment screw, the factory installed screw was completely bottomed out. No wonder it did not run very smoothly. I also installed a hyabusa x24 muffler which i found locally and ordered the mid pipe thru PC. I used the 150 jet and cut a circular hole on top of the air box next to the snorkel hole. I also followed one of the Australian video's suggestions to clip the spring to 100mm and add a 3mm hole to the slide to simulate a pumper carb. The end result was a decent amount of increased power, i feel like it could use some more air so i may take the side cover off to see what happens. Maybe a new filter too. The clipping of the spring and the added hole to the slide really gave it a great throttle response that is especially smoother when you let off the gas and more predictable giving it the beans. Thx for your vids…i will be re-watching your valve adjustment video next as i have just turned the first 1000 miles.
Nicely done. Heard a couple of “eh’s” there and confirmed my suspicion. Hello from Mtl!
what are you using for a top case and where did you buy it
Excellent and informative video!