Well been lurking arond for a week reading some.

We have a 00 DS650 and a 03 Ds650 Baja. Father in law was gonna buy the 00 last weekend and before we went to get it a mutual friend came through and paid him some money he owed and he wound up buying the Baja also. I took him to get both and as we were leaving from picking up the yellow he tossed me the key and said happy belated birthday.

Father in law lives with us so they are kinda both ours anyway. I do all the work on whatever toys we have at the time. We both just came off cruisers. Decided to hit the dirt instead. Atleast this way if we get hurt it' our own fault and not some idiot driver talkin on the cell and running us down at a street light.

I guess I'll start off with a carb question on Frankie (00 Ds650) has a cracked fender and was patched with a metal plate and screws.

The fuel must be shut off when it's not running or the vent line at the bottom of the carb will drain the fuel tank. Any ideas here? I worked on a lot of stuff but never messed wth carbs and I hate dealer pricing so I'd like to fix problem my self. Already got a 00-07 CD based shop manual coming. Are the carbs a bit** to work on? I've never had a carb apart. I can pull an upper intake off a car and put it back on with no problems thats about as far as I have been into a motor. Replace accessories, headers, distributors, radiators, and I can wire up radios, amps, ect.

Fog lights on Baja
Question about opration of fog lights on Baja and how they work. Should they com on when just the low beam is on or should they be on all the time no matter? I see a relay there on the left side light housing (if seated) and a fuse link which only has 1 wire running to it on the right side. If I knew how they worked it would be easier to figure it out. Are they suppose to be on all the time I can pull relay figure out which wire is hot and which one is ground and jumper to figure out right and left and just wire in a new relay. Didn't under stand the fuse on the right side which only has 1 wire running to it.

Thanks for any help!

These machines are wicked.

Oh the guy that came through with money for myfather in law has a 00 Ds650 too so we are planning a trip to little Sahara in like 6 months or so.

 

Not sure on the fog lights but the carb overflowing is an easy fix with the experience you have.

They arent a b*itch to work on - remove the bowl & inspect the needle & seat that the floats ride on - remove the piece of trash keeping the needle from closing off the fuel & reassemble.

 

If it isn't something holding the float open, then it would simply be the float level is too high. Use Forcefed's fix first (Sometimes it is just that simple).

If that doesn't cure it, the floats have a bendable tang. It is possible that someone in the past bent it out of spec and it is not closing off the fuel inlet.

When you get your manual, there will be a measurement for the carburetor float level. Most often, it is measured from the mating surface of the carb (Where the float bowl contacts it) to the lowest part of the float when the float tang is just touching the fuel inlet needle (With the needle seated). It will make much more sense when you look at the parts.

 

Thanks for the info! I have a carb from an 03 coming I purchased it late Monday. I am going to put it on and will jack with the other carb and see what I can make of it. My buddies also got a 00' ds650 and his is leaking from somewhere else. So If i can get this one on mine fixed he can use it while he gets his rebuilt.

The 03 carb should make starting easier. I was reading that 01+ models have a larger starting jet 45 vs 37.5.

I pulled the plug off the fog light relay and jumperd the 2 red wires and the lights came on. Will see about ordering a new relay. If that don't work I am just gonna wire up a toggle and put it on the dash.

I am thinking about trying to copy the fog light brackets off the Baja using some thin sheet metal and instead of slash cut opening just drilling a bunch of holes in it to make it looke like a drilled compensator/suppressor on a pistol/machine gun.

The buddy with the other ds has hid fog lights and head light kits so might do that as well.

Lots of ideas.

 

My free atv has turned into a headache.

Put the 03' carb on it today and hooked a battery upto it and cranked till there was no juice left. Then hooked up a second battery and cranked till it had no juice left. Shooting starter fluid through the intake tube and pulled tube off and shot it diectly into carb. Never got it to run more than a second or 2 and that happened a whopping 3 or 4 times.

Then pulled replacement carb apart and found the rubber diaphram at the top had a small hole in it and wound up using the 03' carb, 01' diaphram, a mixture of bolts, and the bowl gasket from the 01' carb. After messing with everything the 03' carbstarted leaking just like the 01' carb did. It's leaking out the bowl drain. Doesn't matter how tight the screw is its still leaking. Thats what was leaking before. Made sure i had the right bowl from the 03' and evn swapped the bowl and they both leak. I think my combination is working as now you can see spray coming from the carb but the damn bowl drain is leaking.

I am waiting for batteries to recharge before trying again.

So I guess I need to figure out a way to plug the bowl drain!

I think I paid to much for carb considering the condition. Gonna e-mail him and bitch a little and see about getting some of my money back. $140 is alot considering I had some trouble with it (idle control was broke off, hole in rubber diaphram). Supposidly it came off a running 03' model.

 

DO NOT PLUG THE DRAIN!!!!!!!!! That will cause the overflowing fuel to go into your cylinder instead! Adjust the floats!

Also, it has been my experience that the Ds does not start well with even a partially discharged battery - especially with an aftermarket CDI Box.

Pull both spark plugs and clean them and check the gap, then re-install and reconnect them. If your engine isn't starting on starting fluid, then you may be having spark issues.

 

Ds has a procomp cdi.

I don't understand about the whole drain deal. I am thinking the set screw is not sealing therefore its draining the tank. So if the floats are allowing the fuel to continue to pour in then there is some kind of pressure release that opens the drain up?

 

It is not a pressure release, but is simply an open vertical pipe. When the level of fuel rises too high, it goes out the overflow instead of pouring gas into the engine.

If the floats are adjusted properly and the float needle (aka inlet needle) is functioning, they will close off the fuel supply before it reaches the level of that overflow pipe. As the level goes down from the fuel being metered by the carburetor and used by the engine, the float drops down and pulls the float/inlet needle down, once again allowing fuel into the float bowl from the gas tank.

The level of fuel in the float bowl of a carburetor has a significant effect on performance. If it is too low, the engine starves for fuel and runs lean. If the level is too high, the mixture runs too rich and can flood the system - prohibiting starting (I assume that this is the problem that you are having). The float level needs to be within 1mm or so of its specified measurement to operate properly. Even that 1mm can make a difference in performance.

 

Here is a snippet that applies to you from a very respected member of these forums: OMR.

Step 6 - DS Float Maintenance and Pilot Cleaning

1- If you have inconsistent main jet setting, float height adjustment may be the problem. If you find your jetting always rich, that is, after a trail ride the plug looks gas soaked, and black is the color on end of plug and porcelain is dark brown; adjustment to the float is required.
I feel that the factory spec is a little on the rich side. The spec is 10mm(.394).
Trying to bend the tab and hit this dimension is like hitting a moving target.
I have found more consistent results using this procedure:
With float bowl cover removed, turn carb upside down.
Note that the floats are formed with a crowned end surface. How can you take a measurement off a surface that is not flat - You can?t.
But there is a edge just below this crown that is straight.
I take a first measurement to this edge, at the pinned end. Write down reading
I take a second reading to this edge, at the unpinned end. Write down reading.
Subtract second reading from first reading.
My Spec: 0 to 5/64(.080) That is - The second reading should be equal to first reading or lower to as much as 5/64(.08). Mean reading of .040 or 1 mm.
I have used this spec for 3 years and have not had inconsistent readings or plugs fouling out.
If you are doing power testing runs and find that top end is inconsistent. That is, sometimes strong and sometimes flat. Float height is the issue.

2- Pilot Cleaning
If your motor starts hard or not at all. Pilot circuit is dirty or clogged.
Remove pilot screw, be careful not to loose small spring and washer.
With a air compressor, that has a rubber tipped nozzle, blow air into the
orifice that the pilot screw was removed from. Spray alittle carb cleaner
into orifice and blowout again. Gas has a tendency to dry-up and leave deposits
around the pilot air/fuel passage. Try to clean twice a year or when having starting problems.

 

Thanks! Will get into the manual and see if I can figure this out.