2002 DS650 - Engine Noise & Probs
 

Hi All,

New to DS650's so thought I best join here and ask you guys as there are some proper knowledgeable guys here from what I can tell.....

I have today bought a 2002 DS650, in mint condition with a nice spec but have got some problems after getting it home :-(

First of all when I rode it the 1st time it was stone cold and pulled real nice, engine was quiet and all seemed well!!

Got it home and the bike is dreadfully slow, my old LTZ400 was much faster so I knew straight away that there must be a problem..... Tried warming it up before riding again and still no difference!! The bike will rev fine when in neutral and rides ok in 1st & 2nd just not particularly fast at all... Get it into 3rd and it seems to bog down a bit, slow down in 3rd to a sensible speed that should still pull nicely and the engine just cuts straight out.

So ok, I thought I've gotta get it setup.....

Run it again to show someone the symptoms and the engine is making a definite noise that doesn't sound good at all.... It;s quite a fast paced noise and definitely sounds like it could be coming from the top end, also the noise seems to be louder from the right side of the bike (as riding). It's like a gentle knocking/tapping, the noise doesn't change if the clutch is engaged and gears cycled.

The bike is fitted with a "rev box" (whatever that is) and under the tank/cowling to the left side is a black box that says "ProCon" on it, the bike has also supposedly been dynojetted and has a K&N filter.

I have lots of pics if it would help anyone?!?!

ANY advice is most greatly appreciated, any suggestions big or small welcome as I don;t have a Rotax/Bombardier specialist anywhere near me :-(

Many Thanks, Jay

2002 DS650 - Engine Noise & Probs
 

First things first. Rip that pro-comm CDI off of there and throw it away... If it is now already your problem, then it will be soon. Get your self a stocker or better yet a Big Gun CDI. On e-bay for about $150.

Second, how much did your elevation and or weather change from picking it up. It sounds like you either went really rich on the carb or really lean. Pull the plug and tell us what color it is.

Another possibility is check all the hose and clamps connections from the filter all the way to the intake between the carb and motor.

As for the clicking, it may be that the Cam Chain Tensioner went bad. But let's start there....

Brenten

2002 DS650 - Engine Noise & Probs
 

Thanks Brenten....

I wasn't aware the Pro-Comm was a bad unit but thanks for the heads up, I didn;t know what the seller meant by "rev box" but know you've said CDI I get ya :-) The elevation changed but not by much, maybe a 100ft or so?!?! One thing though about fuel, the 1st run it was cold so choke was on..... 2nd run forgot to switch choke off.... Could that be anything?? The choke was then obviously turned off when we were inspecting it looking for obvious faults. It still runs kinda like choke is on all the time, really does feel bogged down as you rev it when riding and REALLY down on power!! Possibly even a little black smoke at times, but the tiniest of tiny hints... Not plumes!! lol

I've already taken the closest plug out, it was dry and brown (kinda like a biscuit brown) coloured with just a touch of pitting.... No coking up, wetness etc etc I did notice that the spark was quite weak when I checked plug so I'm inclined to agree with your opinion on the Pro-Comm and will be looking for a new CDI straight away!!

I did read a thread somewhere about the chain tensioner, might have to check that tomorrow!!

Really gutted as I've had a few Raptors & Banshees with no problems.... Hope all goes well in the end for this little beauty as it's a real nice quad!!

Cheers, Jay

2002 DS650 - Engine Noise & Probs
 

Once we get you up and running it should be more or less problem free. What the choke tells me is that the bike is jetted really lean and needs more fuel. If it ran good with Choke on and not with the choke off she needs more fuel... sounds like you are in need of a larger main jet in the carb... Sounds like you have the stock carb, so you will want to read up on the Stock Carb Mods Summery that OMR wrote up. Many have sworn by those improvements...

2002 DS650 - Engine Noise & Probs
 

Yeah definately sounds like a must.... I've just ordered a copy of the service manual with digital delivery as well to have a browse over the usual service adjustments.

I'm quite worried about the knocking more than anything as it's obviously a mechanical/physical problem and hoping it's not a full strip & rebuild :-S

I could handle cam tensioner or even valve clearances but if I've got to take the motor out and have it overhauled I'll be pulling my hair out!! lol

The "bulletproof"ness of the Rotax engine is kinda why I fancied the DS650 in the 1st place, I'm not one to judge a book by it's cover so will see how this pans out before I pass final judgement!!

2002 DS650 - Engine Noise & Probs
 

I sent you a PM with my number. Give me a call later and maybe you can describe it a little better...

2002 DS650 - Engine Noise & Probs
 

Thanks.... Where in the world are you?? You say later... It's midnight here!! ;-)

2002 DS650 - Engine Noise & Probs
 

My bad, [img]i/expressions/face-icon-small-smile.gif[/img] I am one of those stupid American's that does not think beyond his own back yard LOL

2002 DS650 - Engine Noise & Probs
 

Hey I'm rather fond of america :-P

And my girlfriend is Canadian :-S (Please don't hate the player!!)


Will call you when timing is right, thanks again Brenten!!

Cheers, Jay

2002 DS650 - Engine Noise & Probs
 

May also want to check the air/fuel mixture screw and the overflow hose that so many others have had issue with. Simple stuff that creates grey hairs. ProComm has to go like Brent said. And for the price of admission the OMR mods are unbeatable.
Welcome to the forums, and we'll have you up and running in a jiffy.