Ds650 baja starting problem

[Shane Stump]

Ok guys needs some help asap ready to set this thing on fire..thing would never start valves were tight i adjusted the calves to correct shims on intake n exhaust have plenty of clearance in between cam lobes n shims..problem is i done set tdc about 10 times now its dead on..will not fire one hiccup sprayed gas into carb while cranking n while not all it does is make a loud backfire n some flames come out. Its like valves are tight but  there not.idk how it could be firing wrong with it at tdc. I need help asap

[Ajmboy]

It sounds like the timing is off.

[Frank Angerano]

It’s most likely 180 deg out of time. It’s very easy to make this mistake. 

There are also a few different marks on the flywheel. Make sure that you have the correct mark and make suite it’s on the compression stroke when aligning with the cam. 

Aside from the few things listed above the only other things I can think of is the timing chain is jumping off of the sprockets ? Or the pick up coil is loose delivering the spark at the wrong time.  

 

[Shane Stump]

Yea figured it was out of timing as well but set it tdc then aligned cam marks parell to head cams facing away from each other.. There is only one mark on flywheel. Other marks are lil punch marks about 4 or 5 of them around flywheel..tensioner is working properly so its not jumping teeth..sounds like it sparking at wrong combustion..how would i check to see if its not 180 out?

[Shane Stump]

How would i know if its on compression stroke? 

[Frank Angerano]

So let’s back up for one second and recap.

Did you pull the head off of so why?

Did the bike run while you own it?

reason I’m asking is in my experience I’ve missed things during a rebuild back in the day and had to go back to see where I failed.  

You are missing something. I looked at the manual and can see that there is only one timing mark that’s labeled “c” ? 

The  lobes state they should be facing downward and there is a small hole on tye cam sprocket that should be on top ? 

I would go back double check that. If all looks right then I would look at tye triggger cool maybe it’s loose ? 

Can you post a few pics of the timing marks you see on tye engine as well as the top end cam and sprocket ? 

[Shane Stump]

Yes i pulled head off to instalm new shims.no guy said all he did was changed starter clutch n it would never fire for him after that so i reset timing n still nothing. Cams dowward as in tapered part touching valve buckets? If thats the case then yea there off. I have them at 45° facing away from each other as cam sprokets marks are parallel to face of head. 

[Shane Stump]

Yes i will get pics when i get home from work

[Frank Angerano]

Cam lobes facing down, sprocket marks parallel to the head cover and the sprocket should have a small hole on the top side about 1 o’clock ish. 

[Shane Stump]

This is what i have at tdc.

 

[Frank Angerano]

It looks good. Check this out maybe it will help. 

 

[Frank Angerano]

It’s shows the TDC and how it’s done. 

[Shane Stump]

I dont get what he was doing when he said he reaches his hand around on clutch side n rotates it.? Does the pick up coil have to be aligned up with that rasied edge on the flywheel. Cus the way i have it at tdc pick up coil isnt in center with it.

[Shane Stump]

N there is no c mark on flywheel just the one dash mark?

[Shane Stump]

Still no luck.had put in new shims for ex and intake clearance is .5 on intake .6 on exhaust still doesnt even pop or make sound till i spray gas in intake boot. Valves are not bent either.. Any other ideas?? Im going nuts here 

[Shane Stump]

Also when at tdc everything lines up on top end except for flywheel mark doesnt line up on case mark.pickup coil instead lined up with raised edge on flywheel either idk if that's normal or not.?

[Shane Stump]

Still no luck.had put in new shims for ex and intake clearance is .5 on intake .6 on exhaust still doesnt even pop or make sound till i spray gas in intake boot. Valves are not bent either.. Any other ideas?? Im going nuts here 

[Shane Stump]

Also when at tdc everything lines up on top end except for flywheel mark doesnt line up on case mark.pickup coil instead lined up with raised edge on flywheel either idk if that's normal or not.?

[Ajmboy]

@Shane Stump  I merged your new topic with this one since it seemed like a continuation. 😉

[Shane Stump]

Thanks

[Eddies 680ds]

On 6/24/2018 at 2:36 PM, Shane Stump said:

Ok guys needs some help asap ready to set this thing on fire..thing would never start valves were tight i adjusted the calves to correct shims on intake n exhaust have plenty of clearance in between cam lobes n shims..problem is i done set tdc about 10 times now its dead on..will not fire one hiccup sprayed gas into carb while cranking n while not all it does is make a loud backfire n some flames come out. Its like valves are tight but  there not.idk how it could be firing wrong with it at tdc. I need help asap

 

[Eddies 680ds]

Yeah I’ve got an 07 board out 30 over and when I go to start mine at either spins without catching the flat will or when it does catch I hear almost like a grinding sound like my clutch has blown apart or something and interested to read more about this

[Eddies 680ds]

Yeah I’ve got an 07 board out 30 over and when I go to start mine at either spins without catching the flat will or when it does catch I hear almost like a grinding sound like my clutch has blown apart or something and interested to read more about this

[Eddies 680ds]

Yeah I’ve got an 07 board out 30 over and when I go to start mine at either spins without catching the flat will or when it does catch I hear almost like a grinding sound like my clutch has blown apart or something and interested to read more about this I’m new to the four stroke game but Damn sure impressed by the amount of torque and just raw power this thing has. First time I test drove it I actually scared myself which gave me a healthy dose of respect for it.

[Eddies 680ds]

On 6/24/2018 at 2:36 PM, Shane Stump said:

Ok guys needs some help asap ready to set this thing on fire..thing would never start valves were tight i adjusted the calves to correct shims on intake n exhaust have plenty of clearance in between cam lobes n shims..problem is i done set tdc about 10 times now its dead on..will not fire one hiccup sprayed gas into carb while cranking n while not all it does is make a loud backfire n some flames come out. Its like valves are tight but  there not.idk how it could be firing wrong with it at tdc. I need help asap

My 2007 ds650 has a similar starting problem, but not as extensive. I can push start Mine anytime and it will start but when I go to use the starter it just spins and sometimes makes a grinding sound not sure what exact parts I need.

[Eddies 680ds]

I hope I can download this repair manual if not does anyone know of a good reliable site to download the pdf? I’m going to post step by step with photos of my starting problem fix.

[Eddies 680ds]

On 10/11/2018 at 3:20 PM, Eddies 680ds said:

My 2007 ds650 has a similar starting problem, but not as extensive. I can push start Mine anytime and it will start but when I go to use the starter it just spins and sometimes makes a grinding sound not sure what exact parts I need.

You need a sprag clutch but before you order pull your side cover off. Take off the single big nut and washer....THEN your gonna have to order a flywheel puller( not expensive) ok after magneto pops off on the inside is where your problem  is. Should be eight smaller bolts holding a gear to the mag, four of which hold a sprag cradle/housing. Mine was all chewed up and barings were all over the place/ . Now behind the mag and gear you have large starter gear/flywheel. You wanna check the outcroped landing inwhich the sprag rose on. It can’t have any livers or to many dings or problem will repeat itself if not worse. You can find a sprag for as little as twenty or the flywheel and sprag for like  a hundred. Make sure you follow tork specs and use lock tight when putting things back together.

 

On 10/11/2018 at 3:20 PM, Eddies 680ds said:

My 2007 ds650 has a similar starting problem, but not as extensive. I can push start Mine anytime and it will start but when I go to use the starter it just spins and sometimes makes a grinding sound not sure what exact parts I need.