Dune buggy rebuild

[Daren Todd]

Well......... it runs!!!! But there is a but starts and idles good. But as soon as you get on it, it stalls out and dies It's got a vacuum actuated fuel valve on the bottom of the fuel tank. Got a sneaking suspicion that the diaphragm has a Crack in it and it's not allowing the fuel valve to open all the way.



Toying with the idea of draining the gas tank, removing the fuel delivery valve and putting a good ol' fashioned fuel shut off valve in there and let it gravity feed to the float And while I'm in there, I'll pull the bloody screen out of the pick up tube in the bottom of the fuel tank.

 

[Daren Todd]

Got her done sort of The reverser that I purchased off ebay said standard forward reverse. Well..... it's forward, neutral, reverse so with the handle I ordered for it, it only has forward and nuetral. Not enough throw on the handle to catch reverse. The running issue ended up being the air filter figures, stupid and simple. So, the air filter for the time being till I can figure out something else is a piece of panty hose and some electrical tape probably gonna pick up some thin foam like on the little honda motors and come up with a more permanent solution.


Here's a video of me running it down the road. County just seal coated it, so I just kept it straight and didnn't try anything crazy. Other issue is I threw the chain a couple times trying to get crazy in the back yard. Not sure if I need to tighten the chain or loosen it slightly


Here'so the video


https://youtu.be/lq0LJUU2nio

 

[ShaunBlake]

... The running issue ended up being the air filter ...

... Other issue is I threw the chain a couple times trying to get crazy in the back yard. Not sure if I need to tighten the chain or loosen it slightly


https://youtu.be/lq0LJUU2nio

So did you discover the air filter problem before you pulled the fuel check valve and hacked out the screen?

Did the original run without a chain tensioner? (And is the chain length about the same?) I'm having trouble seeing how the chain could get thrown if the motor mounts are correct for off-road vehicles.

 

[Daren Todd]

Discovered the air filter issue after I redid the pepcock on the fuel tank.

When I tried to blow it around in the back yard to do a donut, it would toss the chain. I'm thinking the frame is shifting slightly when it catches on a bump. Back has an independent suspension. Gonna have to get one of my son's over here and have them try to mimic the issue while I watch There isn't a chain tensioner. Chain tension is adjusted with a bolt on the back. To get any more tension, Ill have to cut off a motor mount on the engine. I'm wondering if the axle is tweaking slightly or it could be a lateral roll.

I'll see the guy I bought it from tomorrow. Will ask how he corrected that issue. Chain was sloppy loose when I bought it though.

Wet grass and bald tires are gonna be fun

 

[Russell King]

There are some chain tensioner that are basically a hoop of plastic that runs between the chains and sprockets


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[sawmill]

Daren, those grandkids are gonna love it. Better have plenty of gas on hand.
Gotta get some pics when they first see it.

 

[D2Cat]

Daren, that's nice! I just gotta rag on your camera tech. She has to move faster to keep up with you!!!

 

[Daren Todd]

Daren, that's nice! I just gotta rag on your camera tech. She has to move faster to keep up with you!!!

I think she was expecting me to slam on the brakes and whip it back into the driveway.


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[ShaunBlake]

Daren, that's nice! I just gotta rag on your camera tech. She has to move faster to keep up with you!!!

I think she was expecting me to slam on the brakes and whip it back into the driveway.

Actors! They can never follow directions, always trying to ad-lib and ruining the take! sheesh! Somebody call Casting and get another face out here!

 

[CaveCreekRay]

Daren,

Could it be the chain tension issue is worn sprockets and a worn chain? Might be simpler to replace them and then load it up with chain wax.

That stuff is amazing. I have 7000 mi on a 650 dual sport bike and I still haven't had the need to adjust the chain.

Or, if you can, drop a link.

Just a thought. Sure hauls boo-tay.

 

[Daren Todd]

Actors! They can never follow directions, always trying to ad-lib and ruining the take! sheesh! Somebody call Casting and get another face out here!

Can't find good help these days

 

[Daren Todd]

Daren,

Could it be the chain tension issue is worn sprockets and a worn chain? Might be simpler to replace them and then load it up with chain wax.

That stuff is amazing. I have 7000 mi on a 650 dual sport bike and I still haven't had the need to adjust the chain.

Or, if you can, drop a link.

Just a thought. Sure hauls boo-tay.

I'm probably gonna see about dropping a link. Drive sprocket from engine is brand new. You can run it all day long with out throwing the chain. Issue showed up when I blew it around in the back yard trying get to get it to do a donut. Back yard has some rough spots. When it started to come loose I hit a spot where the dogs dug and it hopped the back end. At the same time it popped the chain off. Seems to be a common occurrence when putting some torque on the side and it hops. Wondering if it's and axle flex or shift. Gonna have to get my son over and run it while I watch to see what it will do.

Chain tightens some when the back suspension compresses. The motor pivots some the way it mounts. So air born the chain loosens. Haven't had a chance to check and see if they make a direct bolt on belt tensioner for that motor.

 

[Corney]

Daren,

Could it be the chain tension issue is worn sprockets and a worn chain? Might be simpler to replace them and then load it up with chain wax.

That stuff is amazing. I have 7000 mi on a 650 dual sport bike and I still haven't had the need to adjust the chain.

Or, if you can, drop a link.

Just a thought. Sure hauls boo-tay.

What make of 650 dual sport, KLR?

The tractor of motorcycles?

I use chain wax and adjust my chain regularly. I have 15,000 miles on my KLR now and the sprockets are pointy and I am assuming the chain might be worn? $60.00 I am replacing the chain because who knows where we will end up?

 

[Corney]

Daren you are way younger than I thought!

You can't be my Grampa cause I'm greyer and balder than you!

Fix it because I know those grandkids will push it to the max!

How do I know that?

Go big or go home!

 

[skeets]

I have never looked at one of these beasts closely but might there be a way of using a spring loaded chain tensioner on it? It wouldnt take to much pressure to keep it fairly tight HD uses a tensioner on their cam chains so i guess it would work

 

[Daren Todd]

I looked at it last night, and looked on line to see what was out there. They have a spring loaded one similar to a belt tensioner on a car. Only issue I saw, was where to bolt it. No bolt holes near where you would mount it, tensioner it self looked like it had a skate board tire for a roller.

 

[Daren Todd]

Talked to the parts place for the kart. They said the chain adjustment is off the back bolt for the motor mount. And said that it probably needs to be snugged up slightly. Said that's usually why it throws it when you get crazy So, I have a splice link for the chain coming so I can remove a couple links and get some wiggle room. Haven't decided about the reverser yet. Whether I'm gonna replace the handle to get reverse, or afro engineer the handle to be able to get reverse.

 

[CaveCreekRay]

Corney,

1997 Suzuki DR650. Bought it new. Also picked up a sweet 2000 DR 200 from a neighbor who bought it new for his wife. That didn't go so well. I saved his marriage and he gave me a great price.

The KLR is a beast. The guy in town that rides the camo KLR gets about 90k on the clock and then buys a new one and transfers the old plastic to the new machine. He'd laugh at my DR 650 because it looks brand new after 18 years.

 

[mwjoerin]

Just found this thead, I have virtually the same cart with a dead engine. Been thinking about digging into the valves and rings, but an inexpensive engine may be the better solution. Looks like you mail ordered yours, what was your source?

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[Daren Todd]

Just found this thead, I have virtually the same cart with a dead engine. Been thinking about digging into the valves and rings, but an inexpensive engine may be the better solution. Looks like you mail ordered yours, what was your source?

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Ebay, here's the link. Was around $312 including shipping. There's a short case and long case for the motor. So make sure and check the bottom of the page for each seller for measurements to make sure it's the correct motor.

http://www.ebay.com/sch/i.html?_fro...A0.H0.Xgy6+motor.TRS0&_nkw=gy6+motor&_sacat=0