Author Topic: DL650 K5 Engine Change  (Read 1419 times)

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Offline Roadrocket

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DL650 K5 Engine Change
« on: July 16, 2020, 08:06:40 »
Last year I bought a K5 DL650 from a friends brother, an avid Strom owner that took this very bike on a 10000 mile trip to Timbuktu with a group led by Nick Saunders. The Wee Strom had been laid up for SORN for over 4 years and was a well maintained bike before being laid up with 46K of foreign adventures but now a none runner. With the sale, came a nearly new K6 DL650 engine with very little mileage. I purchased the Wee as a general commuter and runabout after recently selling my Enfield Himalayan, a great bike in its own right, but not for the long haul daily 50 mile commutes I'd be doing. (Incidentally, I'll be seeking another Himalayan in the future). The first issue on the DL650, was the state of the fuel tank. It was like a forest growing in the tank, the fuel pump was u/s for sure. With the fuel pump replaced, new battery, some light electrical work a service on the original engine and the DL was a runner. It passed the MOT with no advisories and it rode very well. After a few months use, I noticed quite a high oil consumption and plenty of piston slap when the engine was cold. The DL rode very well and was nice a loose, but after a mate said he could smell the oil when he was behind, then the planning for that spare engine swap commenced. When the covid lockdown kicked in March, then the timing was perfect to start the swap. Over the next week, I will put together a photo commentary on the job in hand and find out the cause of the engines oil consumption.

Photos
The DL650 during its 10000 mile trip to Timbuktu with its original owner from new, Steve M. The DL650 never missed a beat and performed very well. The cleaner picture was taken in March 2019 after passing the MOT and following the light overhaul to get it back on the road. Hard to believe it is the same bike.

Offline kwackboy

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Re: DL650 K5 Engine Change
« Reply #1 on: July 16, 2020, 17:43:43 »
Looks in great shape considering its history.

The engine swap shouldn't be a headache, I wish you luck ..  :thumb:
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Offline Pete O Tube

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Re: DL650 K5 Engine Change
« Reply #2 on: July 16, 2020, 19:26:10 »
Road rocket - my neighbour's Himalayan is for sale, if you're interested.

Offline Fat Rat

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Re: DL650 K5 Engine Change
« Reply #3 on: July 16, 2020, 21:06:28 »
I have a low mileage DL1000 engine for sale  :smirk:
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Offline Rusty Nuts

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Re: DL650 K5 Engine Change
« Reply #4 on: July 16, 2020, 21:14:55 »
There's a Cat B 650 with free luggage floating around somewhere... :whistle:

Offline UK_Vstrom650

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Re: DL650 K5 Engine Change
« Reply #5 on: July 16, 2020, 21:20:31 »
Oooh, a 650 with a 1000cc engine...  :auto-dirtbike:
(You'd not want the 650s brakes with that though!)

Offline kwackboy

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Re: DL650 K5 Engine Change
« Reply #6 on: July 16, 2020, 21:25:08 »
As far as I know the brakes are the same
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Offline UK_Vstrom650

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Re: DL650 K5 Engine Change
« Reply #7 on: July 16, 2020, 21:46:59 »
Ah, in that case...

Do it! Do it! Do it!  :happydance:

Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #8 on: July 17, 2020, 06:59:40 »
Road rocket - my neighbour's Himalayan is for sale, if you're interested.
Agghhh don't have the cash spare at the moment thanks though for the shout

Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #9 on: July 17, 2020, 07:02:46 »
I have a K6 650 low mileage engine that came as a spare. I've actually done the swap already. I thought I'd share the experience for anyone considering it.

Offline Mr Nick

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Re: DL650 K5 Engine Change
« Reply #10 on: July 17, 2020, 11:59:22 »
From my recollection of the SV project I did, apart from the physical engine manhandling (other genders are available), these are fairly straightforward engines to swap over. I'm interested to see if the addition of FI made it any more of a job than I recall than just more wiring just in case I pick up a DL project some day.
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Offline Gert

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Re: DL650 K5 Engine Change
« Reply #11 on: July 17, 2020, 18:19:18 »
At what mileage did the K5 motor give up the ghost? Are you thinking of rebuilding the engine again or will it be too expensive?

Offline Gassoon

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Re: DL650 K5 Engine Change
« Reply #12 on: July 17, 2020, 21:46:25 »
 :thumb:  sounds v interesting, Roadrocket!  Think I recognise that bike of Steve M's - isn't there a pic of it laid oot in the desert, with Steve posing triumphantly, one foot on it, like he's just shot it? lol
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Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #13 on: July 27, 2020, 21:48:53 »
Yes this is Steve M's machine and I know the photo you mean!

Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #14 on: July 27, 2020, 21:54:52 »
At what mileage did the K5 motor give up the ghost? Are you thinking of rebuilding the engine again or will it be too expensive?
The original engine runs fine to be honest. Its got 50K miles under its belt and runs very well. The main reason for the swap was oil consumption and by the sounds of it, piston slap after cold starting. It was using quite a bit of oil and my mates behind could smell it! So having the spare engine under the bench in the garage and during lockdown, I thought what the hell. Nothing to lose. Had I have not had the spare engine, I would probably have just ran it on thicker oil. But with the new motor installed, it feels re-born to ride.

Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #15 on: July 27, 2020, 22:05:06 »
Well received the V5C throught the post with the new engine number replacing the old. The bike is running very well and I think the donor engine has less then 9k miles on it from new. No oil consumption and attaining 65mpg . Maybe even less. The cause for the piston wear was sand. During its trip across the Sahara, it was dropped many times and I am still finding sand everywhere on the bike. Even in the wiring looms, stuck on the inside of the electrical tape. When I removed the air box from the throttle bodies, I noticed the intake snorkles of the airbox post air filter, were actually gold in colour. It was very very fine sand that had become past the filter. Given the colour of the intake snorkels, there must have been quite a lot very fine sand breaching the filter. The bike did 10000 miles in 26 days. Despite the airbox and filter checked before the adventure and even Vaseline added to the airbox seal, the sheer fineness of the sand got past the paper filter. If a K&N air filter had been fitted then the engine wear would be much worse. So I think if the plan is to ride in very dusty conditions, then take a spare air filter and change the oil and filters every 5k miles or earlier in extreme conditions. The only problem I had after replacing the engine, was forgetting to plug in the damn electric fan...the engine nearly cooked itself in the traffic...But so far so good!

Offline Gert

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Re: DL650 K5 Engine Change
« Reply #16 on: July 28, 2020, 07:27:28 »
Thanks for your update. Really didn't expect that much sand to get through the air filter, to do  damage to the motor. Something to consider when riding in sandy conditions then.

Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #17 on: July 28, 2020, 07:42:18 »
Quote removed

I've attached a photo of the airbox snorkel that fits onto the throttle boddies. You can clearly see very fine sand has built up on the inside. Clearly, passing the filtration and into the engines upper cylinders.

Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #18 on: July 28, 2020, 07:48:14 »
A few photos from the swap. The donor engine is incredibly clean and I suspect judging by the lack of oil that has not built up around the chains front sprocket area, has a very low mileage. Note the colour of the engines oil in the donor engine, that has been laid up for many years. It's a gamble whether this will be OK..

Offline Roadrocket

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Re: DL650 K5 Engine Change
« Reply #19 on: July 28, 2020, 07:55:50 »
Video of the first start. A nervous, moment. As this engine may not have run for at least 12 years