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Discussion Starter #1
I have just returned from a trip. On the road my 2006 DL650 started to lose power at about 5500 rpm, but only with a load on it. In neutral is was fine. On the highway I could barely keep up with traffic. I took it to a shop where they figured it was a problem with fuel delivery. So they cleaned the fuel filter and installed a new air filter. They checked compression which was fine, and electrical connection from the throttle which was also fine. At that point they were stumped.
I took it to another shop the next day. They also believed it was a fuel delivery issue. They replaced spark plugs just to be sure. And they said the old plugs indicated that the fuel was running lean. They drained the fuel tank in case it was some bad fuel. The mechanic concluded it was a vacuum problem because, he said, without the air box in, it ran great. He decided the problem was with the plenum boots (under the air box). The rubber was hardened and cracked at the ends. So he cut off the cracked hose ends, and on the bigger one, he tightened the bolts. It seemed to run a bit better, but it still struggles to make much more than highway speeds.
Lastly, let me mention that I can now hear a high-pitched whine periodically, like the sound of a slipping belt on a car (although not that loud; it's just enough to notice).
Any suggestions?
 

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High pressure filter is likely toast, but they should've done a fuel flow test if they knew what they were doing. Chance the fuel pump is tits up too, but I would do a fuel filter bypass first and foremost if the fuel flow test fails or is even close to failing.
 

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My recent purchase, a 2009 DL650, did exactly this. Tuned out it had been sitting for some time with ethanol fuel in it and the pickup filter etc was blocked with garbage. After cleaning everything out with carby/throttle body cleaner and filling with fresh fuel it's working properly again and getting better every time I take it out.
 

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This may seem like a weird suggestion, but how is your battery and charging system? Fuel pumps can operate poorly if system voltage voltage is marginal.

Vinnie

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Discussion Starter #5
I should add that when I say the compression was fine, it measured 43 psi, which is the correct pressure.
 

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Pressure doesn't mean it has enough flow. Check the flow.
 

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High pressure filter is likely toast, but they should've done a fuel flow test if they knew what they were doing. Chance the fuel pump is tits up too, but I would do a fuel filter bypass first and foremost if the fuel flow test fails or is even close to failing.

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
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Discussion Starter #10
My manual says I should get a fuel flow of 168ml in 10 sec.
I ran a test and got a measly 70ml!
My next step will be to follow Big B's advice and do a fuel filter bypass. I have seen the how-to on another forum.
I'll let you know how it goes.
 

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Well, despite my lack of mechanical training, I followed the steps on another forum to do an external fuel filter bypass as suggested by several of you. It was not a difficult job, once I got my head around it. I took the bike for a test ride, and not only was the original problem gone, but the bike ran stronger and faster than I ever remember. It's fantastic. Total Cost: $22.13. I am thrilled. Thanks to all of you who chimed in with advice and links!
 

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Well, despite my lack of mechanical training, I followed the steps on anot"her forum to do an external fuel filter bypass as suggested by several of you. It was not a difficult job, once I got my head around it. I took the bike for a test ride, and not only was the original problem gone, but the bike ran stronger and faster than I ever remember. It's fantastic. Total Cost: $22.13. I am thrilled. Thanks to all of you who chimed in with advice and links!
Any chance of a link?
I’ve got a 2016 dl650 with nasty ethanol/rust issue. I repaired the inside of the tank, replaced the fuel pump and sock but still not quite there on the upper RPMs. Pretty sure the HP filter is toast as well.
 

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If you have the means and remember to, would you mind taking a few pix, and then post them here for all to follow? Perhaps you could include any tips / challenges while undertaking the fuel pump bypass, so that may be of help to someone else in the future? Good luck with your project.
 
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