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Bubba Bauer 05-25-2011 04:20 PM

DR650 owners Beware! Neutral Sending Unit screw up!
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As I was driving down the road with my missus suddenly the bike sounded like a washing machine filled up with screws and gravel brake/stop/swear...

Got home (thats another story) assessed the damage and it`s hmmm... :cry

Started tinkering what caused the carnage and realized MY NEUTRAL LIGHT was not working properly for a couple of days. A little more reading and sometimes on older DR650-s the screw of the neutral sending unit can let go and could cause massive damage!

So beware! If your light goes out or flicker don`t assume it`s just some electrical gremlin (like I did) strip the RHS clutch cover and check the bolts holding the NSU in place or rip the thing out all together.

My question is do you reckon if its a complete strip and rebuild if your clutch inner hub plate assembly is disintegrated to million little pieces?

Everything else looks intact no pitting scoring but metallic particles could be anywhere in the insides.

Bubba Bauer 05-25-2011 04:21 PM

1 Attachment(s)
some more lovely pics

Eggsontoast 05-25-2011 05:05 PM

Fuck me!
That's a real spanner in the works (no pun intended).:yikes

Now that mines apart I'm going to not only loctite but lockwire the bastard' things.

If it were me I'd strip the engine down and assess wether it's worth fixing or not, just bear in mind that all the bearing will need replacing, one of which has a locating tab to prevent it spinning around in the case; as I found out nobody produces this particular model. Suzuki billed me 60, had to bite the bullet...

If anything you could always break the engine and sell it as spares to help fund another block.

If you need help with stripping the engine I can give you a lowdown on where you can and can't cut corners.

Good luck and keep us posted!


ADV8 05-26-2011 02:46 AM

Do you have a pic of the screw that caused the damage
What of the neutral sensor itself ?

GutterTrash 05-30-2011 11:03 AM

sorry to hear about this,,

the nsu screw issue is well documented in the interwebs, and is not limited to older dr's,, post's are around of brand new bikes with finger tight screws. to include the warning sign of erratic neutral light

kimmie 12-29-2013 05:50 PM

Intermittent Neutral Light
Sorry in advance for resurrecting the dead.

The info on the forum has been a great help with the NSU unit on my DR.

As instructed by all web notifications from other DR650 owners Karl has taken out the clutch basket found the NSU and "lock tight" in the possible offending bolts. They aren't going anywhere now.

So I took her out for a spin yesterday and the neutral light is working. However as the engine gets warmer the neutral light at first decides to work intermittently and then not at all.

After about 1 hour, I stopped for about 15 mins got back on and the neutral light is working again but then starts this whole "will I work this time or not" rubbish.

I have no doubt that the NSU bolts are stuck fast but I'm now thinking that it's heat related (all the electrics have been checked and there are no issues).

Can anybody shed some light (sorry for the pun) to the issue.

Thanks heaps,

ER70S-2 12-29-2013 06:49 PM

Your neutral light is a regular bulb, make sure it's plugged in tightly.

Also check that this connector is fully plugged in. It's under the seat and immediately behind the gas tank, left side.

Thumpstart92 12-29-2013 07:36 PM

Holy Moly! That's disturbing

kimmie 12-29-2013 11:52 PM

Thanks ER70S-2.

The bulb and connector have both been checked and are in good order and all connections are sound.

ER70S-2 12-30-2013 11:42 AM

Another guess: you're in Australia so I think you use 3 wires to the NSU switch. That's a second plug we don't use here. You can see it in my NSU pic, it's the green/blue, red/black wire on the left of the frame rail and the unused white plug is on the right (under the circled plug). Is it secure too? :scratch

Karlxx 12-30-2013 03:26 PM

Hi, I am kimmie's other half. BTW the NSU is behaving exactly the same before and after loctiting the fasteners in. The NSU bolts were not coming out, but they certainly were not tight at all.

I traced the loom from the bulb back to where it enters the crankcase. All the connector contacts are clean and no amount of wiggling and bending of the wiring loom will get the bulb to go out (at least while the bike is cold).

I also cleaned the NSU contacts when I loctited the bolts in. The sensor was in good shape. The wires were sound and the "potting" was intact. So I am thinking that replacing the sensor is the next step.

So has anyone heard of the issue with NSU not working when hot?

kimmie 02-21-2014 09:53 PM

Thanks everyone for all the assistance in this thread and others throughout the forum.

Karl tried and checked everything however we couldn't get the sensor to operate as it should.

So I bought a new sensor unit....I know most of you just remove the damn thing and forget about the light but I like to have the light.

Anyway, you know works just like it's supposed to (happy me). The cost of the unit was $73 AUD from the local Stealer plus Karl's time (lucky I have a good rate on

ER70S-2 02-21-2014 10:09 PM

:thumb Thanks for the follow-up, this is the first time I've heard of the switch failing. I like having the light also. :freaky

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