ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 11-11-2010, 06:47 AM   #1
Krusty ... OP
What? Me hurry?
 
Krusty ...'s Avatar
 
Joined: Dec 2004
Location: Richardson, TX
Oddometer: 7,588
DR650SE Index Topic#13- PROBLEMS/FAILURES

DR650SE Index Topic#13- PROBLEMS/ISSUES

Lucky 13... how about some bad luck stories . For such an inexpensive motorcycle, the DR has proven itself remarkably reliable. A few problems have been observed over the years. Some relatively minor, others catastrophic. While epic failures like the third gear problem are dramatic and troubling, they are still very rare.

Share your fixes, dodged bullets and, yes, your disasters...

-HEADER WELD
-BASE GASKET
-CAMSHAFT CHAIN TENSIONER (CCT) GASKET
-UPPER CHAIN ROLLER
-STARTER BACKLASH
-NEUTRAL SENDING UNIT [NSU] SCREWS
-3RD GEAR FAILURE
__________________
SUZUKI DR650SE INFORMATION INDEX
"...choosing a DR indicates an affinity for peace, harmony and enlightenment. Serenity lies in accepting it as it is, changing what you want, and the wisdom of knowing it ain't orange." -psmcd
Krusty ... is offline   Reply With Quote
Old 11-11-2010, 07:33 AM   #2
eakins
Butler Maps
 
eakins's Avatar
 
Joined: May 2002
Location: Fort Collins, Colorado
Oddometer: 17,185
none for me
__________________
Butler Maps - motorcycle maps for riders by riders -
Alaska
AZ map COBDR AZBDR IDBDR South East map
http://www.advrider.com/forums/showthread.php?t=598717
Cycle World Adventure Rally:
http://www.advrider.com/forums/showthread.php?t=956350
eakins is online now   Reply With Quote
Old 11-11-2010, 03:22 PM   #3
Rusty Rocket
Life behind "Bars"
 
Rusty Rocket's Avatar
 
Joined: Dec 2005
Location: Northcentral CT
Oddometer: 8,256
I had an electrical fire in the main wiring harness. Destroyed the whole wiring system. A fellow DR650 ADV'r sent me one from his parts bike just to help an old guy out. Thanks Steve
__________________
In the beginning, there was nothing. Even That exploded
2009 DR650
..1972 Penton Six-Days ..1971 Suzuki TS185.. 2005 KTM 400exc
Member of: AMA, NETRA, Blue Ribbon Coalition, CCCofVT, Berkshire TR, CT Ramblers
Rusty Rocket is offline   Reply With Quote
Old 11-11-2010, 03:40 PM   #4
sagedrifter
Southern Explorer
 
sagedrifter's Avatar
 
Joined: Apr 2006
Location: Jacksonville, Alabama
Oddometer: 1,395
Talking

NSU screws do need to be checked, one of mine had started to come out. Wasn't even finger tight. Check those suckers!

I did the lock tite and star washer method. It was a good practice session to learn about the clutch too, mine was still like new. Then again I was only at 6K then.
sagedrifter is online now   Reply With Quote
Old 11-11-2010, 04:13 PM   #5
appalachian
Ride fat boy ride
 
Joined: Mar 2009
Location: southeast T.N.
Oddometer: 242
Its never happened to me,but...

I bought my bike (a 99 that didnt have a limiter from the factory) from a gent who "forgot" to tell me about the boss that holds a gear in place explode on him and tear the boss in half, then he had it repaired (slob weld job). I found the repair after I had a bolt break off the fly wheel and proceeded to chew up my stator.

Instead of attempting another weld job that probably wouldnt last I decided the best course of action would be to bite the dust and replace the motor cases, I'd rather do it rite as have to waste my time and money (quite a bit by the time its finished) on a roll of the dice.

By chance you own a 98 or 99 model and havent put in a tourque limiter, do so ASAP, An idea of the cost involved...motor cases (new) $700ish (used)$300/$400, service manual $65 new, specialty tools (must have) fly wheel puller $80 the rest of the tools you can improvise becuase some run at $200 a piece, Gasket set $80/$160 (depends), labor bids ran $500 to $700 (main reason I'm gonna do it).

A lotta hassle and cash for a $170 part.
__________________
Takes the road less graveled.
appalachian is offline   Reply With Quote
Old 11-11-2010, 04:54 PM   #6
71tr
Gnarly Adventurer
 
Joined: Jun 2009
Location: Chicago
Oddometer: 462
base gasket

I have a 2003 with about 5k miles complete with leaky base gasket. Recall Suzuki switched from a paper to a metal gasket in approximately '03. The leak acts like a pinhole spitting tiny droplets of oil as the motor revs. A nice bead of high temp silicone has effectively taken care of the problem. I'm planning to take this bike through South America next year and have no plans to replace the leaking gasket.
71tr is offline   Reply With Quote
Old 12-18-2010, 07:24 PM   #7
VtStrom
Adventurer
 
Joined: Aug 2006
Location: Vermont
Oddometer: 72
Quote:
Originally Posted by appalachian View Post
I bought my bike (a 99 that didnt have a limiter from the factory) from a gent who "forgot" to tell me about the boss that holds a gear in place explode on him and tear the boss in half, then he had it repaired (slob weld job). I found the repair after I had a bolt break off the fly wheel and proceeded to chew up my stator.

Instead of attempting another weld job that probably wouldnt last I decided the best course of action would be to bite the dust and replace the motor cases, I'd rather do it rite as have to waste my time and money (quite a bit by the time its finished) on a roll of the dice.

By chance you own a 98 or 99 model and havent put in a tourque limiter, do so ASAP, An idea of the cost involved...motor cases (new) $700ish (used)$300/$400, service manual $65 new, specialty tools (must have) fly wheel puller $80 the rest of the tools you can improvise becuase some run at $200 a piece, Gasket set $80/$160 (depends), labor bids ran $500 to $700 (main reason I'm gonna do it).

A lotta hassle and cash for a $170 part.


THATS THE TRUTH!!
VtStrom is offline   Reply With Quote
Old 11-28-2010, 09:00 AM   #8
Krusty ... OP
What? Me hurry?
 
Krusty ...'s Avatar
 
Joined: Dec 2004
Location: Richardson, TX
Oddometer: 7,588
NSU link- http://www.thumpertalk.com/forum/sho...d.php?t=592472
__________________
SUZUKI DR650SE INFORMATION INDEX
"...choosing a DR indicates an affinity for peace, harmony and enlightenment. Serenity lies in accepting it as it is, changing what you want, and the wisdom of knowing it ain't orange." -psmcd

Krusty ... screwed with this post 12-21-2010 at 11:48 AM
Krusty ... is offline   Reply With Quote
Old 12-08-2010, 07:14 PM   #9
ER70S-2
Beastly Adventurer
 
ER70S-2's Avatar
 
Joined: Sep 2009
Location: SE Denver-ish
Oddometer: 4,693
NSU Information

Don't let the length of this post scare you, it's just several solutions by different riders.

The Neutral Sending Unit screws have been known to loosen themselves and find their way into the tranny gears, not good. Does not seem to be related to model year or mileage. It's a small percentage failure number, but a big disaster $$$ if it happens. After removing the clutch cover: remove, clean screw threads and holes, then Loctite or safety wire. I prefer safety wire.

So if your neutral indicator light quits or starts acting funny......

http://www.advrider.com/forums/showp...ostcount=33543

mx_rob:
"One point though on the screw just gently falling out and settling on the bottom. The hurricane turbulence of the clutch basket and gears in the oil can easily sweep the screw up into places that would be a major bummer for it/them to be."

Like these two pics:
http://www.advrider.com/forums/showp...ostcount=49541
http://www.advrider.com/forums/showp...ostcount=49542

Here's how:
http://www.thumpertalk.com/forum/sho...9&postcount=38

Thanks to LukasM, pics are worth a thousand words:

http://advrider.com/forums/showpost....ostcount=19784

http://advrider.com/forums/showpost....ostcount=19799

Mine only has the single blue wire:
http://www.advrider.com/forums/showp...ostcount=33214

2laneblacktop's step by step and NSU screw sizes:
http://www.advrider.com/forums/showp...ostcount=26847

The two NSU screws, the pin and spring hiding behind the NSU, looking to escape:
http://advrider.com/forums/showpost....ostcount=57707



TREE posted this, I think a good solution:

This is the plan for my NSU bolts . . . easy to wrench and then they will be lockwired.
http://i64.servimg.com/u/f64/11/94/64/62/bolts210.jpg

plodalong posted his idea:
http://www.advrider.com/forums/showp...ostcount=33685

Dyno:
http://www.advrider.com/forums/showp...ostcount=33257


The oil pump drive gear is some sort of resin/fiber construction, so I replaced it (at 15,000 miles). It's $19.94 and #7 here:
http://www.bikebandit.com/2004-suzuk...5873#sch502975

There is also a seal in the clutch cover I'd replace while in there. It's shown in the middle photo on page 3-42 in the service manual.
It's on the crankshaft page, #10 here:
http://www.bikebandit.com/2004-suzuk...5873#sch502988

Secured the NSU and now my clutch doesn't work.
http://www.advrider.com/forums/showp...7&postcount=32
__________________
2004 DR650: 59,658 miles
2013 WR250R

SUZUKI DR650SE INFORMATION INDEX
Quote:
Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -

ER70S-2 screwed with this post 02-18-2014 at 06:29 PM
ER70S-2 is online now   Reply With Quote
Old 12-12-2010, 12:46 AM   #10
LucidMayhem
Mountain scaling freak
 
LucidMayhem's Avatar
 
Joined: May 2009
Location: Waseca, MN, USA
Oddometer: 64
I had my rear brake light shake loose at about 7000k and the Cam chain tensioner gasket leaked at around 5000k miles. I believe that was from over servicing though. Other than that, no problems.
__________________
"Death may be the greatest of all human blessings." -Socrates
LucidMayhem is offline   Reply With Quote
Old 12-12-2010, 12:42 PM   #11
ER70S-2
Beastly Adventurer
 
ER70S-2's Avatar
 
Joined: Sep 2009
Location: SE Denver-ish
Oddometer: 4,693
Oil Leaks

Near spark plug, starts here, with a few following posts:

http://www.advrider.com/forums/showp...ostcount=35690

Including:

http://www.advrider.com/forums/showp...ostcount=35695

And:

__________________
2004 DR650: 59,658 miles
2013 WR250R

SUZUKI DR650SE INFORMATION INDEX
Quote:
Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -

ER70S-2 screwed with this post 12-29-2011 at 10:32 AM Reason: Added Pic
ER70S-2 is online now   Reply With Quote
Old 03-31-2012, 11:04 PM   #12
NordieBoy
Armature speller
 
NordieBoy's Avatar
 
Joined: Dec 2006
Location: Kiwiland
Oddometer: 7,073
Quote:
Originally Posted by Ride-tell-sore! View Post
NordieBoy I done did it! I put on about 85 miles and not a drop! Thanks.
Mine has lasted about 40,000km with the silicon on it.
__________________
DR650 Wiki
NordieBoy is online now   Reply With Quote
Old 04-01-2012, 04:09 PM   #13
Ride-til-sore!
still 20 in-my-mind
 
Ride-til-sore!'s Avatar
 
Joined: Jul 2010
Location: Minn-sota
Oddometer: 380
Quote:
Originally Posted by NordieBoy View Post
Mine has lasted about 40,000km with the silicon on it.
Just got off the bike and put on another 150 miles today. Still no leaks! A little dab-a-do-ya! Lot cheaper then pulling the head!
Ride-til-sore! is offline   Reply With Quote
Old 02-20-2013, 07:35 AM   #14
eakins
Butler Maps
 
eakins's Avatar
 
Joined: May 2002
Location: Fort Collins, Colorado
Oddometer: 17,185
Quote:
Originally Posted by Rob.G View Post
A lot of people strip those screws... they're actually not philips. They're a Japanese "standard" (I forget the exact term)... but if you look closely, they aren't tapered like a true philips.. the slots go all the way down completely. There's a special tool you can get to remove them, but it sounds like you already solved the problem. :)

Rob

-----------------------

JIS screwdrivers - http://www.webbikeworld.com/motorcyc...-screwdrivers/
http://www.amazon.com/Hozan-JIS-4-JI.../dp/B005NIY3PM

the special tool for most is using a hand-hammer impact tool.
http://www.harborfreight.com/impact-...ase-37530.html
http://www.sears.com/craftsman-impac...p-00947641000P
http://www.harborfreight.com/7-piece...set-93481.html - light duty one for smaller fasteners.
i've used a dremel tool in the past with a thin cutoff wheel and made a slot for a flathead screwdriver to work.

later found out the trick, if you only have Philips screwdrivers, is to use the next size smaller one (so it gets the tip down in deeper in the JIS screw) and tap it from the top with a hammer. this helps drive the tool head deeper into the screw and also shocks the screw some to loosen it. if the screw is somewhat buggered up, from previous attempts, tapping the screwdriver in harder can work. often the steel screw, alum. cap & brake res. main body somewhat fuse together if the fluid has never been serviced.

here is a way to modify Philips bits/screwdrivers to fit better in JIS:
http://www.kzrider.com/forum/21-tool...rewdriver-tips

when dealing with the JIS screws on the floatbowl, the same technique can be used but often those hand-hammered tools is key. that is 1 essential tool that every home mechanic should have! once you have those screws out replace with allen bolts from PC, Jesse or the hardware store.
__________________
Butler Maps - motorcycle maps for riders by riders -
Alaska
AZ map COBDR AZBDR IDBDR South East map
http://www.advrider.com/forums/showthread.php?t=598717
Cycle World Adventure Rally:
http://www.advrider.com/forums/showthread.php?t=956350

eakins screwed with this post 02-20-2013 at 10:09 AM
eakins is online now   Reply With Quote
Old 03-01-2013, 10:10 AM   #15
eakins
Butler Maps
 
eakins's Avatar
 
Joined: May 2002
Location: Fort Collins, Colorado
Oddometer: 17,185
Start squeal noise and fixes
http://www.fy-yff.com/2011/08/squeak...-easy-fix.html
http://webpages.charter.net/jrandall...tarter_fix.htm
http://www.advrider.com/forums/showthread.php?t=832297
__________________
Butler Maps - motorcycle maps for riders by riders -
Alaska
AZ map COBDR AZBDR IDBDR South East map
http://www.advrider.com/forums/showthread.php?t=598717
Cycle World Adventure Rally:
http://www.advrider.com/forums/showthread.php?t=956350
eakins is online now   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 02:41 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014