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 05-25-2011, 04:20 PM   #1
Bubba Bauer OP
Gnarly Adventurer
 
Bubba Bauer's Avatar
 
Joined: May 2011
Location: Lower Mitcham SA
Oddometer: 154
Pissed DR650 owners Beware! Neutral Sending Unit screw up!

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...

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.
Attached Images
 
__________________
Bubba Bauer is offline   Reply With Quote
Old 05-25-2011, 04:21 PM   #2
Bubba Bauer OP
Gnarly Adventurer
 
Bubba Bauer's Avatar
 
Joined: May 2011
Location: Lower Mitcham SA
Oddometer: 154
some more lovely pics
Attached Images
 
__________________
Bubba Bauer is offline   Reply With Quote
Old 05-25-2011, 05:05 PM   #3
Eggsontoast
Adventurer
 
Eggsontoast's Avatar
 
Joined: May 2010
Location: Dad's sack
Oddometer: 66
Fuck me!

That's a real spanner in the works (no pun intended).

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!

Pat
__________________
La Moto, c' est une aventure qui mene jusqu' au bout du monde...
Eggsontoast is offline   Reply With Quote
Old 05-26-2011, 02:46 AM   #4
ADV8
Taumarunui..Darwin..
 
ADV8's Avatar
 
Joined: Nov 2007
Location: North of Sydney.
Oddometer: 2,112
Ouch.
Do you have a pic of the screw that caused the damage
What of the neutral sensor itself ?
__________________

ADV8 is offline   Reply With Quote
Old 05-30-2011, 11:03 AM   #5
GutterTrash
Studly Adventurer
 
GutterTrash's Avatar
 
Joined: Jul 2010
Location: downJersie
Oddometer: 595
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
GutterTrash is offline   Reply With Quote
Old 12-29-2013, 05:50 PM   #6
kimmie
Adventurer
 
Joined: Dec 2013
Location: Sydney, Australia
Oddometer: 20
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,
Kimmie
kimmie is offline   Reply With Quote
Old 12-29-2013, 06:49 PM   #7
ER70S-2
Beastly Adventurer
 
ER70S-2's Avatar
 
Joined: Sep 2009
Location: SE Denver-ish
Oddometer: 5,156
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.

__________________
2004 DR650: 61,105 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 is offline   Reply With Quote
Old 12-29-2013, 07:36 PM   #8
Thumpstart92
Gnarly Adventurer
 
Thumpstart92's Avatar
 
Joined: Mar 2013
Location: Central Arkansas
Oddometer: 244
Holy Moly! That's disturbing
__________________
Adventure ain't clean
Thumpstart92 is offline   Reply With Quote
Old 12-29-2013, 11:52 PM   #9
kimmie
Adventurer
 
Joined: Dec 2013
Location: Sydney, Australia
Oddometer: 20
Thanks ER70S-2.

The bulb and connector have both been checked and are in good order and all connections are sound.
kimmie is offline   Reply With Quote
Old 12-30-2013, 11:42 AM   #10
ER70S-2
Beastly Adventurer
 
ER70S-2's Avatar
 
Joined: Sep 2009
Location: SE Denver-ish
Oddometer: 5,156

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?
__________________
2004 DR650: 61,105 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 is offline   Reply With Quote
Old 12-30-2013, 03:26 PM   #11
Karlxx
Dirt Curious
 
Karlxx's Avatar
 
Joined: Jul 2012
Location: Sydney, Australia
Oddometer: 160
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?
__________________
2004 R1150GSA
2003 CBR1100XX

IBA 41759
Karlxx is offline   Reply With Quote
Old 02-21-2014, 09:53 PM   #12
kimmie
Adventurer
 
Joined: Dec 2013
Location: Sydney, Australia
Oddometer: 20
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 what.....it 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 that...lol)
kimmie is offline   Reply With Quote
Old 02-21-2014, 10:09 PM   #13
ER70S-2
Beastly Adventurer
 
ER70S-2's Avatar
 
Joined: Sep 2009
Location: SE Denver-ish
Oddometer: 5,156
Thanks for the follow-up, this is the first time I've heard of the switch failing. I like having the light also.
__________________
2004 DR650: 61,105 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 is offline   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 06:06 AM.


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