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Old 03-07-2011, 02:20 AM   #16
buick driver
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Helpful people here
DR - ThumperTalk
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Old 03-20-2011, 09:57 PM   #17
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Joined: Dec 2004
Location: Richardson, TX
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Dongie's outstanding build-up :
http://www.advrider.com/forums/showthread.php?t=654953
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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
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Old 06-23-2011, 01:46 PM   #18
Sleepy John
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Location: Bris Vegas, Australia
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Nathan and Elena's Aussie Ride-About

Nathan and Elena's Aussie Ride-About... Legend!

http://www.advrider.com/forums/showt...2#post14321492

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'10 R1200GSA Big Pig, '10 DR650SE Piglet
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Old 09-24-2011, 09:11 PM   #19
eakins
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Joined: May 2002
Location: Fort Collins, Colorado
Oddometer: 17,528
Spark plug – 8 ftlbs (96 in lbs)
TDC inspection hole plug – 16.5 ft (198)
Oil drain – 17.5 ft (210) – use 13mm socket
Oil filter cover – 8flbs (96 in) stock – 4ft (48) alum cover
Oil – 2.5 qt w/ filter (10w-40)
Cylinder head cover bolt – 7ft (84)
Valves – adj on the tight end (engine runs quiter)

Handle bar clamp bolt – 16.5 ft (198)
Triple clamp bolts: upper – 21 ft (252) / lower 19 ft (228)
Steering stem (top of triple clamp) top nut/cap – 65 ft lbs
Front wheel axel – 47 ft : tighten first, cycle shocks 5x
Front wheel axel clamp bolts – 7 ft (84 in) : tighten next, top bolt first
Fork top cap – 16.5 ft (198)
Fork preload = 10-20mm
Fork oil height = 6.5” / 16 oz (5.9 lowered – need 2 qt)

Front brake caliper bolts – 19ft (228)
Fr brake Bleed nipple – 6 ft (72)
Fr Brake pad mounting pin – 13lb (156)
Fr brake hose banjo bolts – 16.5ft (198)

Rear brake caliper pad – 13 ft (156)
Rear wheel axel nut – 72.5 ft (cotter pin) / 79.5 (fuji nut)
Rear shock – upper bolt 40 ftlb , lower bolt 37 Nm (cogent) 55nm (stock)
Rear suspension linkage - Dog bones fuji-nuts (both) – 72.5 flbs
Rear suspension linkage – frame fuji-nuts – 58 ftlbs
Chain – 525, 110 link, 14/42 sprockets
Chain free play – 1.2–1.8 in (30-45 mm) 1.2 to 1.8 inches of slack in the middle of the chain
Chain stretch limit: Loosen your axle nut and adjust your chain so there is no play in it. Count out 20 pitches (21 pins) measure between the centerlines of the 1st and 21st pin. 319.4mm (12.6") is the service limit
Swing arm bolt – 55.5 flbs

Counter sprocket bolts - 4.5 ft lbs (54 in) (shoulder/raised area goes in towards engine)
Suzuki counter sprocket seal retainer – part# 24751-32E00
Rear Sprocket – 19.5 ftlbs (234 in)

Cogent rear shock
-lower red adjuster – rebound, 42 click total, out/down is softer
-upper small adjuster – compression, out/CCW is softer
-200lbs w/ gear – 4 out past middle settings.


Quality Bearings:

-Front wheel bearings: SKF 6003-2RS
2 - 17 x 35 x 10
-Front wheel seal:
2 - 23x35x7 (09284-23001 – Suzuki #)

-Rear wheel bearings: SKF 6204-2RS
2 - 20x47x14
-Rear wheel seal (brake side):
1 - 26x47x7 (09283-26019 – Suzuki #)

-Cush Hub bearing: SKF 6205-2RS
1 - 25x52x15
-Cush Seal:
1 - 35x52x7 (09283-34003 – Suzuki #)
-------------------------------------------
Two 6003-2RS
Two 6204-2RS
One 6205-2RS
---------------------------------------------
Go for sealed both sides European or Jap bearings if you don't mind paying more . . . I sure don't.
Any brands like SKF, FAG, NSK etc.
If you want a good Jap sealed bearing for the rear axle hub (x 2) get Honda ones :
part number 96150-6204010 ( generic 6204 bearing ) 20 x 47 x 14 mm size.

Cush drive bearing is a 6205 generic 25 x 52 x 15mm
Honda part number 96150-6205010

Front wheel size is 6003 generic 17 x 35 x 10mm
Honda part # 91065-KA3-832

Before you pay for the Honda ones check they are made in Japan and sealed both sides !

Spark plugs:
Denso irdidium - 5364 (IU31)
Standard ngk - CR10E
NGK irdium - CR10EIX

-Lock nut from 2008 and newer: 08319-2118a
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AZ map COBDR AZBDR IDBDR South East map
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eakins screwed with this post 08-04-2014 at 09:22 PM
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Old 12-15-2011, 07:51 AM   #20
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I'm embarrassed to find that I neglected to add a link to this thread-Who has the most tricked-out DR ? by Zapp22. A great thread that I thought I had included a long time ago . A DR650 farkle-fest .

While I'm at it, let me add another link, The DR650 Highway Touring Thread by planemanx15. Great ideas for making the DR a more capable mile eater .


Here's a buildup of a super clean DR650 motard setup: Will's Funster DR650 Project by willmeyer.
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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

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Old 06-04-2012, 08:34 PM   #21
ER70S-2
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Location: SE Denver-ish
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This is another inmate's idea and it worked well for me. I didn't like repeatedly using steel screws into alum on the oil filter cover. The solution is studs.

First thing I noticed is that the threaded holes in the clutch cover are deeper than the stock bolts, by about 6mm. What looks like a longer bolt, is actually a stud with a nut. The bottom one is the stock Zuki bolt.


This shows all 3 studs (cut/ground to length) screwed into the entire depth available, with the ground ends exposed. Sorry about the fuzzy pic, the camera was smarter than me when I took this pic.


After getting the length right, I flipped the studs to show the factory ends, drowned in Loctite (wiped off excess), and left to dry. DO NOT tighten the studs very tight, that will introduce an unwanted stress into the case bosses. The Loctite will take care of that.

Now, pritty and strong and steel on steel.
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"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -

ER70S-2 screwed with this post 06-05-2012 at 04:45 PM
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Old 06-05-2012, 10:27 AM   #22
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^ ^ ^ That's a cool idea, and thanks for the write-up!
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Old 06-05-2012, 03:20 PM   #23
Heavy
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What size & length studs are they? Not to be lazy but it would be nice to have them in hand when I start the project.
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Old 06-05-2012, 04:44 PM   #24
ER70S-2
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Quote:
Originally Posted by ag_streak View Post
^ ^ ^ That's a cool idea, and thanks for the write-up!


Quote:
Originally Posted by Heavy View Post
What size & length studs are they? Not to be lazy but it would be nice to have them in hand when I start the project.
I knew then (Feb. 2010), but I don't remember now.

Remove your top bolt, chase the threads, bottom a longer bolt in the hole, measure what you'll need.


Stock bolt thread is 6x16mm. Looks like about 27mm. Buy 'em long, cut to fit.
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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." -
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Old 06-10-2012, 03:40 AM   #25
Heavy
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Thanks!

Quote:
Originally Posted by ER70S-2 View Post
.........Stock bolt thread is 6x16mm. Looks like about 27mm. Buy 'em long, cut to fit.
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Old 05-23-2013, 01:22 PM   #26
eakins
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Location: Fort Collins, Colorado
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http://dr650-mods-reviews-tips.sportsontheweb.net/
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Alaska
AZ map COBDR AZBDR IDBDR South East map
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Old 06-06-2013, 05:35 PM   #27
Krusty ... OP
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Joined: Dec 2004
Location: Richardson, TX
Oddometer: 7,592
Another long overdue link. BergDonk is a fabricator and innovator, and is constantly finding ways to make the DR650 a better machine . Here's the link to his DR650 thread:
http://advrider.com/forums/showthread.php?t=646076
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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 06-06-2013 at 05:49 PM
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Old 06-07-2013, 12:33 AM   #28
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Quote:
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That article needs to be edited.
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Old 06-19-2013, 09:45 PM   #29
Krusty ... OP
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Joined: Dec 2004
Location: Richardson, TX
Oddometer: 7,592
Thumb

Thanks, Grifter, for this list of ride reports featuring the DR ...

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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
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Old 09-10-2013, 10:13 AM   #30
Adv Grifter
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Location: Passing ADV Stalkers in California
Oddometer: 6,128
Quote:
Originally Posted by Krusty ... View Post
http://shortwayround.co.uk/ by Jedi Master. (A RTW journey, still in progress. The trip started on a F650, but reliability issues led him to swap to a DR650 mid-trip . Of particular interest is the DR650 Preparation Page (http://shortwayround.co.uk/suzuki/). A very well thought out guide for what needs and issues to address and what to bring along for long distance travel on the DR.

A Solo Trip from Gibraltar to Australia (DR650s are for old ladies) by Linda Bootherstone-Bick

Just another Alaska ride by snowrider

Snowrider to Mexico by snowrider

Dirtbikes & Death Roads, 2200 Miles in Bolivia by RockyRoads

2 blokes, 2 bikes on the Silk Road

Lower Latitudes- Better Attitudes by Lone Rider

Chameleon DR650 by David Early

Europe to Timor Leste (2006-2009)
Quote:
Originally Posted by Krusty ... View Post
Thanks, Grifter, for this list of ride reports featuring the DR ...
And thanks to you for digging up all the reports listed above and on Post
#11. Just shows the DR's history goes back quite a long way.
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