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Old 09-11-2012, 04:33 AM   #1
rosiethestarfish OP
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Location: Broken Hill, NSW, Australia
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dr650 countershaft oil seal issue

Hi guys,

This is my first post so be gentle. I recently bought a dr650 se 2009. I am currently having a major issue with the countershaft seal. I have read multiple threads from both adv rider and thumper talk. The impression I get is this typically happens on earlier model bikes. So far I have fixed this problem three times. The first time I simply glued it back in..the solution lasted less than 5 k. The next time I used better glue and I also centre punched (reccommended in another thread). The seal has since popped out again.

I have run out of ideas. I am hoping someone has had a similar problem and has found a successful solution. I am really worried about this. Its not a slow leak, when the seal goes all the oil comes gushing out of the bike and all over the back end of the bike. It will only be a matter of time until I cook the engine.
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Old 09-11-2012, 06:33 AM   #2
OldPete
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I've used adhesive silicone on fork seals that wanted to work out of place.
Clean and dry the seal/counter bore with a drying agent like brake clean.
A light smear on seal and bore, press seal in by hand... wait 24 hours or more before use.

next.. be gentle
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Old 09-12-2012, 05:15 AM   #3
greer
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Have you over-filled the oil? 2 quarts/liters is all you need. Seems like I read over-filling might be part of the problem. Good luck and let us know how it goes.

Sarah
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Old 09-12-2012, 06:04 AM   #4
wos
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There was a thread up in Canada I think. A couple had the same problem with a newer model of that engine. They found that the factory had messed up the case machining on some of these motors and an oversized seal was available. Maybe you could get your dealer to call the suzuki tech line.
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Old 09-13-2012, 04:37 AM   #5
greer
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More reading:

http://drriders.com/topic1190.html

http://drriders.com/topic4128.html

http://drriders.com/topic2395.html

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Old 09-13-2012, 03:13 PM   #6
LukasM
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Not an uncommon problem on the DR.

Bergdonk made a retainer plate for the seal, check towards the end of his thread:

http://www.advrider.com/forums/showthread.php?t=646076
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Old 09-13-2012, 08:53 PM   #7
rosiethestarfish OP
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Thanks for the info guys. I saw the retaining plate, great idea. It does seem odd to me that Suzuki dont offer a plate as an after sale part or that one of the accessories providers dont make one. All good I will contact berg and see if he is willing to make another. Thanks guys
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Old 03-04-2013, 11:35 AM   #8
HAPPYTRAILSINC
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OK GUYS,we have a new 2012dr650 w/loose counter shaft seal here in the shop!
bike came in leaking oil on left side-filled w/oil and started-instantly found leak-c/s seal popped out- popped back in only to come right out due to the oil pressure
so i called the answer man at suzuki~
here is the answer directly from "steve wolf"-suzuki's western service advisor!
has says the problem cames from a too tight of chain running @ high speeds warps/distorts the cases thus ovalizing the c/s seal hole!
if it still under warranty suzuki will replace the cases
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Old 03-04-2013, 02:12 PM   #9
wee-twin
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Has been talked about and solved in the DR650 thread. If covered under warranty, have Suzuki take care of it. Regardless of if Suzuki fixes it or not, procycle has manufactured a counter shaft seal retainer. Installing the retainer is cheap insurance either way. If under warranty, Suzuki has admitted the seal seat was overmachined on some bikes.
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