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Old 05-15-2012, 01:05 PM   #64336
deathu
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Aftermarket ignition switch

Hi,

I just managed to buy a used DR650SE a few days ago.. these bikes are VERY rare here in Europe, it took me over 6 months to find one in my area. The bike is not in a good shape, but given the fact that since the day I first rode one i knew this was the DS bike for me, I had no alternative but to buy whatever DR650SE I manage to find..

Now to get to the point of my post, one of the many things I need to sort out on this bike is the ignition switch, which is operational but in a very bad shape. I have to "play" alot with the key to be able to turn it on. Once turned on, it won't retain the key inside. I'm thinking about replacing the ignition switch entirely, but for some reason I can't find any aftermarket one for sale, and the OEM one seems overpriced at over 130$. Does anyone know of an aftermarket ignition switch for the DR650SE? - OR - does the ignition switch of any other Suzuki model fit the DR650SE?
For some reason, I only seem to find aftermarket alternatives for the older, pre-1996 DR's.

Thanks!
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Old 05-15-2012, 01:18 PM   #64337
DockingPilot
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Black Acerbis tank on the 2012 grey.




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Old 05-15-2012, 01:31 PM   #64338
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That looks nice!




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Black Acerbis tank on the 2012 grey.




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Old 05-15-2012, 02:27 PM   #64339
asrvivor
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No Luck

Man I'm having terrible luck today. Both front fork seals blown. SHIT! Gotta 1500 mile trip in 2 days and no time. Anyone have the specs on how much oil goes in front forks, PLEASE? Dammit...........
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Old 05-15-2012, 02:36 PM   #64340
Rob.G
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Wiring Questions

I have a set of those Denali LED lights (from Twisted Throttle) on my DR650. They're currently wired up using the wiring that came with them and their own switch. I would like to eliminate this wiring and connect them to the high-beam switch so they only come on when that switch is activated. My headlight has been replaced with a low-beam-only HID model so I have a "spare" prong coming off of my high-beam connector.

Not being an electronics type, and not being able to read a wiring diagram very well, I was wondering how I can go about doing this? Is it just a matter of connecting the power leads from the lights to that "spare" prong?

Thanks.

Rob
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Old 05-15-2012, 02:37 PM   #64341
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Olas screwed with this post 07-27-2012 at 07:38 AM
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Old 05-15-2012, 03:29 PM   #64342
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Just changed the fluid in my front forks - it a little over 16 ounces in each fork. It really a measurement thing, level of oil to top of fork, then volume of oil. Make sure you get all or at least most of the old oil out.

Quote:
Originally Posted by asrvivor View Post
Man I'm having terrible luck today. Both front fork seals blown. SHIT! Gotta 1500 mile trip in 2 days and no time. Anyone have the specs on how much oil goes in front forks, PLEASE? Dammit...........
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Old 05-15-2012, 03:33 PM   #64343
asrvivor
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Quote:
Originally Posted by Escaped View Post
Just changed the fluid in my front forks - it a little over 16 ounces in each fork. It really a measurement thing, level of oil to top of fork, then volume of oil. Make sure you get all or at least most of the old oil out.
Thanks guys. Got a Pm from PPCLI-Jim. Steeeered me in the right direction. I love this site. Never fails, you get everything packed for a big trip and BAM something starts leaking. At least it did it in the drive way. Could have been worse. Although I would have rode the thing the entire trip leaking oil. Who needs shocks really??? lol
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Old 05-15-2012, 03:35 PM   #64344
BergDonk
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Quote:
Originally Posted by deathu View Post
Hi,

I just managed to buy a used DR650SE a few days ago.. these bikes are VERY rare here in Europe, it took me over 6 months to find one in my area. The bike is not in a good shape, but given the fact that since the day I first rode one i knew this was the DS bike for me, I had no alternative but to buy whatever DR650SE I manage to find..

Now to get to the point of my post, one of the many things I need to sort out on this bike is the ignition switch, which is operational but in a very bad shape. I have to "play" alot with the key to be able to turn it on. Once turned on, it won't retain the key inside. I'm thinking about replacing the ignition switch entirely, but for some reason I can't find any aftermarket one for sale, and the OEM one seems overpriced at over 130$. Does anyone know of an aftermarket ignition switch for the DR650SE? - OR - does the ignition switch of any other Suzuki model fit the DR650SE?
For some reason, I only seem to find aftermarket alternatives for the older, pre-1996 DR's.

Thanks!
The stock ignition switch contains a resistor that goes in seriies witht he power circuit to the CDI I believe. Its a security measure to make it hard to hotwire the bike. Some one posted a tutorial a while back on how they sorted it, including what value the resistor is. Once that is sorted, and switch arrangement can work, although you'll lose the steering lock too.

Steve
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Old 05-15-2012, 03:39 PM   #64345
kobukan
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Quote:
Originally Posted by asrvivor View Post
Man I'm having terrible luck today. Both front fork seals blown. SHIT! Gotta 1500 mile trip in 2 days and no time. Anyone have the specs on how much oil goes in front forks, PLEASE? Dammit...........
For a stock setup:
10 weight Fork Oil
19 oz. required per fork
Oil Level Setting: 165mm (6.5") from the top with springs removed and the fork completely collapsed.

But, before you tear it apart, try cleaning the seal with a thin piece of plastic - it has worked for me in the past, for thousands of miles without the leak reoccurring.
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Old 05-15-2012, 04:04 PM   #64346
Monroe
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Quote:
Originally Posted by Olas View Post
that looks like a beautiful day and place to be on the bike
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Old 05-15-2012, 04:18 PM   #64347
Adv Grifter
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Quote:
Originally Posted by asrvivor View Post
Man I'm having terrible luck today. Both front fork seals blown. SHIT! Gotta 1500 mile trip in 2 days and no time. Anyone have the specs on how much oil goes in front forks, PLEASE? Dammit...........
Fork Seals:
find a piece of 35mm film (remember that?) or other very thin but strong plastic. Use it to gently work between the rubber seal lip and fork tube. Work it in there and try to clean out any grit or crud. Use WD40 to flush out crap. Wipe clean. Now ... rotate the UPPER tube within the lower tube (loosen both sets of triple clamp bolts) This can change the contact point and sometimes stop the leak. Clean out crud best you can with the film, be careful not to damage the seal lip. Delicate.

Fork Oil:
If you've only lost a bit of oil and the leak is NEW, then don't worry about it now unless you want to remove forks, drain and re-fill. Just unscrew fork caps with forks on bike, add a bit of oil (based on how much you've lost) a little over or under filled will not hurt a thing. Use 10 wt. Oil. Don't smack yourself in the face when fork cap lets go. Hold down with hand as you turn it.

Header Bolts:
I believe the exhaust header bolts on the DR650 are probably heat treated to pretty high level and are pretty high quality. (Not sure) That is the hottest external place on your bike, so correct bolts are probably a good idea. I know the Suzuki ones are expensive and have to be ordered, but maybe something to think about for the future? Use Anti-seize on the threads. Mine have never loosened. DO NOT over tighten them ... if you strip the internal head threads ... it's gonna cost you.

Make sure your Chain, Sprockets, Tires and battery are ALL OK before you leave. Safety 3rd!
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Old 05-15-2012, 04:30 PM   #64348
notarat
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Quote:
Originally Posted by deathu View Post
Hi,

I just managed to buy a used DR650SE a few days ago.. these bikes are VERY rare here in Europe, it took me over 6 months to find one in my area. The bike is not in a good shape, but given the fact that since the day I first rode one i knew this was the DS bike for me, I had no alternative but to buy whatever DR650SE I manage to find..

Now to get to the point of my post, one of the many things I need to sort out on this bike is the ignition switch, which is operational but in a very bad shape. I have to "play" alot with the key to be able to turn it on. Once turned on, it won't retain the key inside. I'm thinking about replacing the ignition switch entirely, but for some reason I can't find any aftermarket one for sale, and the OEM one seems overpriced at over 130$. Does anyone know of an aftermarket ignition switch for the DR650SE? - OR - does the ignition switch of any other Suzuki model fit the DR650SE?
For some reason, I only seem to find aftermarket alternatives for the older, pre-1996 DR's.

Thanks!
I would comb through some of the online repair manuals for the DRZ400 and DR350 to see if their wire schematics match the DR650 in terms of connections. You can cut, splice, solder, then heatshrink so you can re-use your connectors.

I sent you a PM regarding an auction on fleabay.co.uk too listing a DR switch
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Old 05-15-2012, 04:34 PM   #64349
notarat
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Quote:
Originally Posted by asrvivor View Post
Thanks guys. Got a Pm from PPCLI-Jim. Steeeered me in the right direction. I love this site. Never fails, you get everything packed for a big trip and BAM something starts leaking. At least it did it in the drive way. Could have been worse. Although I would have rode the thing the entire trip leaking oil. Who needs shocks really??? lol
Did you do the film trick first? You may simply have a couple specks of dirt in the seals. Running a piece of 35mm film negative (or equivalent) around the tube in between the tube and seal can clear the dirt out and stop the leak
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Old 05-15-2012, 04:36 PM   #64350
notarat
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Location: Bluff City
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Bluhduh

Quote:
Originally Posted by Adv Grifter View Post
Fork Seals:
find a piece of 35mm film (remember that?) or other very thin but strong plastic. Use it to gently work between the rubber seal lip and fork tube. Work it in there and try to clean out any grit or crud. Use WD40 to flush out crap. Wipe clean. Now ... rotate the UPPER tube within the lower tube (loosen both sets of triple clamp bolts) This can change the contact point and sometimes stop the leak. Clean out crud best you can with the film, be careful not to damage the seal lip. Delicate.

Fork Oil:
If you've only lost a bit of oil and the leak is NEW, then don't worry about it now unless you want to remove forks, drain and re-fill. Just unscrew fork caps with forks on bike, add a bit of oil (based on how much you've lost) a little over or under filled will not hurt a thing. Use 10 wt. Oil. Don't smack yourself in the face when fork cap lets go. Hold down with hand as you turn it.

Header Bolts:
I believe the exhaust header bolts on the DR650 are probably heat treated to pretty high level and are pretty high quality. (Not sure) That is the hottest external place on your bike, so correct bolts are probably a good idea. I know the Suzuki ones are expensive and have to be ordered, but maybe something to think about for the future? Use Anti-seize on the threads. Mine have never loosened. DO NOT over tighten them ... if you strip the internal head threads ... it's gonna cost you.

Make sure your Chain, Sprockets, Tires and battery are ALL OK before you leave. Safety 3rd!
I guess I should read the whole thread before replying, lol
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