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Old 06-01-2013, 10:41 PM   #91
ER70S-2
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You got through the NSU, the torque limiter will be a snap.
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SUZUKI DR650SE INFORMATION INDEX
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"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 06-04-2013, 06:17 AM   #92
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Here's a guide to thread locking compounds and their different applications. Useful to know for the NSU fix, and many other instances. Thanks 955626846

Quote:
Originally Posted by 955616846 View Post
Yep, "red" Loctite seems to be the internet cure all with little regard to the suitability for the application. They are often misused by the "experts" in more applications than just thread locking.

"Red"usually refers to Loctite 263, 270, 271 or 272 thread lockers which will work, but those screws will never be coming out... There is little on these bikes that should require such heavy handed treatment.

"Blue" usually refers to Loctite 242 or 243 - it's a red bottle, likely with a blue band and has blue contents. It is all that is ever required on a bike for bolts M6 and over. Use 242 or 243 on the NSU screws. It will also serve on much of the rest of the bike...

The other tool in the box is Loctite 222 (Purple) for small bolts or bolts that do not take a lot of torque. It is used as a light thread retainer.

Loctite US sites:
Retail: http://www.loctiteproducts.com/p/t_l...r-Blue-242.htm
Industrial: http://www.henkelna.com/industrial/p...ode%3Dfaceted|

The Au site might be a little easier as a guide.
http://au.iloctite.com/en/loctite-22...-threadlockers



This Permatex product is the equivalent to Loctite 242/243
http://www.permatex.com/products/pro...er-blue-detail

This Permatex product is the equivalent to Loctite 222
http://www.permatex.com/products/pro...-purple-detail
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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 06-04-2013 at 06:26 AM
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Old 06-26-2013, 09:28 AM   #93
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As mentioned, there have been a small number of DR650's that have developed oil leaks from the output shaft gasket. Replacing this seal used to be troublesome, as the replacemet gasket would just pop out from oil pressure. Stealing a page from BergDonk's play book, Suzuki has released the fix/preventative: an output shaft seal retainer. The part number is 24751-32E00, and it's an inexpensive piece.
Thanks to 996DL for passing along that P/N...
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SUZUKI DR650SE INFORMATION INDEX
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Old 06-26-2013, 09:36 AM   #94
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Quote:
Originally Posted by Krusty ... View Post
As mentioned, there have been a small number of DR650's that have developed oil leaks from the output shaft gasket. Replacing this seal used to be troublesome, as the replacemet gasket would just pop out from oil pressure. Stealing a page from BergDonk's play book, Suzuki has released the fix/preventative: an output shaft seal retainer. The part number is 24751-32E00, and it's an inexpensive piece.
Thanks to 996DL for passing along that P/N...
i'm seeing less than $15 for the part.
it's a no-brainer for every DR owner.

http://drriders.com/topic6575-160.html

is there a torque spec for those 2 bolts that get reinstalled???
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Old 07-17-2013, 11:28 PM   #95
8gv
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How to bypass sidestand switch...

http://www.google.com/url?sa=t&rct=j...nHPE6RokJqOt_g

It has been brought to my attention that one may encounter a different style of connector than what is seen in this video. One inmate cut the wires, spliced and insulated them. YMMV

8gv screwed with this post 07-19-2013 at 05:15 PM
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Old 07-20-2013, 12:24 AM   #96
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Backfired and died on road

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Here's the link to more info.

Post #70712 http://advrider.com/forums/showpost....ostcount=70712

Still trying to figure what caused the problem. Will report back later.

Dave
Oops, just now reporting back. Tore the bike apart, tracing the wiring harness. When the wires behind the headlight were wiggled, the engine would run. After trying this several times, it was noticed one of the plugs was getting HOT. Killed the engine and started looking closer.

By chance, after tracing the wire from the hot connector behind the headlight clear to the left passenger footpeg, there was no insulation on the wire heading to the tail light. It was rubbing on the inside of the passenger peg and shorting out. That caused low voltage to the CDI box.

The insulation was off for a few inches and the stranded wire was down to only a few strands. Got out the soldering gun and twisted more wire around it and soldered in place. Lots of tape and a section of cable protector was applied.

No problems since then (Oct 2012 to now April 2014= 61.5K miles now).

Dave

smilin jack screwed with this post 04-20-2014 at 07:23 PM
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Old 07-20-2013, 05:22 AM   #97
greer
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Thanks for the follow-up Dave; I'll check my wiring this morning.

Sarah
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Old 08-24-2013, 01:20 PM   #98
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squawk-no-more

Many DR650 owners are familiar with the distressingly noisy squawking the starter can emit, especially in cooler weather. While more of an annoyance than a problem, the fix has arrived...

Warp9 Racing has jumped into the DR650 aftermarket with both feet, and one of their many upgrades is a ball bearing starter cap that replaces the Suzuki brass bearing cap.

And if you haven't sent Procycle enough money lately, all the new Warp9 DR650 parts are available there.

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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 09-23-2013, 01:52 PM   #99
ER70S-2
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Clutch dragging: Hard to find neutral

Copied from the big DR thread:

Quote:
Originally Posted by procycle View Post
Wear in the thrust washer behind the clutch basket can cause the clutch to drag. Heat in the clutch assembly can take away the small amount of clearance.
See this thread over on DRriders.com --> http://drriders.com/topic6671.html
Quote:
Originally Posted by procycle View Post
I would replace #s 2,3 and 8 from this diagram


I would also apply some 'wicking grade' Locktite between the shaft and bearing behind the clutch.

By the way, this is a known problem with DR350s which have the same design.
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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 09-23-2013 at 02:04 PM
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Old 12-26-2013, 01:10 PM   #100
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Clutch Lever Safety Switch / Bypass



I decided to keep the safety switch, but it did fail sometime after 50k miles, the bike wouldn't start. Since I was home, it was a non-event.

Dirty:


Cleaned:




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2004 DR650: 62,400 miles
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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." -

ER70S-2 screwed with this post 01-04-2014 at 12:54 PM
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Old 02-22-2014, 08:03 PM   #101
00Buck
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My '08 with 22,000 km has the distressing starter squawk, especially when cold. I see Warp9 has the fix. But could I remove the cover and apply light grease to the bushing if it is not badly worn? Wondering how long that will last.
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Old 02-22-2014, 08:07 PM   #102
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Quote:
Originally Posted by 00Buck View Post
My '08 with 22,000 km has the distressing starter squawk, especially when cold. I see Warp9 has the fix. But could I remove the cover and apply light grease to the bushing if it is not badly worn? Wondering how long that will last.
They are a sintered bronze bush so designed to be soaked in oil. I feel a lighetr oil is preferred, like ATF. Pour some in and leave overnight, then drain off the excess.

They will squeak and carry on for years without maintenance and little further wear though, and the Warp9 fix is even better I reckon.
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Old 02-22-2014, 08:49 PM   #103
ER70S-2
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Mine started squawking at about 10k miles and I didn't get around to greasing it until 15k. It was silent from 15-50k. My CCT started leaking at 50k so I greased the starter again while I had things apart.

Warp 9 hadn't discovered the DR yet.
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2004 DR650: 62,400 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." -
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Old 03-02-2014, 11:44 PM   #104
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My friend had 2 countershaft seals fall out (literally) of his 2013 Dr650's within a few hundred miles of each other.

Procycle sells this for $23:



Their website is: http://www.procycle.us/bikepages/dr6...l#sealretainer

Get a seal retainer! Avoid being stuck like my friend from New Zealand, coming all the way here, kitting up 2 new dr650's and being stuck waiting for Suzuki America (a week or three) to respond:

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