DR650 owners Beware! Neutral Sending Unit screw up!

Bubba Bauer · 05-25-2011, 04:20 PM

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.

Bubba Bauer · 05-25-2011, 04:21 PM

some more lovely pics

Eggsontoast · 05-25-2011, 05:05 PM

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

ADV8 · 05-26-2011, 02:46 AM

Ouch.
Do you have a pic of the screw that caused the damage
What of the neutral sensor itself ?

GutterTrash · 05-30-2011, 11:03 AM

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

05-25-2011, 04:20 PM	#1
Bubba Bauer ^OP Adventurer Joined: May 2011 Location: Lower Mitcham SA Oddometer: 66	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 __________________

05-25-2011, 04:21 PM	#2
Bubba Bauer ^OP Adventurer Joined: May 2011 Location: Lower Mitcham SA Oddometer: 66	some more lovely pics Attached Images __________________

05-25-2011, 05:05 PM	#3
Eggsontoast Adventurer Joined: May 2010 Location: Dad's sack Oddometer: 62	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...

05-26-2011, 02:46 AM	#4
ADV8 Taumarunui..Darwin.. Joined: Nov 2007 Location: North of Sydney. Oddometer: 2,110	Ouch. Do you have a pic of the screw that caused the damage What of the neutral sensor itself ? __________________ Les .. 1968 Husqvarna MF250 and MF360 - 1971 Norton Commando Fastback - 1973 Kawasaki H2A - 1973 Ducati 750 GT - 1973 Moto Guzzi Eldorado - 1974 Kawasaki H2B - 1974 Triumph TR5T Trophy Trail - 1981 Ducati 900 SD - 1986 Husqvarna 400 WR - 1998 Suzuki TL1000S - 1998 Suzuki TL1000S - 2007 Ducati Hypermotard 1100S - 2008 Suzuki DR780.

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05-30-2011, 11:03 AM	#5
GutterTrash Studly Adventurer Joined: Jul 2010 Location: downJersie Oddometer: 574	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