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Old 10-15-2012, 04:07 PM   #70126
sharpblade
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Joined: Jul 2006
Oddometer: 73
I havn't had a dr650 for 3 years. But today I bought a new 2012 charcoal gray one. Rode it home from the dealership about 40 miles and was so impressed. I had forgotten how nimble it was. So excited and I'm 65 years old.
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Old 10-15-2012, 04:29 PM   #70127
PPCLI-Jim
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Location: Victoria BC where I ride year round.
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ohhhh man! people have to stop linking to your site! My list of "gotta haves"
get's bigger every darned time.


I know that feeling . every time my CC comes close to getting paid off i see a shiny Farckle.
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Old 10-15-2012, 04:49 PM   #70128
Sierra Thumper
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Joined: Oct 2012
Oddometer: 641
Quote:
Originally Posted by deathu View Post
Just a quick note, DO use the clip on the vacuum cap. I did not know about this, and although it was a tight fit mine just fell off during a ride, maybe some 300 miles after installing the tank. The crazy exhaust popping at idle immediately got me thinking of a vacuum leak. Anyway, not a nice thing to fix on the side of the road.
From a lifetime of riding dirt and street, I've learned to secure EVERYTHING on my machines extra well, good clamps, springs, lock/jam nuts, zipties, locktite etc just to be safe. It completely stopped me from having parts loosen up on rides
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Old 10-15-2012, 05:24 PM   #70129
Feyala
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Joined: Aug 2011
Location: Wandering...
Oddometer: 358
Dead DR - ignition?

Long story short, I parked my DR, returned an hour later, it tried to crank once and from that point forward the starter button is about as useful as tits on a bull.

There is no clicking sound when I push it. Nada. The headlights and signals etc still work.

Being in possession of a manual, I set to work. I have checked the following:

* Starter relay is not getting juice when I push it.
* Already disabled the kickstand switch, rechecked the wires and appears to still be kosher.
* Disabled the clutch safety switch by plugging the wires together.
* The PO destroyed the handlebar kill switch, I have double checked these wires twice now and they appear fine.
* Checked neutral connector, seems fine.
* Diode is fine.
* Fuses appear unbroken.
* Battery appears to be in good condition, and no drop in voltage when starter button is applied (expected).

I have some kind of open circuit before juice hits the starter relay, this much seems obvious to me. Especially as headlights work.

The manual does not offer a procedure to test the ignition switch, and google has failed me. I am certain rain has been getting inside - the flap that closes when you remove the key does not work. I have had to use graphite to get the cylinder to move the last few days (new) and the bike was drenched overnight the day before this started.

I would like to know:
* How to test the ignition switch, hopefully without disassembling it?
* What process would you follow to test the wires themselves for an open circuit? Where to begin?
* Is there a temporary way to bypass the ignition switch for testing purposes? I have found info on permanently removing it but I would like to keep the ignition for security.
* Anything I may have overlooked?

I am completely new to diagnosing electrical problems (today was the first I've used a multimeter) so please "dumb down" any advice.

Thanks in advance! This is a real downer mid-tour!
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Old 10-15-2012, 06:14 PM   #70130
ER70S-2
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Location: SE Denver-ish
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Quote:
Originally Posted by sharpblade View Post
I havn't had a dr650 for 3 years. But today I bought a new 2012 charcoal gray one. Rode it home from the dealership about 40 miles and was so impressed. I had forgotten how nimble it was. So excited and I'm 65 years old.
Welcome, '47 was a very good year. You'll need a seat.

Quote:
Originally Posted by Feyala View Post
Long story short, I parked my DR, returned an hour later, it tried to crank once and from that point forward the starter button is about as useful as tits on a bull.

Thanks in advance! This is a real downer mid-tour!
Mine does that about once a year and it's been loose battery terminals.
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Old 10-15-2012, 07:29 PM   #70131
Feyala
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Joined: Aug 2011
Location: Wandering...
Oddometer: 358
Quote:
Originally Posted by ER70S-2 View Post
Welcome, '47 was a very good year. You'll need a seat.

Mine does that about once a year and it's been loose battery terminals.
Battery terminals are fine.

While doing my "Murphy check" before worrying about the ignition, I pulled apart the starter button itself. I accidentally bridged the solder points on the back of the button and it fired up and ran like a top. Going to try to repair the button or replace it with something from Radioshack. I feel dumb but not as dumb as I would have if I paid for somebody to haul me back to Portland.
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Old 10-15-2012, 07:32 PM   #70132
oktulsa17
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Joined: Sep 2007
Location: God's country and he can have it.
Oddometer: 207
Running rough at altitude

This may have been covered somewhere but I'm too lazy to look. Took my '06 to New Mexico recently and it had real problems trying to get to speed as the altitude rose Crossed the Continental divide and on I-40 just had real problems staying out of everybodies way. Just cutting out and spuddering alot. I bought it used and I think the carb has been monkeyed with. It was doing this to some extent in OK at closer to 600 ft, but was real noticeable in NM.

It's back to 'normal' but I'd like to get it running better and maybe know what to do to max performance when I get to altitude.
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Old 10-15-2012, 07:36 PM   #70133
trailrider383
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Joined: Jan 2008
Location: NP, ID
Oddometer: 3,114
Quote:
Originally Posted by Feyala View Post
Long story short, I parked my DR, returned an hour later, it tried to crank once and from
The manual does not offer a procedure to test the ignition switch, and google has failed me. I am certain rain has been getting inside - the flap that closes when you remove the key does not work. I have had to use graphite to get the cylinder to move the last few days (new) and the bike was drenched overnight the day before this started.
I found out the other day what water in the ignition switch can do. I washed the DR good and started it up and let it run for a few minutes. Turned the key to off and it was still running. I had to kill it with the kill switch. Tried it several times and the key woudn't kill it. The next day it dried up and worked perfect again.
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Old 10-15-2012, 07:42 PM   #70134
motolab
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Joined: Feb 2006
Oddometer: 2,319
Quote:
Originally Posted by oktulsa17 View Post
This may have been covered somewhere but I'm too lazy to look. Took my '06 to New Mexico recently and it had real problems trying to get to speed as the altitude rose Crossed the Continental divide and on I-40 just had real problems staying out of everybodies way. Just cutting out and spuddering alot. I bought it used and I think the carb has been monkeyed with. It was doing this to some extent in OK at closer to 600 ft, but was real noticeable in NM.

It's back to 'normal' but I'd like to get it running better and maybe know what to do to max performance when I get to altitude.
How many miles are there on the carb? What monkeying has been done?

Regards,

Derek
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Old 10-15-2012, 08:22 PM   #70135
Chill
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Joined: Aug 2012
Location: QLD Australia
Oddometer: 303
Quote:
Originally Posted by Feyala View Post
Going to try to repair the button or replace it with something from Radioshack. I feel dumb but not as dumb as I would have if I paid for somebody to haul me back to Portland.
If you go for something from radioshack you want to be asking for a "waterproof push-to-make" button. This will then only be completing the circuit whilst it is being pushed. Also can be called a N.O. switch, N.O. standing for "Normally Open"
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Old 10-15-2012, 09:18 PM   #70136
Feyala
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Joined: Aug 2011
Location: Wandering...
Oddometer: 358
Quote:
Originally Posted by trailrider383 View Post
I found out the other day what water in the ignition switch can do. I washed the DR good and started it up and let it run for a few minutes. Turned the key to off and it was still running. I had to kill it with the kill switch. Tried it several times and the key woudn't kill it. The next day it dried up and worked perfect again.
Yikes! Thanks for the heads-up! Could be a problem especially with no kill switch... I will try to find something to cover it when not in use.


Quote:
Originally Posted by Chill View Post
If you go for something from radioshack you want to be asking for a "waterproof push-to-make" button. This will then only be completing the circuit whilst it is being pushed. Also can be called a N.O. switch, N.O. standing for "Normally Open"
I managed to cut clean and re-solder everything. Its a bit worse for wear but works well. Plugged up the kill switch hole with silicone so hopefully it stays dry this time.

If it screws up again (a distinct possibility) I know what to ask for though so thanks!
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Old 10-15-2012, 09:56 PM   #70137
Adv Grifter
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Location: Passing ADV Stalkers in California
Oddometer: 6,128
Quote:
Originally Posted by Feyala View Post
Battery terminals are fine.

While doing my "Murphy check" before worrying about the ignition, I pulled apart the starter button itself. I accidentally bridged the solder points on the back of the button and it fired up and ran like a top. Going to try to repair the button or replace it with something from Radioshack. I feel dumb but not as dumb as I would have if I paid for somebody to haul me back to Portland.
Good work! I suspected it would be one of the several cut outs mentioned. (clutch switch, kick stand or kill button).

WD40 works wonders on these issues. Many times just a good flush with WD will chase out water and allow current to flow.

The other thing that can happen if you let the bike sit in rain too long is the starter can flood out, rust up and get nasty.
Over time if it gets wet a lot it will corrode inside. Pull it apart and scour it well, re-grease and put back together. May need new brushes but should be OK.

Sounds like a nice Bike Cover should be on your X mas list.
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Old 10-15-2012, 09:58 PM   #70138
neo1piv014
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Joined: Aug 2011
Location: Albuquerque, NM
Oddometer: 619
Just cleaning up some of the older parts on this bike, I've noticed that my turn signal switch has been very...sticky...for lack of a better word, and sometimes requires multiple strong presses to actually disengage the signals. At this point, it's mostly just irritating, but getting it moving smoothly again would go a long way towards helping the way this bike feels. Is there a particular kind of lubricant that I should use to grease it up if I took it apart, or is there maybe a relatively inexpensive place to order a brand new set of switch gear for my bike?
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Old 10-15-2012, 10:12 PM   #70139
ER70S-2
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Location: SE Denver-ish
Oddometer: 5,741
Quote:
Originally Posted by neo1piv014 View Post
Just cleaning up some of the older parts on this bike, I've noticed that my turn signal switch has been very...sticky...for lack of a better word, and sometimes requires multiple strong presses to actually disengage the signals. At this point, it's mostly just irritating, but getting it moving smoothly again would go a long way towards helping the way this bike feels. Is there a particular kind of lubricant that I should use to grease it up if I took it apart, or is there maybe a relatively inexpensive place to order a brand new set of switch gear for my bike?
Quote:
Originally Posted by Adv Grifter View Post
........ I suspected it would be one of the several cut outs mentioned. (clutch switch, kick stand or kill button).

WD40 works wonders on these issues. Many times just a good flush with WD will chase out water and allow current to flow.
Grifter has ya covered.
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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 10-16-2012, 01:45 AM   #70140
Magnum Noel
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Location: Wellington NZ
Oddometer: 179
Quote:
Originally Posted by sharpblade View Post
I havn't had a dr650 for 3 years. But today I bought a new 2012 charcoal gray one. Rode it home from the dealership about 40 miles and was so impressed. I had forgotten how nimble it was. So excited and I'm 65 years old.
Put some pics up sharpblade and let us have a look
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