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Old 12-12-2012, 04:07 AM   #71776
TinMan207
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Joined: Feb 2009
Location: Southern Maine -- most days
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Trailtech Dashboard troubleshooting

installed a new Trailtech Vapor and Dashboard last night - the previous owner had one installed but between the miles and broken or chafed wires I decided to make it all new. When I took possession of the bike, the Vapor was mounted, but there was no Dashboard. When exploring the wiring harness last night I found what I assume was his old hookup - the dashboard plugged right into it and after a fashion seemed to work. Left directional light works. Right directional light works. High-beam light works. Neutral light works. In my mind I think "Score!"

Here is where my little story goes sideways. When I put the bike in gear the high-beam indicator light on the dashboard goes out. In the Vapor wiring harness these two lights share a ground (I think). I know, I should have taken pictures last night. I'll try to get over to my buddy's garage and do that later today.

Additional information:
The bike has an aftermarket light/directional/horn control - my best guess is Procycle's Mini handlebar control switch, this was all done by the previous owner.


It has an interesting feature where is will kill the headlight if you wish. When the bike is in neutral, everything works as expected. With the bike in gear, the headlight kill does not work.

I'm no wiring guy, but my buddy is pretty good. As I see it, I have 3 possible areas to focus on to troubleshoot this. The Trailtech wiring harness. The Handlebar Control unit wiring. OR the neutral sensor switch (whatever t iis really called).

Has anyone dealt with anything like this before, or have ideas or thoughts on troubleshooting this?

Thanks in advance
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Old 12-12-2012, 05:16 AM   #71777
phreakingeek
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on my 2nd DR

After taking a rock to the case a month ago and having the DR totaled, I was on the fence about what to do for a replacement bike. (you can see it happen at minute 2:10 here: http://www.youtube.com/watch?v=13cR80h-QNo&feature=plcp the rock i hit was sticking up a few inches out of the dirt and was less than a foot long and kind of pointed. Just bad luck that i hit it and it punched the oil drain up into the case and also caused the rear clamp on the skid plate to knock a hole in the back. The insurance company was going to fix the engine, but the bent frame tube was enough to push the repair cost over 85% of the bikes value.)

I had visions of a KTM 690 Enduro R...or possibly an XR560. I was looking for the holy grail of dirt/road. I weighed all the options and came back to the trusty DR.

I love the versitility and reliability of the DR. My riding buddy Mark is on his 3rd DR...went looking for the better bike and keeps coming back to the DR as well. Now that we're older and slightly wiser...our focus has changed from looking for the max performance to looking for max reliability and comfort. With a few mods, the DR is the only bike that seems to fit. Our motto is 'riding, not wrenching'

Quote:
Originally Posted by procycle View Post
+1 The WR250R is a pretty amazing little bike but like Grifter says nothing is going to be decent on trails and commuting and still be acceptable for hauling a passenger (except a DR650)

You might as well start shopping for your new DR now. You wouldn't be the first one around here to sell their DR only to get another one a year or so later.
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Old 12-12-2012, 05:59 AM   #71778
Mambo Dave
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Quote:
Originally Posted by phreakingeek View Post
After taking a rock to the case a month ago and having the DR totaled, I was on the fence about what to do for a replacement bike. (you can see it happen at minute 2:10 here: http://www.youtube.com/watch?v=13cR80h-QNo&feature=plcp the rock i hit was sticking up a few inches out of the dirt and was less than a foot long and kind of pointed. Just bad luck that i hit it and it punched the oil drain up into the case and also caused the rear clamp on the skid plate to knock a hole in the back. The insurance company was going to fix the engine, but the bent frame tube was enough to push the repair cost over 85% of the bikes value.)
It's difficult to get a feel for just how high up that launched you before you came down, but it obviously sucked.

Question for ya - did you have an upgraded suspension (stiffer springs) on that bike? It sort of looked like the stock springs, as I know mine are so weak that they'd 'disappear' underneath me if I tried anything like that. I'm just wondering if upgraded springs would have prevented some of the hurt (though it's tough to get away from the harm a poorly design skid plate will do).
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Old 12-12-2012, 06:01 AM   #71779
Dirtmonkey8
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Horror Movie

The sound of the rock hitting the case was brutal. And seeing the pig bleeding out like that was very sad. It must have made the rest of the day pretty interesting. Was that in VA or WV? The reddish clay looked familiar but not the straight and open road.
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Old 12-12-2012, 06:14 AM   #71780
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Quote:
Originally Posted by Thumper Dan View Post
Do you really have 75, 000 miles on your DR? Is that with the motor untouched or has the motor been reconditioned?

I only WISH that was my site and over 5 years of adventure. I don't know if Adam ( JediMaster here ) had any engine work done in those miles. I kept up with most of his posts and don't remember any rebuilds but a read through would tell you I guess.
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Old 12-12-2012, 08:15 AM   #71781
isaac004
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Wheels

Don't want to overstep my boundaries here, but just an FYI that I have a stock wheelset for sale in the Flea Market:
http://advrider.com/forums/showthread.php?t=848083
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Old 12-12-2012, 09:06 AM   #71782
TinMan207
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this is the wiring harness that I talked about



The top one is the Trailtech connection. New part is to the right, old/existing half is to the left.

The Bottom connection is the left-hand light/directional/horn switch connection that the previous owner had installed.

this is the aforementioned control switch

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When I was young I hoped to be Rich and good looking. At this point, I think that having great stories of many adventures is a much better plan

06 Suzuki DL650 (2 at the moment!) - 00 DR650
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Old 12-12-2012, 09:11 AM   #71783
805gregg
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[QUOTE=phreakingeek;20231724]After taking a rock to the case a month ago and having the DR totaled, I was on the fence about what to do for a replacement bike. (you can see it happen at minute 2:10 here: http://www.youtube.com/watch?v=13cR80h-QNo&feature=plcp the rock i hit was sticking up a few inches out of the dirt and was less than a foot long and kind of pointed. Just bad luck that i hit it and it punched the oil drain up into the case and also caused the rear clamp on the skid plate to knock a hole in the back. The insurance company was going to fix the engine, but the bent frame tube was enough to push the repair cost over 85% of the bikes value.)

What skid plate did you have?
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Old 12-12-2012, 09:12 AM   #71784
Rusty Rocket
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Just saying HI on 12/12/12 @ 12:12
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on one side the sign it said "Private Road", but on the other side it didn't say nothin'
2009 DR650
..1972 Penton Six-Days ..1971 Suzuki TS185.. 2005 KTM 400exc
Member of: AMA, NETRA, Blue Ribbon Coalition, CCCofVT, Berkshire TR, CT Ramblers
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Old 12-12-2012, 09:47 AM   #71785
ER70S-2
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Best I can do:

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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 12-12-2012 at 09:55 AM
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Old 12-12-2012, 09:48 AM   #71786
phreakingeek
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springs

That bike had the .80 fork springs and the 8.3 shock spring from Procycle. It was quite a bit stiffer than stock, but still not stiff enough. I didnt go very high, but the rock i landed on was about 20 feet from the water bar that i went over...I was doing about 30-35mph at the time. We've ridden that area a number of times and I've had a few incidents with rocks on the skid plate, but this one was just bad luck. Bottoming out on a flat landing with a rock right were the case would contact it.


Here's the rock:



Here's the damage (after i removed the skidplate that was also destroyed):


Quote:
Originally Posted by Mambo Dave View Post
It's difficult to get a feel for just how high up that launched you before you came down, but it obviously sucked.

Question for ya - did you have an upgraded suspension (stiffer springs) on that bike? It sort of looked like the stock springs, as I know mine are so weak that they'd 'disappear' underneath me if I tried anything like that. I'm just wondering if upgraded springs would have prevented some of the hurt (though it's tough to get away from the harm a poorly design skid plate will do).
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Old 12-12-2012, 09:50 AM   #71787
phreakingeek
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GW Forest

That was FDR72 in the GW Forest...VA side.

Quote:
Originally Posted by Dirtmonkey8 View Post
The sound of the rock hitting the case was brutal. And seeing the pig bleeding out like that was very sad. It must have made the rest of the day pretty interesting. Was that in VA or WV? The reddish clay looked familiar but not the straight and open road.
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Old 12-12-2012, 10:09 AM   #71788
phreakingeek
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skid plate

I had the Ricochet brand plate from Rocky Mountain. Now i have a Pat Walsh Designs plate on the new bike. Looking for ways to add some shock absorbing/damping to the mounts so that it will disperse impacts instead of transferring it directly to the frame.

I found a nice mount that would provide impact and vibration damping made by Sorbothane. Unfortunately, even their toughest material (Duro 70) doesnt provide enough shear strength for a skidplate. My riding buddy is working on a project to mount a skidplate then RTV a second skidplate to it. Hoping to get impact damping by spreading impacts over a larger area and adding extra strength with two plates...unfortunately, that means a lot of extra weight

[QUOTE=805gregg;20233212]
Quote:
Originally Posted by phreakingeek View Post
After taking a rock to the case a month ago and having the DR totaled, I was on the fence about what to do for a replacement bike. (you can see it happen at minute 2:10 here: http://www.youtube.com/watch?v=13cR80h-QNo&feature=plcp the rock i hit was sticking up a few inches out of the dirt and was less than a foot long and kind of pointed. Just bad luck that i hit it and it punched the oil drain up into the case and also caused the rear clamp on the skid plate to knock a hole in the back. The insurance company was going to fix the engine, but the bent frame tube was enough to push the repair cost over 85% of the bikes value.)

What skid plate did you have?
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Old 12-12-2012, 10:13 AM   #71789
NordieBoy
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Quote:
Originally Posted by phreakingeek View Post
Here's the damage (after i removed the skidplate that was also destroyed)
A perfect hit, just in the right place.

I keep thinking that shark fin needs to come off if a bash plate is on...
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Old 12-12-2012, 10:25 AM   #71790
Rusty Rocket
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Quote:
Originally Posted by phreakingeek View Post
That bike had the .80 fork springs and the 8.3 shock spring from Procycle. It was quite a bit stiffer than stock, but still not stiff enough. I didnt go very high, but the rock i landed on was about 20 feet from the water bar that i went over...I was doing about 30-35mph at the time. We've ridden that area a number of times and I've had a few incidents with rocks on the skid plate, but this one was just bad luck. Bottoming out on a flat landing with a rock right were the case would contact it.


Here's the rock:



Here's the damage (after i removed the skidplate that was also destroyed):
Yow! I hit a rock and dented my skid plate, but it wasn't dead center like yours. Mine was off to the side a bit. It got far enough in to hit the bolt. Just nicked the drain bolt and oddly enough loosened it slightly. I had no idea this had happened. Luck would be with me. It didn't fall out while I finished the ride. A friend was over a few days later and wanted to see my bike. Went into the garage and there was a small puddle of oil. After checking, I was relieved to find the bolt loose. I took off the skid plate and banged out the big ole dent and put it back on. Hope I never do a boingo like yours.
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..1972 Penton Six-Days ..1971 Suzuki TS185.. 2005 KTM 400exc
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