DR650 owners Beware! Neutral Sending Unit screw up!

Discussion in 'Thumpers' started by Bubba Bauer, May 25, 2011.

  1. Bubba Bauer

    Bubba Bauer Been here awhile

    Joined:
    May 25, 2011
    Oddometer:
    156
    Location:
    Lower Mitcham SA
    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... :cry

    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 Files:

    #1
  2. Bubba Bauer

    Bubba Bauer Been here awhile

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    Oddometer:
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    Location:
    Lower Mitcham SA
    some more lovely pics

    Attached Files:

    #2
  3. Eggsontoast

    Eggsontoast Adventurer

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    That's a real spanner in the works (no pun intended).:yikes

    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
    #3
  4. ADV8

    ADV8 Taumarunui..Darwin..

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    Ouch.
    Do you have a pic of the screw that caused the damage
    What of the neutral sensor itself ?
    #4
  5. GutterTrash

    GutterTrash 8UP

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    downJersie
    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
    #5
    SkunkWizard likes this.
  6. kimmie

    kimmie Adventurer

    Joined:
    Dec 15, 2013
    Oddometer:
    20
    Location:
    Sydney, Australia
    Sorry in advance for resurrecting the dead.

    The info on the forum has been a great help with the NSU unit on my DR.

    As instructed by all web notifications from other DR650 owners Karl has taken out the clutch basket found the NSU and "lock tight" in the possible offending bolts. They aren't going anywhere now.

    So I took her out for a spin yesterday and the neutral light is working. However as the engine gets warmer the neutral light at first decides to work intermittently and then not at all.

    After about 1 hour, I stopped for about 15 mins got back on and the neutral light is working again but then starts this whole "will I work this time or not" rubbish.

    I have no doubt that the NSU bolts are stuck fast but I'm now thinking that it's heat related (all the electrics have been checked and there are no issues).

    Can anybody shed some light (sorry for the pun) to the issue.

    Thanks heaps,
    Kimmie
    #6
  7. ER70S-2

    ER70S-2 Long timer

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    Your neutral light is a regular bulb, make sure it's plugged in tightly.

    Also check that this connector is fully plugged in. It's under the seat and immediately behind the gas tank, left side.

    [​IMG]
    #7
  8. Thumpstart92

    Thumpstart92 Been here awhile

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    Holy Moly! That's disturbing
    #8
  9. kimmie

    kimmie Adventurer

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    Thanks ER70S-2.

    The bulb and connector have both been checked and are in good order and all connections are sound.
    #9
  10. ER70S-2

    ER70S-2 Long timer

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    :hmmmmm
    Another guess: you're in Australia so I think you use 3 wires to the NSU switch. That's a second plug we don't use here. You can see it in my NSU pic, it's the green/blue, red/black wire on the left of the frame rail and the unused white plug is on the right (under the circled plug). Is it secure too? :scratch
    #10
  11. Karlxx

    Karlxx Dirt Curious

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    Hi, I am kimmie's other half. BTW the NSU is behaving exactly the same before and after loctiting the fasteners in. The NSU bolts were not coming out, but they certainly were not tight at all.

    I traced the loom from the bulb back to where it enters the crankcase. All the connector contacts are clean and no amount of wiggling and bending of the wiring loom will get the bulb to go out (at least while the bike is cold).

    I also cleaned the NSU contacts when I loctited the bolts in. The sensor was in good shape. The wires were sound and the "potting" was intact. So I am thinking that replacing the sensor is the next step.

    So has anyone heard of the issue with NSU not working when hot?
    #11
  12. kimmie

    kimmie Adventurer

    Joined:
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    Oddometer:
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    Location:
    Sydney, Australia
    Thanks everyone for all the assistance in this thread and others throughout the forum.

    Karl tried and checked everything however we couldn't get the sensor to operate as it should.

    So I bought a new sensor unit....I know most of you just remove the damn thing and forget about the light but I like to have the light.

    Anyway, you know what.....it works just like it's supposed to (happy me). The cost of the unit was $73 AUD from the local Stealer plus Karl's time (lucky I have a good rate on that...lol)
    #12
  13. ER70S-2

    ER70S-2 Long timer

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    :thumb Thanks for the follow-up, this is the first time I've heard of the switch failing. I like having the light also. :freaky
    #13
  14. tasamoto

    tasamoto n00b

    Joined:
    Jan 21, 2016
    Oddometer:
    5
    Location:
    Galashiels, Scotland
    I have 97' model, the neutral light has not been working since I bought the bike. I've had few rides on it but reading above decided to check it out.
    the first 'thing' which drop down from the engine while I unscrew the oil drain bolt was... NSU screw...
    When I've removed the cover the second screw was loose and in half way to join the first one.
    I've screwed them back tightly with loctite, unfortunately NSU light still not working. so need to check all the section through...
    #14
  15. Carl Childers

    Carl Childers Ghost in the Machine

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    Go to the DR650 Thread there is information galore over there on this sublect and members who will be tripping over each other to help you out.
    #15
  16. Zapp22

    Zapp22 ZAPP - Tejas

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    I assume you replaced the bulb?
    my bulb went out - scared me... checked/rechecked the nsu it was fine. finally got the bulb fitted correctly - ok now
    #16
  17. ER70S-2

    ER70S-2 Long timer

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    Since one screw was out and the other half way out, the spring and/or plunger may have also fallen out.
    [​IMG]
    #17
  18. tasamoto

    tasamoto n00b

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    thanks for advices, yes I've checked a bulb and was ok, and i'm sure I saw the plunger, need to check for the spring
    #18
  19. tasamoto

    tasamoto n00b

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    Oddometer:
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    i've checked the NSU and as ER70S-2 pointed there are not the spring and plunger behind the unit. at first should i worry about it?!? should i use kind of magnetic tool to try to find and to pick up the spring and the plunger from the engine?
    and if i not find them, can i just buy somewhere those two items? I've plugged the NSU to negative and the neutral bulb lighted, so just need these two parts to fix the problem
    #19
  20. ER70S-2

    ER70S-2 Long timer

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    I wouldn't worry about the spring near as much as I'd worry about the plunger. If you're lucky the spring will get chewed up in the gears and collected by the oil filter, which may have already happened. If you can find the plunger with a magnet, add a magnetic drain plug to pick up the remaining spring (or its pieces) and then 'hope for the best'.

    The plunger won't just lie in the bottom of the engine, there are hurricane like forces, caused by oil flow, happening in the crankcase; just waiting to wash the plunger back up into the transmission, a bad thing.

    The spring and plunger are available separately, parts #34, 35.
    [​IMG]
    #20