Pre '96 Suzuki DR650S

Discussion in 'Thumpers' started by DRS Canada, Dec 5, 2004.

  1. puntoMX

    puntoMX Lost in Cyberspace

    Joined:
    Sep 6, 2008
    Oddometer:
    398
    Location:
    Santiago de Querétaro, Mexico
    Hello Jeremy, yes it is possible and this is what I'm going to do:

    [​IMG]
    This is just a quick and dirty drawing, the gray part is the current assembly

    Now, from hearth to hearth (center to center), it will be 20.5mm; drill a hole of 10mm on both sides but they need to be exactly and straight. Now there is no need for bushings on the down part as the "legs" are spaced 30mm from each other, but you will need a 3mm longer bolt (could be that the old one fits without any problems). I'll be doing this in the next week or so, no way I'm going to do this with just a hand-drill so I need to take it to a workshop (a friend of mine has one :D ). I can live with a 2.5mm shorter shock. :evil

    [​IMG]
    Upper Bushing

    You see in the drawing it's 13.97mm long but that's 14mm, the 6mm radius is more like 6.5mm but that could be a tight fit.


    I use a KLR650 2008-2010 shock, I believe that the older KLR650 shocks are a bit longer but can't confirm that. I used bushings as future changes to an after-market KLR shock would be easier. I paid 140USD at eBay (plus shipping), mine has some 8500 miles on it they say but it is in a mint condition. After-market shocks can be found as low as 350USD but I couldn't find anything for the older DR.

    Replace your shock as soon as you can, corners are such a challenge with no oil in the shock as the tire would bounce and skip all over the place. :lol3

    -Ronald-
  2. Bnd1t02

    Bnd1t02 Adventurer

    Joined:
    May 22, 2010
    Oddometer:
    20

    Geez, even your quick and dirty is clean and pretty. Skillz. Mad Skillz. I could print these and run them down the street and the machine shop would impressed. Awsome work. Keep us posted on the the ride caracteristics and what kinda weight you put on her and what kinda sag you get with the weight.

    Jeremy
  3. Bnd1t02

    Bnd1t02 Adventurer

    Joined:
    May 22, 2010
    Oddometer:
    20
    Hey Ronald,

    In your pics your bike kinda looked like you had a smaller than stock front wheel? Is that right, or ya just runnin a more street friendly tire? Looks like you have a 18" (sportsman class sumo) although it could jsut be the angle.

    Just curious.

    Jeremy
  4. puntoMX

    puntoMX Lost in Cyberspace

    Joined:
    Sep 6, 2008
    Oddometer:
    398
    Location:
    Santiago de Querétaro, Mexico
    Hello jeremy, it's just the stock rim and a 90/90 - 21 M/C 54S Metzeler Tourance, rear is a 130/80 - 17 M/C 65S. They are cheap here, say 150USD for the pair, made in Brazil where most tires are coming from today (or from China). They do a great job on the pavement, best tire I ever have used, but... the sidewalls are a bit soft compared with the knobby ones. Here, off-road is mostly stone/rocks and compacted dry dirt, so, knobbies won't do any good for me.

    I'm still testing the KLR shock and I'm going to modify indeed the shock so the bike will be lower. Darn DR rollers are noisy so, I'll change those any way for ball-bearing ones. Control of the bike is so much better than before, yes, even before the old shock was leaking. It's worth it I would say, no need for an 400USD after-market shock.
  5. Trust

    Trust I'll fix that

    Joined:
    Jun 3, 2008
    Oddometer:
    1,525
    Location:
    pines & sand, NC
  6. knybanjo

    knybanjo kinda slow

    Joined:
    May 8, 2006
    Oddometer:
    25,055
    Location:
    out in the clover patch
    Yeah...I'm pretty sure that the counter shaft splines are the same.
  7. BigHerm

    BigHerm What Would Merle Do

    Joined:
    Jan 5, 2009
    Oddometer:
    627
    Location:
    Chicago
    looking for mirrors. I need the right for sure but will buy a set. I assume the 96 and on will fit. Anyone need to clean out the garage????
  8. tdrrally

    tdrrally Long timer

    Joined:
    May 16, 2008
    Oddometer:
    3,462
    Location:
    doing hard time in charleston,wv
    i will tell my set go for $50.00 shipped
  9. BigHerm

    BigHerm What Would Merle Do

    Joined:
    Jan 5, 2009
    Oddometer:
    627
    Location:
    Chicago
    found what I need on CL in 5 min for 5.00. thanks for the offer though
  10. tdrrally

    tdrrally Long timer

    Joined:
    May 16, 2008
    Oddometer:
    3,462
    Location:
    doing hard time in charleston,wv
    drat there goes my bar end mirrors:rofl

    congrats:D
  11. BigHerm

    BigHerm What Would Merle Do

    Joined:
    Jan 5, 2009
    Oddometer:
    627
    Location:
    Chicago
    pm braceface he has some to sell and he is too lazy to post them. Make him an offer
  12. Gibbonboy

    Gibbonboy Just Plain Lost

    Joined:
    Oct 4, 2008
    Oddometer:
    212
    Location:
    Suskyhanny County, PA
    I've been working on my 90 for a while, wanted to paint it and had an issue where it would quit in wet weather. Thanks to some folks on here, I tried several different things and the problem is gone. I bought the bike in Sep 08, rode it all over and was pretty happy with it. I'll list what I did to it, then some pics.

    New fork seals (I was being a puss about this, making a mountain out of a molehill, took me maybe 30 minutes once I actually did it)

    New plug boots, seals, etc.

    Repacked/rebuilt the muffler, and lowered the mounting by 1 1/2". The side panel and rear fender were badly burnt and melted by the leaking can and the tip rotating and pointing directly at the fender.

    Added a piece of metal on the rear fender where it melted, cut out the slotted area in the side panel, filled the hole with some mesh, and put a better heat shield inside the panel.

    Cut a Thermarest Trail seat into the seat foam, added about 1 1/4" of foam on the sides, and recovered it. I screwed up my first attempt, but I'll ride it for a while to see if I want to make changes before I cover it again.

    Removed the side stand switch.

    Still to do:
    Fab new windscreen, 1-2" taller.
    Paint my rubbermaid top box and remount.
    Make/buy a waterproof mount for my radio.
    Same for GPS.


    And some pics- what it looked like before I really started, I had stripped some of the decals off, especially the tank.

    [​IMG]

    And now:

    [​IMG]

    Closer shot of the seat and side panel:

    [​IMG]


    Anyway, been riding it for a few days and I'm really tickled. Thanks to all who contribute to this thread, keeping a 20-year-old thumper running is a full-time job (at least it seems like it). I expect the paint to chip and scratch, but touchups are cheap.
  13. Bnd1t02

    Bnd1t02 Adventurer

    Joined:
    May 22, 2010
    Oddometer:
    20
    Hey guys,
    Some of you are aware that I have been trying to sort out a motor mount
    crack on my engine cases. The first question is wether the 90-91 inner engine cases are the same as the 92-95? The reason I ask this is cause 685 sent me the manuals and there was a seperate one for the 90-91's. I am still new to these bikes and are unaware of the differences.

    My second question is if anyone has heard of torque related stress cracks on these motors? The very front motor mount hole under the oil return line
    has a crack around the perimeter of the form on the case. There is no dents, scuffs, scratches or replaced parts leading me to beleive this bike has had any traumatic impacts anywhere near the motor. The welder that I had look at it said that he has seen some torque related cracks due to loosened motor mount bolts. Anyone here of this or experience this?

    Jeremy
  14. tdrrally

    tdrrally Long timer

    Joined:
    May 16, 2008
    Oddometer:
    3,462
    Location:
    doing hard time in charleston,wv
    i have heard the crank on the e-start bikes is longer
    the case should be the same less the e-start mounts
    i would say any non e-start engine would be the same
    this would include the sp600 as well:D
  15. BigHerm

    BigHerm What Would Merle Do

    Joined:
    Jan 5, 2009
    Oddometer:
    627
    Location:
    Chicago
  16. 685

    685 Scarred Adventurer

    Joined:
    May 6, 2009
    Oddometer:
    1,041
    Location:
    Tucson (east side) AZ
    I've been traveling. . .not in sunny hott Tucson anymore for a while, but in overcast cool Western Washington, hoping at least until mid October. I'll be working driving a semi with double trailers to central WA and the Skagit valley (north of Seattle) to pick up fresh corn or carrots for a frozen food plant here in Chehalis.

    I brought the DR for my transportation--easier to trailer than a car--so it's my sole trans for the rest of the summer and into the mid autumn. It's a great bike, but is in it's 20th summer, so pray for me that it answers the call each day it's needed. Should be interesting if it needs something, my only other trans is a 28 foot motor home.

    While at my brother's (he had steel and a oxyacetelene torch) I fabricated some very simple and light duty saddle bag racks and mounted a box on the luggage carrier. Gotta be careful about weight, but for groceries and protective clothing it all should be effective. The side boxes are Pelican 1550 cases, btw. The box is one of those stocking boxes that they use to stock health and beauty aids in Grocery stores. With a top that actually closes (unlike a milk crate.)

    [​IMG]

    [​IMG]

    [​IMG]

    The only project on tap this summer is to get a new tube in the rear tire--the current one requires daily air checks.

    My DR got dangerously low on oil--I got overly distracted by other things. Check that oil, you guys!
  17. 685

    685 Scarred Adventurer

    Joined:
    May 6, 2009
    Oddometer:
    1,041
    Location:
    Tucson (east side) AZ
  18. BigHerm

    BigHerm What Would Merle Do

    Joined:
    Jan 5, 2009
    Oddometer:
    627
    Location:
    Chicago
    300 miles
  19. puntoMX

    puntoMX Lost in Cyberspace

    Joined:
    Sep 6, 2008
    Oddometer:
    398
    Location:
    Santiago de Querétaro, Mexico
    Part II on the KLR650 shock:

    [​IMG]

    I just did it with a handdrill, starting will a small 1mm drill, followed by a 4mm drill, 7mm drill,
    and finally a 9.9mm drill, I got it 0.5mm on the left side so I had to do it the same on the
    other side, most won't even see it.

    [​IMG]

    This is how it looks now, I could have cut the lower parts off but it doesn't border me to
    have those holes there.

    [​IMG]

    This is how the bikes looks now, the highest point at the back is now 101cm and seat height
    at the lowest point is 87cm. Shock is now set at 3 for pre-load and the max for rebound,
    I don't know what the KLR guys are complaining about but when that shock is lubricated and
    NOT under load, it's easy to set the pre-load to a higher level (Design fault my :kat).
    I also lowered the front by 12mm and see how that goes. I'm pooped, it's 01:26 AM :D.

    Will post back tomorrow... well, later today. :wink:
  20. nikolic

    nikolic Been here awhile

    Joined:
    Apr 27, 2007
    Oddometer:
    480
    Location:
    Serbia
    I must admit I expected you will leave the seat hight over the 90! But anyway
    nice job, for a good buck!