the DR650 thread

Discussion in 'Thumpers' started by sleepywombat, May 1, 2006.

  1. Dyno

    Dyno Conquistador

    Joined:
    Nov 10, 2006
    Oddometer:
    2,038
    Location:
    Bottom of Lake Huron
    A suzuki fable.

    A young boy (it's my story, dammit!) caves in and get a DR650SE. 2000 model, pretty good shape, "the Neutral light stopped working last fall". :eek1

    It's home less than 5 minutes when he turns it on it's side and tears the cover off to rip the clutch out.

    Problem # 1: The bolt next to the clutch cable mount. It's open to the elements on the back side of the threads.

    [​IMG]
    (If this bolt comes out of your case intact, put some never seize on it while you still can.)

    A few well placed curses and a stainless EZ-lok insert later, the young man returns his attention to the NSU. He looks for the screws that are supposed to be falling out. They aren't. Not very tight, but intact. Instead, he finds a bad solder joint:

    [​IMG]


    The dude re-does the solder joint, and adds red loctite AND safety wire.
    [​IMG]
    If the light stops working again, the guy will ride without worry after re-arranging some wires on the relay.

    The moral of this story?

    Sometimes a bad switch is just a bad switch.

    (But at least now I'm not worried about it, I know what shape the clutch is in, and all the bolts are removable again.)


    And then they lived happily ever after.
    [​IMG]
    The End
  2. Lil' Steve

    Lil' Steve PussyWagon™ Chauffer

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    Oct 3, 2006
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    NYC, AZ

    I love a happy ending. :cry
  3. BlackBeast

    BlackBeast Been here awhile

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    Jul 7, 2006
    Oddometer:
    984
    Location:
    Ontario, CANADA
  4. (none)

    (none) poser

    Joined:
    Jan 25, 2007
    Oddometer:
    2,666
    Location:
    Middle of nowhere Georgia
    So what is that plastic gear in there? I don't like plastic parts in motors, especially gears...
  5. DRPhoenix

    DRPhoenix Viking

    Joined:
    Feb 17, 2007
    Oddometer:
    215
    Location:
    British Columbia
    Know what I need to do, just wondering if anyone else has experienced this. Last years tire change went over small dent in front rim, this years tire change reveals dent turned into crack:eek1 (upper left of photo).
    [​IMG]
  6. SkunkWizard

    SkunkWizard recycle crime scene tape

    Joined:
    Mar 26, 2009
    Oddometer:
    914
    Location:
    "the Planet Van Nuys"
    Give it the float test by the famous Carroll Smith

    Throw it in the ocean, if it floats it's still good
  7. blackcap

    blackcap Been here awhile

    Joined:
    Jul 21, 2008
    Oddometer:
    565
    Location:
    Wollongong aka stink-town, Australia
    yes, the pilot jet, sorry, late at night etc etc. and after inspecting the old pilot jet there certainly was a speck of crud lodged in there. its the little black dot inbetween the pilot jet and single strand of electrical wire i used to push it out with. for reference, the wire is about 0.28mm diameter.

    [​IMG]
  8. WARRIORPRINCEJJ

    WARRIORPRINCEJJ Crazy, on a ship of fools...

    Joined:
    Jun 29, 2009
    Oddometer:
    17,570
    Location:
    Leanna Decker's panties
    Well blackcap, is your bike squared-away, and ready to take on the world?...


    .
  9. Krusty ...

    Krusty ... What? Me hurry?

    Joined:
    Dec 18, 2004
    Oddometer:
    7,606
    Location:
    Richardson, TX


    Oil pump gear.
  10. DRPhoenix

    DRPhoenix Viking

    Joined:
    Feb 17, 2007
    Oddometer:
    215
    Location:
    British Columbia
    :D It surely would float, but thinking I must have nailed it close to the factory weld point. Looking to relace hub to a better than stock rim, so looking to the DR650 thread for the usual awesome advice and tips.

    Cheers, Alex.
  11. AKoffroader

    AKoffroader Adventurer

    Joined:
    Jun 20, 2008
    Oddometer:
    506
    Location:
    Chugiak Alaska
    Freaky

    Thanks for taking the time to post this comparison. I'm thinking about a Sargent seat as well, looks good!!!

    I know what you mean about the V Strom thing. Had one for a month last summer. Put around 1,000 miles on it and sold it. Great bike but just kind of boring. I'm a dual sport guy. The V Strom is a road bike no matter what they say.

    AK Greg
  12. blackcap

    blackcap Been here awhile

    Joined:
    Jul 21, 2008
    Oddometer:
    565
    Location:
    Wollongong aka stink-town, Australia
    just a few more tweaks here and there. still need to get through the run in period with the new transmission then ill dial in the carb some more when im more confident opening the engine up fully. for now she is good to run around though and ill try to start a rebuild thread somewhere here if anyones interested.
  13. ADV8

    ADV8 Taumarunui..Darwin..

    Joined:
    Nov 10, 2007
    Oddometer:
    2,385
    Location:
    North of Sydney.
    You should see how much it wobbles even from new. :lol3

    The pin it rides on is not fixed in the case but relies on a circlip allowing movement in and out,up and down.
    Never read of a failure but it seems hokey,maybe the floatyness is what stops it wearing out or flying to bits. :D

    [​IMG]
  14. Elvis70

    Elvis70 No speed traps in the sky

    Joined:
    May 8, 2008
    Oddometer:
    5,058
    Location:
    Fayetteville, AR
    I have the Sargent. Ride all day on it, and I could not do that on the stock seat. I love it.
  15. ADV8

    ADV8 Taumarunui..Darwin..

    Joined:
    Nov 10, 2007
    Oddometer:
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    Location:
    North of Sydney.
    I could ride all day on the stock seat.
    I can ride all day on the Corbin.
    The difference between them is the day after. :lol3
  16. Adv Grifter

    Adv Grifter on the road o'dreams

    Joined:
    Jan 18, 2010
    Oddometer:
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    Location:
    Passing ADV Stalkers in California
    I've read of a few cracked plastic gears, not broken IIRC. This was back probably 10,000 posts ago! :D

    I believe it was Lucas or Nordie Boy who suggest to replace it on high mileage bikes if your inside there anyway. Not ever likely to fail but it's not an expensive part, easy to do, so why not? I know I will do mine next time, I'm at 30,000 miles.

    BTW, clutches on DR650's do NOT ever seem to wear out!

    I worry a little about HIGH HEAT and OIL contamination slowly degrading the plastic gear's integrity over time. Any Industrial Chemist's out there? :ear

    I wonder what would happen if the gear broke? I imagine you'd hear it, but plastic bits should not break anything steel, right? As long as you shut it right off, should be OK regards losing oil pressure. But I guess the bits could clog oil passages. Roh Row! :eek1 What do you think?

    :ear:ear:ear
  17. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
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    7,172
    Location:
    Kiwiland
    Bung it up on the wiki.
    http://dr650.wikia.com/wiki/Main_Page
  18. NordieBoy

    NordieBoy Armature speller

    Joined:
    Dec 2, 2006
    Oddometer:
    7,172
    Location:
    Kiwiland
    Apparently mine is slipping a bit but the conditions have to be right.

    1. Good MT21 rear
    2. 2nd gear
    3. uphill stutter bumps
    4. 7,600rpm
  19. blackcap

    blackcap Been here awhile

    Joined:
    Jul 21, 2008
    Oddometer:
    565
    Location:
    Wollongong aka stink-town, Australia
    i havent managed it on the stock one just yet but the EBC kit went pretty quick after a fully loaded dash through central austraila and the simpson desert :1drink
  20. ADV8

    ADV8 Taumarunui..Darwin..

    Joined:
    Nov 10, 2007
    Oddometer:
    2,385
    Location:
    North of Sydney.
    Being roller bearing the pressure would be very low but a knock or rumble wouldn't be far off from the big end under any kind of load with 0 pressure. :D
    I was more concerned about replacing the suspect transmission gears at 50000 kms which should be sometime this year (work has cut riding time right back over the last 7 months or so)
    The clutch,if I had more machine tools here would be fitting a RMZ basket to the DR gear so a slipper centre could be fitted.