the DR650 thread

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

  1. thetable

    thetable Long timer

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    Is that a silicone cover or potting compound? Definitely looks like the latter, which would just be poured in and allowed to cure. It is odd that they wouldn't use enough to cover everything though.
  2. Mongle

    Mongle Knuckle dragger

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    I don't know if I would call that normal...:lol3 I refuse to pull mine off and look at it now...I do not want to know if mine looks like that...because if it did it would bother me....
  3. procycle

    procycle Long timer

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    Evidently there is some crystalline filler used with the rubbery (silicone?) potting material. Looks to me like some of the filler was not very level when they poured the potting material in.
  4. eakins

    eakins Butler Maps

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    please explain that more in detail, step by step with the proper torque specs, if you have all that info. that would also be good for krusty's DR index.


  5. ChromeSux

    ChromeSux Plated and screwed

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  6. Paddle007

    Paddle007 Been here awhile

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    That filling in the CDI box reminds me off the Ford modules from the mid 70s to the 80s. I have seen many of those that were so hot it dripped down the inner fender. Never seemed to bother them.
  7. Adv Grifter

    Adv Grifter on the road o'dreams

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    As noted in above post. In A&P school we learned to do criss cross or star patterns on most assemblies, and doing 3 stages of tightening to ensure
    even pressure and alignment. No idea if Suzuki provide more detail on this. I've never seen any specifics ... just following standard practices.

    One thing to add: Once everything is loose ... make certain motor is fully seated correctly and not hung up anywhere. Basically, just wiggle it around a bit and look at motor mounts to see if all looks OK. Then tighten back up. Look specifically for cracked mounts, bolts or frame bosses.

    The more I read, more I feel its a counter balancer issue. But just a guess.
  8. isaac004

    isaac004 Been here awhile

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    Ok, per the suggestion of inmates here I did verify a few things:
    -With the front axle clamp loosened (and the axle tight), I still experience the same stiffness.
    -I purchased a Motion Pro Fork Alignment Gauge, which verifies that the forks are parallel when measured below the fender and just above the brake rotor.

    I also noticed today a strange noise today, which I recorded. The noise sounds like a clunking during each compression/rebound. The "stiction"/drag I am feeling may be more related to damping then actual friction...kind of hard to explain.

    Watch the video and let me know what you think. Notice the noise, and how I have to pull the bike up and "aid" it on its rebound to return to a somewhat normal ride height.
    <iframe width="560" height="315" src="http://www.youtube.com/embed/eI5ZEIfTJ_g" frameborder="0" allowfullscreen></iframe>

    http://www.youtube.com/watch?v=eI5ZEIfTJ_g

    I'm wondering if there is something wrong with the Ricor Intimidators, be it product flaw or operator error.
  9. Jammin

    Jammin Living on a DR

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    That is weird but at least good to know it's "normal" :huh

    I can't imagine Suzuki made all of these CDIs like that. There must be some design function for that then, right? Maybe cooling off the capacitor...

    Ok, now for testing a CDI from a late model DR in an old DR. Jeff, do you have access to a 2006 or thereabouts CDI?

    I was told by a mechanic in South Africa that Suzuki introduced a sort of anti-theft feature (to prevent hot wiring) on the DR by changing the resistance in the ignition switch over the model years so that a CDI from a late model couldn't be put into an old DR. Im not sure how true this info is. If it is true, I need to figure out what resistance the 2006 CDI needs and figure out a way to mod my ignition switch to match that.
  10. planemanx15

    planemanx15 Long timer

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    Setting: 2 up with a top case, on a really curvy back road in my area, my friend on his 2008 R6. He couldnt believe that the mighty DR was able to handle the curves and keep up with him through it all! Granted he is riding a year less than me, but has almost double the miles...Gotta love the Doctor! :D
  11. thetable

    thetable Long timer

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    Is it possible that the Intiminators were installed upside down? It looks like the way they are supposed to work, only backwards.
  12. isaac004

    isaac004 Been here awhile

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    That is possible. I install them in the orientation you see here, with the nut side pointing up to the sky. I did this because it is how the Gold Line Emulators are installed.
    [​IMG]

    I did buy this bike with Ricor's second hand, so I do not have the instructions. Can someone verify if this is the right orientation, and/or provide a copy of the instructions?
  13. procycle

    procycle Long timer

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    Suzuki calls for the same CDI part number from 1998 to current. 96 and 97 are a different part number but I don't know exactly what the difference is.

    The anti-theft resistor is in the key switch which is also the same for 1998 to current with 96 and 97 being different. That makes me think that your SA mechanic is correct but it would only apply to 96 and 97 bikes. I couldn't find any mention of what year your bike is.

    HERE are instructions for eliminating the factory key switch and replacing it with a simple on/off switch. Details for wiring in a separate resistor can be found there.
  14. Escaped

    Escaped Been here awhile

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    I have the instruction at home, but yes they slide in "bolt side up" and add about 1/2 inch to preload.

    With the Intiminator you must use 5W fork oil.

    There is a good thread here on adv rider with pictures on the installation procedures.

  15. Escaped

    Escaped Been here awhile

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    Here you go :evil

    http://www.advrider.com/forums/showthread.php?t=468588

    [​IMG]

  16. thetable

    thetable Long timer

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    That should be correct. Since no modifications are necessary to install them, you should be able to just pop them out too, and see if the issue resolves itself. Could be that one is bad. They should keep the front end from compressing while pushing on the handlebars, not from rebounding.
  17. isaac004

    isaac004 Been here awhile

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    Thanks all for posting and verifying the correct orientation of the Intiminators. I did install them in the correct position, so I am still puzzled and confused on why my fork is making the sounds that it makes, and moves slowly.

    I think at this point I just need to disassemble it again and inspect.
  18. planemanx15

    planemanx15 Long timer

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    I don t have a noise, but have the same issue with my forks. When I start to brake for a light, my forks move quickly through the first 2 inches, then slow. When I stop, they don't spring back until I start to throttle up and take off. Strange issue, not sure where to start so I'm just "observing" for now lol
  19. Mongle

    Mongle Knuckle dragger

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    Sounds to me like there isn't any preload on the spring. Maybe hearing it rattle inside? Which would also make the fork rebound slowly. Just a thought.
  20. eakins

    eakins Butler Maps

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