DR650 project: known issues, problems and the fixes!︱Cross Training Adventure

In our first vid we talked about how the DR650 is great value for money and provides such a solid base for adventure riding, dual sport or commuting. But unfortunately they can't do a serious update of the bike as otherwise they'll have to do a major overhaul to meet new emission requirements, and it won't be a cheap bike anymore. So Suzuki just does minimal updates. This is a summary of everything that we think needs attention and will be addressed through this DR650 video series. Some of these issues have been fixed in recent DR650 models. Just pause to read the detailed info. Dodgy little fuel filter: Suzuki have put a tiny little sock fuel filter here. It takes very little to clog this up, so if your bike is ever starving for fuel check this before anything else. We recommend removing it and putting a decent one in like this. NSU bolts: Sitting under the clutch is a little black plastic plate called the neutral sending unit. It senses when the bike is in neutral and triggers that green light on your dashboard. These screws can work loose over time, drop into your crankcase and potentially ruin your gearbox. I have been informed these have been loctited since 2012. Some guys just fit longer screws and Loctite them, others wire them safely. If your DR650 neutral light ever flashes or disappears, stop riding immediately and check it isn't these bolts at fault! You will often hear a weird sound as the loose screws vibrate. Wheel bearings: The Suzuki accountants thought they could save three cents on each bike by only having seals on one side of the wheel bearings. This isn't a huge issue, but if you'll be doing deep creek crossings we'd recommend fitting bearings with two seals immediately... otherwise just put decent bearings in when the originals wear out. Rubber mounted pegs: This is just bizarre. Whenever you stand on the DR650 these pegs bend and it feels as if your boots will slip off, which they might if there's plenty of mud. At the very least get some wider washers which will bypass the rubber grommets and let you stand like a man should, whether he's riding an adventure bike or pissing in the toilet. We suppose this is meant to reduce vibration but couldn't feel any difference after fixing the pegs in place. DR650 Upper chain roller: There is some debate on this, but most feel this is completely unnecessary and is likely to snap off eventually when the rear suspension takes a big hit. It then leaves a hole which can allow water and mud through to rust your frame from within. Remove it and fit a 8mm-1.25 thread set screw. I have removed it on some bikes, left it on other times. It's never caused me problems. Counter shaft seal retainer: Surprise surprise, this is a known issue Suzuki actually fixed, and it only took them 17 years to do so. The countershaft seal can pop out, then you lose most of your engine oil, potentially on to the rear tyre to get you sliding around speedway style on the road. There is a cheap aftermarket DR650 plate available, definitely get one of these as cheap insurance against seizing your engine. These were finally fitted as standard on 2013 models onward. Stock part is 24751-32E00

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Видео DR650 project: known issues, problems and the fixes!︱Cross Training Adventure канала Cross Training Adventure