DR650 - Neutral light woes

[paulj]

If the neutral light on your DR650 stops working it may be a good idea to stop the bike immediately and investigate.

Mine did just that a month or so ago – I checked out the wiring and found a slightly corroded connector just under the seat on the left by the airbox (where the workshop manual said). A few squirts of CRC and presto – the neutral light returned and I put the seat back on and afterwards, me on the seat.

A few weeks later, it went out again – this time for good. A check with the meter and a jumper lead pointed me to the neutral switch inside the clutch cover.

A trawl of the web (ADV Rider) showed that there had been a few instances of the neutral switch holding screws working loose, the reasoning being that the plastic surround of the switch assembly, slowly deforms over time and the screws rattle out and drop into the crankcase - ouch. So – off with the clutch cover and the result you can see in the pics.

Where the screw is I do not know – the engine is to be stripped down this winter in an effort to get to the bottom of the third gear growl me and one or two others have heard so maybe it will pop out then!

Meantime – do I replace the screw and ride on oblivious? Hmmmm – bugger’d if I know!

And to really piss me off, we are getting day after day of clear blue skies and little wind. :crybaby:

[marks]

if it were me I would worry everytime I rode the bike imagining that freaking screw dropping between some gears or somesuch. I would have to do something about it..

what an absolute bummer

[Crisis management]

Love the tool kit, is that the expanded suzuki kit?

I wouldn't be too concerned about it, the screw will sit happily in the sump somewhere, get covered in gunge and stay put forever (probably).
The oil system has a mesh screen and filter that will prevent the screw being sucked up and it would be almost impossible to get it into the gear train as they are always in mesh.
Unfortunately, if you want it out you will have to split the cases to find it.

Good luck with that decision!

[paturoa]

I wouldn't be too concerned about it, the screw will sit happily in the sump somewhere, get covered in gunge and stay put forever (probably)..... it would be almost impossible to get it into the gear train as they are always in mesh.

If he rides his DR like I ride my KDX then, it being found upside down with the engine running is a possibility that may result in the screw going somewhere it isn't wanted.

[necrolyte]

You could put said bolt back in with a drop of loctite thread lock...

[scracha]

You could put said bolt back in with a drop of loctite thread lock...

The screw would get chopped up like a hot knife through butter.

[paulj]

Love the tool kit, is that the expanded suzuki kit?

Unfortunately, if you want it out you will have to split the cases to find it.

Good luck with that decision!

Yeah - I realise the case has to be split to get amongst the innards - that's a winter job - I had hoped the screw would be sitting provocatively in view but there seems to be a tangle of webs etc stuffing up that idea.

Decision: the remaining screw is loose so try and back it out without removing the clutch, then replace both with Loctite'd SSteel socket heads - I may need to grind down an Allen key to get in to tighten it - otherwise the clutch basket comes off too.

The lost one can stay that way - I've been close to upside down a couple of times so maybe it isn't going to be a problem in the short term.

No that is not the expanded Suzy kit - that precision adjusting tool is for use on the owner who is now a screw loose.

[What?]

If it helps you make your decision, I know a bloke who could tell you exactly what happens when KTM throw a surplus washer into the crankcase of one of their V-twins (it ain't pretty...)

[paulj]

If it helps you make your decision, I know a bloke who could tell you exactly what happens when KTM throw a surplus washer into the crankcase of one of their V-twins (it ain't pretty...)

Whaaaa - I have some idea of the mess that it could do - looking at the switch carefully shows that the bottom screw has been out for some time - the sender switch only started to show symptoms as the top screw has loosened and allowed it to disconnect from the operating pawl.

So far so good - the difference now is of course ... "I know about it".

However the owners of any DR650's with more than about 15k on the clock would be well advised to knock off the clutch cover and check the screws, replacing them with loctite'd 5mm x 20mm bolts.

[Crisis management]

However the owners of any DR650's with more than about 15k on the clock would be well advised to knock off the clutch cover and check the screws, replacing them with loctite'd 5mm x 20mm bolts.

Preventative maintenance!!!! Wash your mouth out boy. :eek5:

Good tip though, let us know how you get on with the whining 3rd gear as most DR's I know seem to have that problem and every owner so far just fits ear plugs or a louder exhaust.

[cooneyr]

Check if it has worked it way over to the other side of the engine and is now stuck on the stator (or whatever its called) magnets. Dont know much about the internals but guessing its not impossible. Other thing - the guys on the Yahoo DR650 forum go on and on bout magnetic sump draining bolts. Maybe now is the time to find one?????

Thanks for the pics - I'd heard about the issue but thought it was harder to get at than that.

Seriously keen to hear about the 3rd gear whine when the time comes. Mines been doing it for 8000kms now (probably more but I've only owned it that long). :D

Cheers R

[XF650]

Re 3rd gear whine
My XF does it too (same motor as DR)
Has anyone noticed a difference if using full synthetic oil?

[cooneyr]

Re 3rd gear whine
Has anyone noticed a difference if using full synthetic oil?

I suspect but cant confirm that is what started if for me. Too clean and flushed all the "muck" out of where ever it is that is whining. Complete hearsay and utter rubbish probably but full synthetic doesn't help (on my bike anyway).

Cheers R

[XF650]

I suspect but cant confirm that is what started if for me. Too clean and flushed all the "muck" out of where ever it is that is whining. Complete hearsay and utter rubbish probably but full synthetic doesn't help (on my bike anyway).

Cheers R

I don't want to hijack this thread with 'another' oil debate but mine has run semi synthetic & didn't stop the whine. In fact it's worse with 16th front sprocket, I assume because of more load?

[tri boy]

Third gear may whine on DR's, but no where near as loud, or as often as their owners.:dodge:
Ooooh, my bum is sore from riding 50k. Ooooh, the fuel tank is too small. Ooooooh, my panty line is digging into my crotch.:killingme
Big girls.:motu:
(jumps on Scrambler, and dives into nearest waterhole:Oops:).

[warewolf]

However the owners of any DR650's with more than about 15k on the clock would be well advised to knock off the clutch cover and check the screws, replacing them with loctite'd 5mm x 20mm bolts.What!? Don't tell me the mighty DR650 is less than totally bomb-proof and has some technical foibles more commonly associated with those fickle Euro beasts? :Pokey:



:jerry:

[clint640]

What!? Don't tell me the mighty DR650 is less than totally bomb-proof and has some technical foibles more commonly associated with those fickle Euro beasts? :Pokey:
:jerry:

Shhhh! if all the DR riders knew that, apart from oil & filters, the only thing I've done to my LC4 motor in 40 000km is a $20 countershaft seal & a splodge of sealant on the cam cover they'll all bloody want one.

Hey Paul, have you tried fishing around in the cases with a magnet to retreive the offending screw?

Cheers
Clint

[GaZBur]

What!? Don't tell me the mighty DR650 is less than totally bomb-proof and has some technical foibles more commonly associated with those fickle Euro beasts? :Pokey:
:jerry:
They better be bomb proof as my mechanical knowledge is only good enough to check the oil and water - oh thats right they don't have water (see what I mean)

Third gear may whine on DR's, but no where near as loud, or as often as their owners.:dodge:
Ooooh, my bum is sore from riding 50k. Ooooh, the fuel tank is too small. Ooooooh, my panty line is digging into my crotch.:killingme
Big girls.:motu:
(jumps on Scrambler, and dives into nearest waterhole:Oops:).
If you are quoting me here it is a missquote and I take offence :girlfight: - i said 150k not 50k. I don't whine - I may however turn away and cry silently!
I didn't actually complain about the small tank because every 150k I can get off at a gas station to readjust my underwear and rest the sore bits!
Oh damn I shouldn't have admitted all that - I don't know if I will be allowed to post here again as I may bring DR owners into dissrepute!

Good Luck with the screw Paul. Most people could ride for years and it probably be no problem - my luck would be to have it mash something serious in a place only a helicopter can get to!

[cooneyr]

Third gear may whine on DR's, but no where near as loud, or as often as their owners.:dodge:
Ooooh, my bum is sore from riding 50k. Ooooh, the fuel tank is too small. Ooooooh, my panty line is digging into my crotch.:killingme
Big girls.:motu:
(jumps on Scrambler, and dives into nearest waterhole:Oops:).

You've obviously not met the right DR650 owners. Transalper and did a 950km ride in 15 hours. Does that make me hard - does it does it? Am I worthy to ride the Submar, I mean Scrambler :rofl:

The only thing we complain about is bloody euro trash riders always going on about how much better their bikes are. :bash:


What!? Don't tell me the mighty DR650 is less than totally bomb-proof and has some technical foibles more commonly associated with those fickle Euro beasts? :Pokey:



:jerry:


Shhhh! if all the DR riders knew that, apart from oil & filters, the only thing I've done to my LC4 motor in 40 000km is a $20 countershaft seal & a splodge of sealant on the cam cover they'll all bloody want one.

Hey Paul, have you tried fishing around in the cases with a magnet to retreive the offending screw?

Cheers
Clint

See what I mean!!!!!! :whistle:

Actually - the only thing I go on about is not having enough money to get me one of said euro trash bikes! Bloody Lotto

Cheers R

[clint640]

You've obviously not met the right DR650 owners. Transalper and did a 950km ride in 15 hours. Does that make me hard - does it does it?


Geez, those DR650's must be slow. I maintained a better average than that over 23 hrs on my girlfriend's Super Sherpa :Pokey::D

Clint

[tri boy]

Geez, those DR650's must be slow. I maintained a better average than that over 23 hrs on my girlfriend's Super Sherpa :Pokey::D

Clint


Bwaaahaaahaaaahaa, "shunted" by a Sherpa.:clap:

[cooneyr]

Geez, those DR650's must be slow. I maintained a better average than that over 23 hrs on my girlfriend's Super Sherpa :Pokey::D

Clint

LOL good one :D Take the roads into account though - Maruia West Bank, Breaburn, Porika, Tapawera Dry Weather Road, Mt Arthur. Twas a Dusty Butt route checking trip.

Challenge for ya - bring the super sherpa down to NN on the 5th Jan and do the DB with us. More than welcome, I'm sure we can even find a suitable waterhole for the submarine :yes:

Cheers R

[clint640]

LOL good one :D Take the roads into account though - Maruia West Bank, Breaburn, Porika, Tapawera Dry Weather Road, Mt Arthur. Twas a Dusty Butt route checking trip.

Challenge for ya - bring the super sherpa down to NN on the 5th Jan and do the DB with us. More than welcome, I'm sure we can even find a suitable waterhole for the submarine :yes:

Cheers R

:D I suspected that might have been on slightly more challenging roads... I bet the weather was better though :D

I don't think I'd be allowed the Sherpa for a DB, & it unfortunately doesn't fit in the schedule for 08, if it's on again in '09 I might have to give it a go however (on the KTM) ;)

Clint

[cooneyr]

......I don't think I'd be allowed the Sherpa for a DB, & it unfortunately doesn't fit in the schedule for 08, if it's on again in '09 I might have to give it a go however (on the KTM) ;)

Clint

If we manage to knock the Northern SI DB route of this year (heres hoping) there are murmurs on the wind of a McKenzie/Central route for next year ;)
Righty O time for the thread to go back on topic. Triboy this is all your fault :spanking: Bloody Trumpy riders sticking their oar in - oh wait........ :rofl:

Cheers R

[paulj]

What!? Don't tell me the mighty DR650 is less than totally bomb-proof and has some technical foibles more commonly associated with those fickle Euro beasts? :Pokey:
:jerry:

Yeah - I reckon - it's a silly bloody fault really - a bit more thought or Loctite on assembly and I wouldn't be writing this tome ...

And such a bastard of a thing to get at ...

[homer]

If the neutral light on your DR650 stops working it may be a good idea to stop the bike immediately and investigate.

Mine did just that a month or so ago – I checked out the wiring and found a slightly corroded connector just under the seat on the left by the airbox (where the workshop manual said). A few squirts of CRC and presto – the neutral light returned and I put the seat back on and afterwards, me on the seat.

A few weeks later, it went out again – this time for good. A check with the meter and a jumper lead pointed me to the neutral switch inside the clutch cover.

A trawl of the web (ADV Rider) showed that there had been a few instances of the neutral switch holding screws working loose, the reasoning being that the plastic surround of the switch assembly, slowly deforms over time and the screws rattle out and drop into the crankcase - ouch. So – off with the clutch cover and the result you can see in the pics.

Where the screw is I do not know – the engine is to be stripped down this winter in an effort to get to the bottom of the third gear growl me and one or two others have heard so maybe it will pop out then!

Meantime – do I replace the screw and ride on oblivious? Hmmmm – bugger’d if I know!

And to really piss me off, we are getting day after day of clear blue skies and little wind. :crybaby:

If a little screw get between the gears when its moving id guess itlll be quite fucked

[paulj]

If a little screw get between the gears when its moving id guess itlll be quite fucked

The screw or the gears? The season of goodwill awaits.

[warewolf]

Yeah - I reckon - it's a silly bloody fault really - a bit more thought or Loctite on assembly and I wouldn't be writing this tome ... Sounds just like the KLR doohickey, they could fix it easy in the factory, but they don't.

[NordieBoy]

But the KLR doohickey actually breaks whereas this is just a screw coming loose, being ingested and killing the motor.

Worlds apart really :D

[GaZBur]

But the KLR doohickey actually breaks whereas this is just a screw coming loose, being ingested and killing the motor.

Worlds apart really :D
Too right - I just looked at the manual and DR's don't even list a part called a doohickey.

[rok-the-boat]

Harley Evos are known to lose dipsticks in their gearboxes - they just fall off, or break off when inserted incorrectly. The gears mash them up real nice to no ill efect - monkey metal, basically. I have seen it two or three times. Just change the oil, flush out with diesel, and add more oil etc.

[cooneyr]

Bump

I decided to investigate this "issue" so got a gasket and took the side cover off for a looksee. Got the #2 Phillips head out and undid the easily accessible screw - whoa that was loose. Got another #2 Phillips head bit that comes in them "sets", ground it to about 20mm long, hammered a 6mm ring spanner over it, cut the spanner down to about 50mm and slowly got the other screw out (took about 10 mins). Break cleaner on cotton buds to clean the holes, cleaned the screw threads, red loctite, and put the whole lot back together.

Don't know if it was ever going to be a problem but the screws were defiantly not tight so every possibility of them falling out. Highly recommend that people have a look at theirs. Fiddly but not really that hard to do and all for the cost of a gasket $35 and two drops of loctite. I probably could have got away with not replacing the gasket but already had it so....

Transalper now has the tool (sorry didn't take any pics before I gave it to him) and any others in Chch DR650 riders are most welcome to use it. Would be easier to replace the Phillips head screws with loctite'd hex head 5mm x 20mm bolts but still need the tool to get the old screws out.

Cheers R

[Transalper]

Yep, did mine today, will do Js next weekend.
I got lucky and the Gasket stayed intact when I split the side cover off. We used some goo just for extra seal when sticking it back together.
I used Loctite 243 on the screws in the end, they were not hard to undo, but not convinced they were anywhere near coming loose enough to work their way out either. Still worth a check IMO.

Was due for an oil change on mine so did that, haven't refilled it yet, thought we'd give the loctite some time to cure first.
Cooneyr just layed his on it's side without dropping the oil. In the end we layed mine on it's side to finish too, just to get the fiddley screw back in.

Here's cooneyr's tool and the gasket goo I used.

[Skinny_Birdman]

Here's cooneyr's tool and the gasket goo I used.

How is that photo not "censored" you dirty boy?

[cooneyr]

How is that photo not "censored" you dirty boy?

Tools and goo - LOL. You want to share anything?

Cheers R