41 replies to this topic

[bigboy292000 TT Bronze Member]

FAQ Version 1.2; 10/25/08

This is a collection of FAQs for Suzuki DR 650. Please send in suggestions for additions or changes. Mods – please sticky this in DR forum! If this does not prove useful, we’ll kill it.

The links provided from here are from various sources. Can’t promise that everything will be up when you look for it! Many link to DR650 Wikia, as there is a ton of info there, but I figured people don’t know about it always. I have saved several things in PDF format because pictures on forums are known to disappear over time.

NOTE: It is completely possible that not the best thread or page about the specific subject is linked to in this FAQ draft. If so – please don’t get ticked off but rather PM me and I’ll fix/add stuff! This FAQ will rock if we all make it rock!

NOTE 2: Huge thanks obviously goes to people that contributed to threads and pages that I link to. Props to all of you!

Exhaust

• Exhaust page on DR650 Wikia
  
• Header polishing
  
• Header weld grinding
  
• How to repack your FMF-Q2 silencer (by mx_rob)

Intake

• Intake page on DR650 Wikia
  
• (please send me more links)

Seat

• Seat page on DR650 Wikia
  
• Corbin seat fit issues: fix 1, fix 2

Tires

• Tires page on DR650 Wikia
  
• Where to buy tires

Luggage

• Luggage page on DR650 Wikia
  
• Some examples: Givi knockoff top box, Givi top box, Dirt Bagz

Windscreens

• Windscreen page on DR650 Wikia
  
• Various windscreen advice threads: Turbo City and various options discussed

Fuel tanks

• Fuel page on DR650 Wikia

Guarding and Protection (skid plates, crash bars)

• Guarding and Protection page on DR650 Wikia
  
• KTM MX fender install

Lighting

• Lighting page on DR650 Wikia
  
• Buell headlight mod
  
• Some 100W light bulb information
  
• Trailtech HIDs
  
• Where to connect accessory lights
  
• Brighten up your turning signals cheap
  
• Tail light conversion

Suspension

• Suspension page on DR650 Wikia
  
• Cogent Dynamics suspension and brake upgrades
  
• How to make your own damper rod tool
  
• Save $$$, Replace Your Own Fork Seals
  
• Installing a DRZ shock into your DR

Controls

• Risers – experiences with Rox, Dirtly.com (Ebay), Tusk
  
• Highway pegs

Engine upgrades

• Engine page on DR650 Wikia

Carb work and carb tuning (jetting)

• Tuning the 39mmFCR
  
• Tuning Mikuni tm 40
  
• DR650SE Needle Comparison (an epic thread by mx_rob)
  
• How to do simple carb mods (step by step), PDF with pictures is here
  
• The BST-40 Bible (by laramie LC4 on advrider) – stock carb. PDF with pictures is here
  
• Basics on carb adjustments

Routine Maintenance

• How to change oil
  
• How to adjust valves. PDF file with photos here.
  
• Chain maintenance and lubrication (no lack of opinions on this!)
  
• Is your chain too loose/tight?

Electrical

• Electrical page on DR650 Wikia
  
• DR650 generator capacity test results
  
• Kick Stand Safety Switch (and how to bypass it)

Drive / gearing

• Drive page on DR650 Wikia (includes 520 conversion and 525 options)
  
• How to change the counter sprocket ( CS ) / front sprocket. PDF version with photos here.

Common (and not so common) problems

• Surging / cutting out issues: read this, this or this
  
• NSU (neutral sensor unit) screw backing out: read this and this
  
• Upper chain roller breaking off: read this and this. Already broke off? Read this.
  
• Fixing cam chain tensioner gasket leak
  
• Base gasket leak (typically 2003 and earlier): read this, this and this, and then search some more... lots of threads on this.

[Nick250 TT Member]

Nice work Bigboy.

Nick

[texas-dr TT Bronze Member]

just like Mumbles said in Dick Tracy, "BigBoy did it !!!!!!!!!!! ":thumbsup:

[lowercasee TT Platinum Member]

Wow, very nice post! Hopefully the mods can make it a sticky.

[RAD2007 TT Bronze Member]

gggggggggggoooooooooooooooaaaaaaaaaaaaaaallllllllllllllllllllllllllllllll:banana:

thank you for the work

[greer TT Silver Member]

Thanks so much for doing this!

Cogent Dynamics (http://www.motocd.com/) offers suspension upgrades and brake systems for the DR; I received fast, friendly service when I ordered brake pads.

And regarding risers, please include these from Tusk:
http://www.rockymoun...dFamilyId=12976

Whoops, maybe there's a way to shorten the link. Thanks again.

Sarah

[decerebrate TT Bronze Member]

thank you

[Icelander-DR650 TT Bronze Member]

Bigboy you are amazing! Thank you very much for what was obviously a lot of effort to put this together. I'd kind of hoped that over the winter with snow on the ground in many places that it would come together.

Again, Thank you!

[bigboy292000 TT Bronze Member]

OK folks, thanks for great comments, I updated the FAQ... and added the problems section.

[ivtriedeveryusername TT Bronze Member]

Here are a few links for the DR650 manuals.

1990-1995 - http://sonnentag.net....ice_Manual.pdf
1996-2008 - http://sonnentag.net....ice_Manual.pdf

Hosted by a user on this forum.

[AndrewL TT Bronze Member]

Good work on the FAQ.

....................................................

ivtriedeveryusername said:

Here are a few links for the DR650 manuals.

1990-1995 - http://sonnentag.net....ice_Manual.pdf
1996-2008 - http://sonnentag.net....ice_Manual.pdf

Hosted by a user on this forum.

The links have come through abbreviated. Also, do those manuals infringe copyright?

Cheers

[Talbertnz TT Bronze Member]

Awsome work this faq will help many!!!

just wanted to sugest adding www.dr-650.de
A german dr 650 site for those that speak the language.

[greer TT Silver Member]

Another link for an online manual:
http://www.deakin.ed...c_adm/DR650.pdf

Sarah

[Rusty Rocket TT Bronze Member]

Thanks for doing this!

[drjunkie TT Newbie]

thank for the links, makes it easy to catch up on mods.

[DRGRIN TT Newbie]

Just acquired a 2000 DR 650. Looks like I have some reading material. I have plenty of questions, looks like most of my questions will be answered.
Thanks

[greer TT Silver Member]

Tool Tube and Trail Jack:

http://www.thumperta...ight=trail+jack

Sarah

[Rick Blunden TT Bronze Member]

See:

http://www.advrider....t=415263&page=7

Rick

[bigboy292000 TT Bronze Member]

Well, unfortunately - I am not able to edit my own post (the FAQ) anymore... I guess there is a time limit. I emailed Thumpertalk folks for an exception on time limti to edit but never got a reply...

We'll see.

[Icelander-DR650 TT Bronze Member]

This is how to install a shock from a DRZ400 (2002 or later) on a 1996+ DR650 I should have put this here earlier.

http://www.thumperta...ad.php?t=726501

Jesse said that the DRZ400SM would be better than the DRZ400S and that I will not have to get the shock revalved for the 8.1 spring that I've ordered. (I'm about 180 with gear and ride aggressively)