The Suzuki DR650, a stalwart of the dual-sport world, has earned a reputation for rugged reliability and simplicity. It's a bike known for taking you practically anywhere, from fire roads to cross-country adventures. However, even this dependable machine has its quirks and potential pitfalls. Understanding these common DR650 issues will not only help you avoid headaches but also empower you to keep your trusty steed running strong for years to come.

The DR650's Achilles Heels: What to Watch Out For

While the DR650 enjoys a well-deserved reputation for reliability, it's not without its shortcomings. Many of these issues are well-documented and relatively easy to address, but ignoring them can lead to bigger problems down the road. Let's dive into some of the most common DR650 woes.

The Infamous Neutral Sending Unit (NSU) Screws

This is arguably the most talked about DR650 issue, and for good reason. The two screws that hold the Neutral Sending Unit (NSU) in place on the back of the clutch basket can loosen over time. If they back out completely, they can wreak havoc inside the engine, potentially causing significant damage.

  • The Problem: Vibration and heat cycles cause the screws to loosen.
  • The Solution: The most common fix is to remove the clutch cover, clutch basket, and NSU, then apply a thread-locking compound like Loctite to the screws and re-torque them. Many riders also choose to safety-wire the screws together for added security. This is often referred to as the "NSU fix."
  • Is it Necessary? While not every DR650 experiences this issue, it's considered preventative maintenance that's well worth the effort, especially if you plan on putting serious miles on your bike.

Base Gasket Leaks: A Messy Situation

Another common complaint is oil weeping or leaking from the base gasket, the seal between the cylinder and the engine case. This can be a nuisance, making your bike look dirty and potentially leading to oil loss.

  • The Problem: The original base gasket can degrade over time, especially in hot climates or with high mileage.
  • The Solution: Replacing the base gasket is the definitive fix. While it requires removing the cylinder, it's a manageable job for a mechanically inclined individual. Consider upgrading to a higher-quality gasket, such as a Cometic gasket, for improved durability.
  • Temporary Fixes: Some riders have had success with carefully cleaning the area and applying a sealant like RTV silicone to the outside of the gasket, but this is generally considered a temporary solution.

The Stock Carburetor: Love It or Hate It

The DR650's stock Mikuni BST40 carburetor is a point of contention for many riders. While reliable, it's often criticized for being lean from the factory, resulting in sluggish throttle response and potential surging.

  • The Problem: Lean fuel mixture. This is often exacerbated by modifications like aftermarket exhaust systems.
  • The Solution: Several solutions exist, ranging from simple to more complex:
    • Shim the needle: Adding shims under the needle raises it slightly, richening the mixture. This is a simple and inexpensive fix.
    • Adjust the pilot screw: Fine-tuning the pilot screw can improve idle and low-speed performance.
    • Install a jet kit: A jet kit, such as the Dynojet kit, provides a selection of jets and needles to optimize the carburetor for different conditions and modifications.
    • Carburetor Replacement: Many riders opt to replace the stock carb with a pumper carburetor, such as a Mikuni TM40 or TM42. These carbs offer improved throttle response and performance.
  • Which is Right for You? The best solution depends on your needs and budget. Shimming the needle is a good starting point, while a pumper carb offers the most significant performance gains.

The Soft Suspension: A Common Gripe

While the DR650's suspension is adequate for general riding, it's often criticized for being too soft, especially for heavier riders or those who plan on carrying luggage. This can lead to a bouncy ride and bottoming out on rough terrain.

  • The Problem: Soft springs and insufficient damping.
  • The Solution: Several options exist to improve the DR650's suspension:
    • Replace the Springs: Upgrading to stiffer springs in both the front forks and rear shock is a common and effective modification. Race Tech and Procycle are popular suppliers.
    • Fork Emulators: Installing fork emulators, such as those from Race Tech, improves the damping characteristics of the forks, providing better control and a more plush ride.
    • Re-valve the Shock: Having the rear shock re-valved by a suspension specialist can significantly improve its performance.
    • Aftermarket Shock: Replacing the entire rear shock with an aftermarket unit, such as a Cogent Dynamics shock, offers the best performance but is also the most expensive option.
  • Consider Your Riding Style: Choose a suspension upgrade that matches your riding style and weight.

The Seat: Comfort is Key (or Lack Thereof)

The DR650's stock seat is notoriously uncomfortable, especially for long rides. Many riders find themselves squirming and shifting after just a few hours in the saddle.

  • The Problem: Thin padding and an uncomfortable shape.
  • The Solution: Fortunately, numerous aftermarket seat options are available:
    • Seat Covers: Adding a gel seat cover can provide some added comfort.
    • Aftermarket Seats: Companies like Seat Concepts, Corbin, and Sargent offer complete aftermarket seats with improved padding and ergonomics.
    • Custom Seat Modifications: Some riders choose to have their stock seat modified by a professional upholsterer.
  • Try Before You Buy: If possible, try out different seat options before making a purchase to find the one that's most comfortable for you.

Electrical Gremlins: Keeping the Lights On

While generally reliable, the DR650's electrical system can occasionally experience issues, particularly with wiring connections and the charging system.

  • The Problem: Loose connections, corroded terminals, and a weak charging system.
  • The Solution:
    • Inspect Wiring: Regularly inspect wiring harnesses for loose connections, chafing, and corrosion.
    • Dielectric Grease: Apply dielectric grease to all electrical connections to prevent corrosion.
    • Charging System Test: Periodically test the charging system to ensure it's functioning properly.
    • Upgrade the Stator: If you plan on running a lot of electrical accessories, consider upgrading the stator to a higher-output unit.
  • Proper Maintenance is Key: Regular maintenance and careful attention to detail can prevent many electrical problems.

Clutch Chudder: A Vibrational Nuisance

Some DR650 owners experience a phenomenon known as "clutch chudder," which is a noticeable vibration or shuddering sensation, particularly at low RPMs in higher gears.

  • The Problem: Play in the clutch basket assembly.
  • The Solution:
    • Clutch Basket Modification: Several companies offer modifications to the clutch basket to reduce play and minimize chudder.
    • Clutch Basket Replacement: Replacing the entire clutch basket with an aftermarket unit can also address the issue.
  • Not Always a Problem: Some riders are more sensitive to clutch chudder than others. It doesn't necessarily indicate a serious problem, but it can be annoying.

Modifying for the Long Haul: Enhancing Reliability

Many riders modify their DR650s to improve their reliability and performance for long-distance travel and off-road adventures. These modifications often address the weaknesses mentioned above and enhance the bike's overall durability.

  • The NSU Fix (Again): It bears repeating – this is a crucial preventative measure.
  • Procycle Countershaft Seal Retainer: This retainer prevents the countershaft seal from popping out, a common issue that can lead to oil leaks.
  • Case Savers: Installing case savers protects the engine cases in the event of a chain break.
  • Skid Plate: A robust skid plate protects the engine from rocks and other debris.
  • Handguards: Handguards protect your hands and levers from damage in a crash.
  • Larger Fuel Tank: A larger fuel tank extends your range, essential for long-distance travel.
  • Proper Luggage Racks: Sturdy luggage racks are crucial for carrying gear securely.

Frequently Asked Questions (FAQ)

  • Is the DR650 a reliable bike? Yes, the DR650 is known for its reliability. However, addressing known issues like the NSU screws is important.
  • How often should I perform the NSU fix? It's generally recommended to perform the NSU fix as preventative maintenance when you first get the bike, and then check it periodically.
  • What's the best way to improve the suspension? Start with stiffer springs matched to your weight and riding style. Fork emulators or a shock re-valve are good next steps.
  • Is the stock carburetor okay for off-road riding? The stock carburetor can work, but a pumper carburetor will offer better throttle response and control.
  • How do I prevent oil leaks? Regularly inspect seals and gaskets, and replace them as needed. Consider upgrading to higher-quality gaskets.

Conclusion

The Suzuki DR650, despite a few common issues, remains a fantastic and versatile motorcycle. By understanding and addressing these potential problems, you can ensure that your DR650 provides years of reliable service, whether you're commuting to work or exploring remote backcountry trails. Tackle those common issues early, and your DR650 will continue to be a trusty companion for years to come.