DR650 project: how to fix that noisy starter motor!︱Cross Training Adventure
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- เผยแพร่เมื่อ 26 ส.ค. 2024
- From www.crosstraini... How to fix that noisy Suzuki DR650 starter motor. The Suzuki DR650 is an awesome bike once you fix the basic problems that Suzuki is too lazy to fix themselves. One of these problems is when your starter motor sounds like like a rooster. This DR650 starter motor noise often happens in the warranty period, and some Suzuki dealers are as lazy as the Suzuki designers and will say it's normal and don't worry about it. Bullshit. Suzuki try to save money but not putting enough grease on key components. Insist it is fixed under warranty. Suzuki only fix key issues if it starts to cost them, so force the issue.
If you aren't under warranty, here is how to fix that DR650 starter motor noise yourself. Make sure you don't move the bike at all or you cam chain could jump a tooth! If you have an old slack chain definitely find TDC first before you start to be on the safe side.
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We've done a whole series of vids on how to fix and modify the DR650 on our Adventure Oz channel on TH-cam - we modified a stock DR650 into a serious adventure bike weapon! We covered all the necessary mods and parts for a DR650 and Full Force Racing Components will upgrade the suspension in stages too. It also looked at common problems like the noisy DR650 starter motor.
The big bush pig, the Suzuki tractor, the doctor... whatever you call her the DR650 has been around in its current format since 1996 and Suzuki thinks the design is so brilliant the only changes made each year are colour and graphics... or they think new stickers will fix the suspension and other major design faults... who knows? It didn't fix the starter motor noise.
We looked at derestricting the DR650 engine, reducing weight, fixing the ergonomics, tyres, getting a good fuel range, protective gear and setting the big girl up as an adventure bike... and fixing the noisy DR650 starter motor.
Off the showroom floor, the DR650 is fine around town and doing easy dirt roads - the suspension is far too soft and underdamped for anything else which we found out quickly. Also water can get into the DR650 starter motor.
Now before we start whinging and whining too much, what do we like about the bushpig? She's cheap which leaves lots of money to spend on mods. It's a lot lighter than it's nearest competitor the KLR650 which is more of a highway and easy dirt roads bike. The engine is a super reliable air cooled basic design with plenty of grunt and mid range power, and really starts to come alive with some basic mods we'll cover. And once that dicky suspension is sorted, the DR650 handles beautifully, and surprisingly loves to do wheelies. It's just it has basic design flaws like this noisy starter motor.
![Turning the DR650 into a Monster! - [ PROCYCLE FUEL AND AIR ]](/img/n.gif)
PERMANENT SOLUTION? You can remove the bronze bushing from the commutator end cap that the armature slides into and replace it with a needle roller bearing. It will never squeal again. Thanks to @UCBZK4d2bCBBWYB-uA8qoSfQfor this tip!
1998 or 1999 MODEL? These were equipped with a solid idler gear that created a problem when the engine kicked back during shutdown, breaking out the gear bearing bosses. If you own one it's probably already been fixed. But it's worth checking as it can be incredibly expensive to fix.
Wow. Thanks for the video. Mine XF 650 squeals as a roster since I bought it a few months back. I always thought it's a starter clutch bearing. Any idea what dimensions are for the needle bearing?
Do you know the exact Size of it ?
I was also curious how to find out what needle bearing fits in there? My DR has been crowing since 08,has 51,000 miles on it........I hate to jump in real quick on fixing things. It might get better.
Yeah, can we know what size needle bearing to put there? Whould save us the downtime to remove/mesure/order.
Hey, i bought a used starter for my DR 1998 model. It was used from a 2015 model, according to the seller it was supposed to fit 1996 to 2021. I just noticed that the shaft was a bit longer than the one i took out. Do anyone of you know if this matters? The gear has been changed to resolve the kickback issues as well. Would really appriciate a feedback.
My starter has sounded like a rooster since the day I bought it from the previous owner. I had seen this video you made (as well as many other videos of yours, good stuff) and tucked it away for future reference. Over the past week my DR has had a hard starting issue and yesterday it became a 'click no start" issue.
I was 99% sure it was my battery just taking a shit.
Today I dropped in a brand new battery and still, click, no start. I tapped on my starter and tried again. This time it groaned and convulsed a little.
My battery issue suddenly became a starter issue. I referenced my Clymer manual as well as your video and pulled the starter. I disassembled the starter as you did in your video here, but the guts of mine were vastly different looking than yours. Mine were black and full of crud. The seals had clearly failed and moisture had penetrated into the heart of the beast causing rust to rear its ugly head and bind up the brushes.
In fact, my brushes were completely seized inside their guides, all four of them. I proceeded with caution before forcing the fuckers out of their nests by pressing on the back of the coil spring where it rests on the brush and rehabilitating their guides with a scrapey type tool.
I cleaned everything up, including the gaps between the copper comutator contacts.
I schmood some grease in the appropriate holes and greased the seals as well.
Slapped her all back together praying she wouldn't do the half turn fart and let the smoke out routine when I pressed the starter button.
Fired right up! Man am I happy about that. Some good old elbow grease and a lick of patience just saved me some money. Thanks for the confidence boost with this vidjayo here ;)
I purchased a DR650 a few weeks ago and have been watching your videos and have learned a lot. Thank you for posting them. On your recommendation I pulled the starter last night to do this job even though my bike wasnt making any noise. My bike was made for the US market so I am not sure if its the same as the Auzzie bikes but I imagine that it is. The roller bearing on the end of the starter entering into the bike case is lubricated by splash oil from inside the engine and in my observation should not be greased. The seal is on the inside of the bearing keeping the oil from entering the case of the actual starter. I really don't think this end should be greased. When I pulled mine, new engine oil dripped out of the bearing and it was as happy as it could be. The other end of the starter has a plain oillite bearing which I could imagine might dry out over time. There certainly was some dust buildup from the brushes and it was worth cleaning out.
THANK YOU. My bike started doing this in October and I had no idea why. Your videos have been extremely helpful and my go-to for DR and Adventure riding tips since I got my DR last February.
I really appreciate that you point out the easy to loose parts easy screw ups that can be done. I’m the one that will screw it up. Great videos , keep up the good work.
Cheers Jeff. I'm an expert and losing stuff!
Thanks for the video! Just greased the noisy starter motor of my DR, while having the cylinder off for base gasket change. 👍🏻
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Good suggestion, thanks. Things need maintenance. Just want to add it's better to apply grease in a much smaller amount than you did. Otherwise, heat would spread excess all over the starter innards, eventually resulting in some greased electrical stuff that don't require to be greased. Also, since starter was unmounted, a nice cleaning of the surrounding area (usually hardly taken care of) is advised before reinstall. Hey, but that last is me, not necessarily a rule!
Just did the starter greasing on my 2017 and your video was great.. Thx for posting. Cheers!
Cheers Paul, I've just bought a new DR650 so it will be interesting to see how long before the rooster emerges. Only took 12 months last time...
love your DR videos, keep em coming. Love the adventure rides too.
Good bit with the roosters. Pretty funny. But I would have liked to hear the actual noise itself.
Change the end cap bushing out for a needle roller bearing. Never squeaks again and the bike cranks faster and draws less starting current.
Can you tell us the model/size that fit in there?
I've surprisingly never had that starter noise .... But if I do .... Thanks for posting this .
Excellent video. I appreciate your effort to document the upgrades. I have a 2011 model I bought a few months ago. Only had 1200 miles on it! Very nice bike. I really enjoy riding it.
Totally love your No Bullshit commentary and advice, just wondering if you ever thought of going into stand up comedie??? as I'm always in hysterics watchig your videos. I've finally succumbed to buying a Bush Pig because after owning the high end of motox bikes and not having the reliability and the high cost of running them I've returned to the bullet proof DR. Thoroughly can't thank you enough for your videos on the DR , I owe you a carton or three of beer, cheers 🍻
The good old bush pig!
Nice vid I was thinking of taking look at the starter before I do the Trans America Trail this year. I know Warp9 sells an upgraded bearing cap that uses ball bearings instead also. I have like 22k miles on my DR and the starter is still kickin but I'd like to keep it kickin for me :)
You can remove the bronze bushing from the commutator end cap that the armature slides into and replace it with a needle roller bearing. It will never squeal again.
Good tip, I've included that in a pinned first comment. 👍
Careful any viewers if you take tensioner out and motors not on top dead center your gonna bend all 4 valves and need to redo the head
This is what must have done when replacing the stater motor 4 valves later I didn’t think just pulled it out
Thanks for posting this video.Cheers from Ireland.
cheers jimmy. i'm not sure how you'll feel about the terrible irish ride vid we posted on our enduro channel though lol.
EXELLENTLY DONE TA !
Our pleasure!
You really should mention finding TDC or whatever before doing this, like all the other guides, seems important not to jump the chain without the tensioner in place. I rocked my bike side to side while doing this and I might have a big headache ahead of me. Not sure if it was in neutral, will know soon.
there's a lot of stuff the vid doesn't cover because it's a brief overview. that's why i mentioned not moving the bike, linked to a more detailed vid within this one, mentioned it in the video description and also with more detail on all the forum threads.
I love your videos
Stating the obvious but don't forget to put the piston on TDC before removing the cam chain tensioner.
actually i did see that in someone else's vid and i should have mentioned it... my DR is still so new i didn't bother because the cam chain wasn't loose at all.
Bike is hard starting. Get a terrible sounding slam or knock when attempting to start ( it has started but doesn't stay running). Had someone lube the starter. Is it possible that he didn't reassemble the cam tensioner or that it jumped out of time? If that is a possibility I at least know where to look
@@crosstrainingadventure Well shit, I didn't do that. I just did this on a 2013 with 8K miles. I made sure not to move it at all, does that mean i'm ok?
God I love this f*cking channel.
Will a universal ignition work as a substitute for OEM
Your great channel influenced my son & I to buy DR's. Mine is new & my son picked up a nice 2016. However, his vibrates so bad when riding it that it blurs his vision & rattles his teeth. We checked engine mounts/bolts and all is tight. Any thoughts?? Many thanks!!
Great tip...Thanks!
I'm busy swapping my starter motors on my DR'S, I took the cam chain out of the second DR and it's upside down. Would it have any issues being upside down?
Im actually not really interested in stopping it sound like a rooster because it doesnt bugger me... i just dropped the pilot jet and it landed underneath the starter motor... im so stupid...
Im gonna fix the starter noise anyways while im on it.
Thanks for this video
brilliant video, thanks
hi Mr.ADVENTURE OZ. I recently dropped my Dr 650 n broke my clutch laver. I replaced it with a brand new 1. but for some reason the bush pig won't start ... do u know where can I start to try to fix this problem... Thanks u I love ur videos . from San Diego California USA...
that could be one of many things, not sure how the clutch lever would have affected anything though....
ADVENTURE OZ thank u so much... it means alot to me.
You probably broke the little clutch safety switch that plugs into the lever housing. It can be bypassed quite easily. I’m hoping you got it fixed by now as this is an old post.
Unbelievably, I hadn't notice this bloody rooster noise before watching this vid, though it's likely been occurring with my bike for some time now. Damn, I now have to worry about that too! Or maybe should I just follow Harley's riders' advice: use ear plugs!
good alarm clock though frogzie, if you could rig up the DR in the bedroom somehow?
to find TDC, is it necessary to be on the compression stroke? how do you tell if it is or not?
You can remove that plug that covers the crankshaft witness hole (I’m not sure the real name of it) and look for the mark. I think it looks like the letter T. If you don’t see it, remove the big plug on the stator cover and turn the crankshaft with an Allen key. Removing one of the spark plugs will make this way easier.
Any particular grease I should use?
I have some sta-lube extreme pressure moly-graph multi purpose grease sitting around. I figure that'll do
The Hundredth Monkey, best keep any petroleum based grease away from those rubber ‘O’ rings or they may swell and leak even more, best use a silicon grease on the rubber contact points.
Oh god. My DR has made this noise since the day I bought it. I just thought it was normal. Now that's going to bug the living shit out of me until I fix it.
funny thing is i'm not sure how long it would take for that bushing to wear out if you did ignore it.... but in any case it's annoying suzuki just doesn't put a bearing in there and get it right from the start. :(
I had a 2006 DR650 and put nearly 50,000km on the thing. Didn't start squawking at all until about 45,000km then it would do it maybe once every 10 times. Never removed or greased the starter so it's not as common an issue as you may think
it doesn't happen to every DR but it is so common that the rooster crow is a known issue
well done thanks.
Does the bike have to be in gear .... to remove the starter motor and grease and Put back in???
good question, jamie. i don't see why the bike would have to be in gear but it wouldn't hurt to have it in gear...
they hide the startermotor verywell
Wow so could you do this for all motorbikes that have very loud Shit sounding starter motors?
I would also like to know the answer for that please!
it might be caused by other issues but it does make sense to pull apart any starter motor to put some grease in there and check the brushes and make sure no water is getting in.
Great info vid, TY there Mate
Don't put that kind of grease on rubber. Use rubber grease only.
Are the early DR 650's Electric start?
probably.... only familiar with 1996 onward. :(
Is that the shinko 705? If so how do u like it and if not what is it and how do u like it?
no, stock trailwings
His aren't, but I run the 705's on my DR650, and as long as you know what they're good at, they're amazing tires for the price. I kid you not, I got almost 20k out of a 705 front, and I usually get about 6 or 7k off my rears. They're great on the highway, really good on packed dirt, abysmal in the mud, etc. I use my bike for commuting, and they've been my go-to tire for years.
Is this the same starter on the DRZ?
i doubt it, all four of my DR650s have made this sound but owned three DRZs over the years and never heard it
Maybe it is from having to turn over that massive slug of a piston on the DR that started life in a steam driven locomotive?
Wow nice bike but just a bad designing, I will stick with Honda 😁👍 oh Suzuki make some good sports bikes 👍👍
Hondas have the cam chain tensioners that break and lunch the whole engine,thats much better.
BARRY
HANS
this didn't show up in my sub box
Wish I had the video 6months ago
i wish i had this five years ago when i had my first DR650... everyone was saying this noise was normal..... doh.
Had a lot of fun with the cam chain thingy
likewise, i was totally stumped until i found that other guy's vid
XRs are kickstart only, your argument is invalid.
XR650L is electric start.
@@andyblack5687 And has the subframe that snaps off,and the battery box falls out the side....