Today, I service a starter motor in a Suzuki DR650 motorcycle.

[@dylantaylor9707]

I don't have a dad that taught me how to do it all. I have Dino teaching me how to look after my DR and a few other great youtubers showing me how to tinker.

[@DinosTinkerShed]

I'm humbled, I'm glad I can help out. Thank you for the kind comment Dino

[@dylantaylor9707]

Dino do you have a video of the rooster sound?

[@emptyfridge3962]

Your videos are a gift to every DR owner! Thank you!

[@DinosTinkerShed]

Thank you for the kind comment. More DR to come. Dino

[@ljbadmin3884]

I don't even have a DR, but still find myself coming back to your channel to watch your maintenance vids. Thanks for sharing. Be well.

[@DinosTinkerShed]

Thank you for taking the time to comment, I'm glad you enjoy the content Dino

[@bmwe6xcsm913]

Today I had to do this because of some nasty issues with the starter. It works great, it spins like a new one, the engine starts from the first quarter of the second I press the switch. You, sir, are a genuine treasure here! May God bless you!😊

[@DinosTinkerShed]

I am so happy that the content was able to help you service your starter, and thank you so much for taking the time to comment and let me know. It really does help. Dino

[@user-js4vh2lw6n]

Dino the best thing about owning a Dr 650 is finding your channel! I've learned so much and appreciate all the effort you put into your videos.

[@DinosTinkerShed]

Thank you so much for making a comment, I've been sick all week and am finding it hard to get motivated to edit, but its comments like yours that get me back in the chair. Thanks again. Dino

[@louvega8414]

This is the best online tutorial for this job. Love your work, Dino!

[@DinosTinkerShed]

Thank you so much Lou Vega, I am glad you like the video and the channel as a whole. Dino

[@victorgenty]

I’ve learned so much about my own DR through your videos, thank you Dino!

[@DinosTinkerShed]

Glad you are enjoying them. Dino

[@ronbosgra8230]

Bought a used 1992 DR650 RSE yesterday and boy, does that starter engine squeal. This video is much appreciated!

[@DinosTinkerShed]

Glad you found it usefully, have fun with your DR Dino

[@royjmcc7]

finally, a DR video!

[@fontanajim]

Great video with all the important detail so most anybody can service the started. For those who want to fix this problem for good read on. When my 2017 started to crow I installed a Warp 9 Started Cap as it has a bearing instead of a brass bushing. Poor design choice Suzuki. I don't expect to have to do this service again. The cost of the Warp 9 replacement part is $69 US. The cost to replace all the washers, o-rings and gaskets, especially the exhaust gaskets isn't cheap. The exhaust gaskets alone are about $29 US. Thanks Dino I enjoy your videos!

[@DinosTinkerShed]

Glad you enjoyed it, I agree with the warp 9 option as the best solution for sure and your comment on parts cost is very accurate, things can add up very quickly for sure. Thank you for the comment and insight. Dino

[@MalJ-eb7nv]

A very clear and informative step by step video. You sure get the camera in to the hard to see spots! Thanks Dino.

[@DinosTinkerShed]

Thank you Mal, it is a bit challenging to get in so tight but I think it helps with the explanations. As always, thank you for the comment. Dino

[@davidpianosi4512]

Thankyou... excellent content and quality. Your attention to camera work and lighting was very satisfying and appreciated.

[@DinosTinkerShed]

Awesome, thank you! Dino

[@MrJack1948]

kzbin.info/www/bejne/gJDGdWiYfNyVqM0

[@onitutu]

I just wanna say that i appreciate your detailed video. I really appreciate it so i can do all the work by myself without being afraid to screw it up. Thanks a lot Dino, cheers from Chile

[@DinosTinkerShed]

Thanks for the feedback, I'm glad you like the videos. Dino

[@bobhildebrand1732]

You do a great job on these. I appreciate the help!

[@jean-philippepelletier1480]

Thanks, very well made video! And the quality of your explantion are perfect and done with dedication! 10/10

[@DinosTinkerShed]

Thank you vary much, its fun to do and I'm glad its helpful. Dino

[@shadetreediesel6973]

This channel needs way more subscribers! Great info

[@DinosTinkerShed]

Thanks for the support, glad you enjoy the content. Dino

[@SA_bluemonday]

Thanks for another great DR how-to! Yea this is also on my long list of cumpolsory todo´s for my DR650.

[@DinosTinkerShed]

Thank you, and good luck on the carb cleaning, you'll do great! Dino

[@aussiefarmer8741]

Its a lot of work for such a little job. I like the way you explain these bike jobs. I'm no stoop when it comes to mechanics but It helps to learn from others mistakes. Not that you show that. These are little maintenance things that I will need to do now or latter so this helps me plan for them. Now back to the tractors and building sheds and all the other house renovations. Well done again. Thanks

[@DinosTinkerShed]

Thank you for the comment, I agree they bury the starter rather deep in the bike and its a bit of a chore to remove it. I agree that its best to learn from other peoples mistakes when you can and believe me, I make my fair share. Maybe I should put out a video showing a few of the worst. Again, thank you for taking the time to comment and good luck with the house renovations. Dino

[@aussiefarmer8741]

@@DinosTinkerShed I just pinched the DR oil filter outer sealing ring, now it leaks. Damm, The bike shops want $9 & $14 for a new 1. Two different shops. Buggered if im paying that for an o ring. Bastards, The trouble is everything is an hour away from here. I think I'll go to a bearing/ seal shop and buy 6 or so for a cheaper price. I hate to encourage price gouging. What they don't realize is they might win with that sale, but I won't go back there for any parts in the future. Big Mistake! I so dislike greedy people. Reasonable products for a reasonable price I say. Sorry for the rant my friend. This old farmer doesn't put up with much shit these day's. Love your vids. Keep it up.

[@DinosTinkerShed]

I hear you. Let me know if you can find the right O-ring, my experience is that even though I have two master sets of O-rings, both metric and imperial, the factory O-rings are somewhere in the middle so you can never find an exact fit. I think this is also a way manufacturers force you back to the dealerships for parts. I would say though, that some things that you buy from 3rd party vendors are genuine Suzuki Parts sold to you at a mark up over the dealer cost, so I always call my dealer to get their price first before I order form online retailers. I grew up in a farming community myself, and although I did not grow up on a farm I had both friends and family that did (Woodstock Ontario is the dairy capital of Canada after all), my experience is that they are hard working no nonsense people that understand the value of honesty, helping out your neighbor and a fair deal. I'm afraid retailers and dealers have forgotten that concept a long time ago so don't worry about your rant, it is an accurate statement. Thank you for the comment and the rant 😀 Dino

[@aussiefarmer8741]

@@DinosTinkerShed I may go down the self O ring making kit yet. See how we go.

[@jw8556]

Great camera work as well as spanner work

[@DinosTinkerShed]

Thank you so much. Glad you enjoyed it Dino

[@jarrodleis4046]

Excellent video. I have a 2020 and I have the rear shock removed to install the plex valve upgrade. I was just starting to hear the odd squeak from my starter lately. The bike has a five year warranty so I was going to just let it go an have the dealer replace the starter when it gets bad but after watching your video I have decided to go ahead and lube the starter bushing while I already have the bike apart for the shock. If I’m feeling extra ambitious I will do a how to video on the plex valve install. Again great video.

[@DinosTinkerShed]

Thankyou for the comment, I look forward to seeing the valve upgrade Dino

[@07mickd]

ive seen a few vids now on how to do this and this one is by far the best tutorial thank you p.s subscribed

[@DinosTinkerShed]

Wow, thank you for the feedback, I'm glad you found it usefull, and thank you for the sub! 😁 Dino

[@jamieclinton4010]

Thank you mate I followed you step by step !! Easy as !! Cheers

[@DinosTinkerShed]

Glad it helped

[@rayphipps4601]

Thank you for a very clear step by step lesson , I now have the confidence to tackle this much need maintenance. With respect I have just one comment, the negative battery terminal lead should always be disconnected before the positive lead and reconnected after the positive lead, just a small point but an important safety issue. Again thank you from Australia. Ray 🇦🇺🦘

[@DinosTinkerShed]

Thank you for the feedback. Your not the first to catch the cable lol. Thank you for taking the time to comment and mentioning the negative cable. Dino

[@ozankiraz68]

This is exactly what I needed, thank you!

[@DinosTinkerShed]

Glad it helps Dino

[@TillDeathDualUsSport]

Outstanding, sir! I will keep this video on tap, and hope that my rooster doesn’t crow anytime soon😄 Hope you had a great Christmas! Cheers🍻

[@DinosTinkerShed]

Christmas was great, I think the squeal just means it wants to ride LOL. All the best in the new year. Dino

[@justgjt]

Damn...we had 43.3 deg C on Christmas Day down here in Australia then had 5 consecutive days with temps over 40 deg C. I removed the armature end cap metal bush and replaced it with a needle roller bearing. The starter spins a lot faster and no more squealing.

[@michaeliarossi6006]

Great step by step Dino! I'm planning on knocking out my starter motor over the weekend and this really helped explain the process. By the way, it would be awesome if you did a video on changing the tires/removing the wheels. That's one thing I have yet to do and something that I'm truly paranoid about...having to change/repair a tube when I'm out in the bush.

[@DinosTinkerShed]

Thank you for the comment, Karl and I actually filmed installing his tires but did not think the footage was quite good enough to upload. I will be getting new tires and will try again. Thanks for the comments. Dino

[@davidfalgout7304]

as always great job and thanks for sharing!

[@DinosTinkerShed]

Glad you enjoyed it.😀 Dino

[@jonwoodworker]

With the guidance of this video, I replaced my starter cap with the Warp9. Night and day difference, starts as soon as I hit the button and no rooster call. The Warp9 looks really cool, but you never see it...lol

[@DinosTinkerShed]

I have heard good things about the warp9 cap, it makes sense how it is designed, good to know it works well. May have to look into that in the future. Thanks for the feedback. Dino

[@jonwoodworker]

@@DinosTinkerShed I did the cap when I did the NSU, because it's right there and you already have most everything out of the way.

[@DinosTinkerShed]

Makes total sense . Dino

[@pacopaez04]

Thanks Dino

[@mattnorris7288]

Thanks for the tutorial, very easy to follow along. Just curious about the orientation of the banjo bolts when installing, do they need to be threaded so that the drain hole on the side of the shank aligns with the oil line itself?

[@DinosTinkerShed]

It makes no difference. The banjo itself has an internal gallery that moves the oil around the bolt and into the line itself. Dino

[@rosarioroberto5823]

Greetings What a fantastic detailed video 🇺🇸🍾🎉🇺🇸 Would you provide me with your windshield brand name. Thanks for assisting me, keep producing more videos.

[@DinosTinkerShed]

I'm glad you enjoy the content. My windshield is actually a BMW 650 Dakar windshield that I fitted to the dr. I like it alot but it is very thick and a bit on the heavy side. Thanks again Dino

[@andrewgreen1181]

I've checked my starter and all I did was take of the oil lines and the timing chain tensioner and you can get the starter motor out

[@DinosTinkerShed]

Thank you for the feed back. I often take a few more items off just to give me a bit more access and also for better cameras angles. Feedback like this always helps. Dino

[@evergeendata]

another great video. Question - when do you know when to use Anti-Sieze, and when to use Lock-Tite? Does it depend on the heat exposure to the threads?

[@justgjt]

You would use anti-seize when you want to remove the bolt/nut/stud in the future. There are different types of anti-seize depending on hot (copper based) or cold (silver/nickel) applications. Loctite is used when you do not want the bolt/nut/stud to loosen unless you you loosen it. There are different types of thread locking products for heat, oil and normal temps along with different strengths. If you use a higher strength locking medium and it wont release using normal tools you can always release it with heat ( which is sometimes not practical ) Make sure both treads are clean and dry prior to application and setting and also remember you do not need a lot the locking compound. Hope this helps.

[@DinosTinkerShed]

I can't really add anything to the great explanation from justgit other than the manual will often let you know what and where to use both products. Thank you for the question. Dino

[@jasonyamahaxt660z6]

Great video

[@cranerigging3604]

That's interesting at 6:23 . Looks like the Suzuki factory pet cock valve uses engine vacuum to open fuel flow ? Sorry for all the questions but I'm trying to figure this all out before I buy that 2003 DR 650 .😀

[@DinosTinkerShed]

That is correct, when you shut off the engine the petcock shuts off. it draws vacuum from a tiny port near the top of the carb. when I added the larger Safari tank this port must be caped off. It is a nice option but I was so used to a three position petcock that I found it odd at first. Great question, thanks for asking. Dino

[@cranerigging3604]

@@DinosTinkerShed Thank you for the reply and nice work on the starter service ! 👍 Can you " Roll Start " the DR 650 in a pinch if the starter would fail assuming the road or trail had some down grade to get momentum ?

[@DinosTinkerShed]

@@cranerigging3604 sure can, it has a fair amount of compression but you can. The petcock has a prime feature so even if you need to fill the float bowl before you roll start it you can.

[@chicanopatriot4322]

Dino Dino the bambino thanks for the great vids. Can you recommend a manufacturer who makes good replacement gaskets please and thank you

[@DinosTinkerShed]

I have had great luck with Winderosa gasket sets over the years. These are made in the USA and the die cuts are clean and precise. I will say though, that I purchased a cheap set from China when I worked on the small 50cc Baja mini bike, I paid $15 off amazon for them and they were not to bad. I would use these again in a small project like that mini bike without hesitation although for my DR I think I would stick with the brand name. Thanks for the question. Dino

[@chicanopatriot4322]

Gracias senor.

[@donut3110]

Watching all of your videos preparing myself to get a DR650. Kind of late to the game going on 32 with a first bike but still young at heart haha I had a question which isn't really related to the video but it caught my attention watching you disassemble everything. Would it be a good idea to go to a hardware store and make all of the bolts/fasteners the same type and size? I noticed the 6mm hex bolts could supplement both the 10mm and 8mm bolts seen on a majority of the bike, which made me think you could reduce almost all of the tools needed to 2-3 common standard hex or security star bit sizes.

[@billhamilton2366]

Don’t be cheap. Buy the replacement end cap with the sealed ball bearings.

[@mt1885]

I did mine a while back and replaced all of the o-rings in it.

[@DinosTinkerShed]

Good option for sure, mine seemed in really good condition so I left them as is. Thank you for the comment Dino

[@mt1885]

@@DinosTinkerShed Mine was a low mile bike I got it only has like 1,700 miles and a 2006.

[@ianduplessis6457]

Hi Dino, the casket infront of the screw on the camshaft tensioner - do you have the parts number for that casket?

[@anticomillennium]

Ciao Mr. Dino, ti scrivo da Roma - Italy. Ho da pochi mesi acquistato il mio DR650SE. Seguo ogni tuo video. Moto fantastica. Quando io accendo il suo motore sento spesso una specie di urlo. Dipende forse da questa scarsa lubrificazione ? Considera che la mia moto è un modello del 1998 e sono sicuro non abbia mai subito questa accortezza. Proverò comunque a farlo. Grazie del tuo prezioso aiuto

[@DinosTinkerShed]

Hello Marco, yes most likely it is dry starter bearings, if you take it apart and service it, the noise should go away. Thank you for following my content, and have fun on the DR!. Dino

[@GasForHalf]

Curious if you've run into the loud clunk noise that many DR650 owners report. It happens when I shut off the bike and then again while starting. Any ideas or other video tutorial for that issue?

[@DinosTinkerShed]

Yes mine makes the clunk, from what I recall it Is part of an anti kickback mechanism or something. That is a great idea for a video. I'll have to do some research on it to ensure I get the right information. Thanks for the comment and great idea. Dino

[@GasForHalf]

@@DinosTinkerShed Sounds good, I'll keep an eye out for a video in the future!

[@muzzkeg8172]

@@DinosTinkerShedAny thoughts on the anti kickback issue, I have similar and assumed it was associated with the starter clutch. I have my flywheel cover off at the moment and starter clutch bearing seem fine.

[@JRClaybrook1]

Get video! I heard you mention using a "jis" screwdriver. Can you tell me what that is verses a regular Phillips? Thanks!

[@DinosTinkerShed]

Hey thanks for the question. JIS stands for Japanese industrial standard and is a screwdriver profile very similar but not quite exactly the same as the Philips that we know in north America. Although very hard to see the angle of the tip is slightly different and locks into the fasteners on Japanese motorcycles and power equipment better than a Philips leading to less cam out and fastener damage. I hope this helps and the k you again for the question. Di o

[@JRClaybrook1]

@@DinosTinkerShed learn somethin every day. Thanks for taking the time to share that.

[@B3nAn]

Hi Dino, what kind of grease do you use? Is it the same grease you used for the swing arm? Tell me the name please

[@DinosTinkerShed]

Thank you for the question. I use a synthetic wheel bearing and suspension grease from motomaster here in Canada but any good quality bearing grease will work for you. Thanks again for the question. Dino

[@OutsiderOG]

when i first bought my dr it had 750km on the clock and it did the rooster sound but a few thousand km later and i never hear it? Should i still grease it?

[@DinosTinkerShed]

If it has stopped making noise you are most likely fine. If you wanted to service it is more of a preventive measure. Thank you for the question Dino

[@thinkjeremiah]

Question. Does the DR 650 starter turn clockwise or counterclockwise?

[@RickReynolds-n4w]

Dino, does the engine have to be at TDC to remove and reinstall the cam chain tensioner?

[@DinosTinkerShed]

@@RickReynolds-n4w I do not believe it does, however the only thing I could see being impacted is that there is pressure on the cam lobes if it is not and I'm not sure if this pressure could somehow slip the cam chain when you remove the tensioner. If it was me I would take the time and set it to TDC just to be sure.

[@RickReynolds-n4w]

Did you put the bike in the video at TDC when you removed the cam chain tensioner?

[@DinosTinkerShed]

@user-cs3ky8qq2f I don't think I did for the video,, however this was a while ago, so I can't quite remember. I just looked it up and the manual does not mention setting TDC so I think you are OK.

[@frooke2]

What about replacing that brass bushing with a bearing?

[@DinosTinkerShed]

Yes I believe warp9 offers a kit replacement for the bushing. I think it completely replaced the end cap. Thank you for the question. Dino

[@jasonhewlett2913]

@@DinosTinkerShed Yes they do just got one in the post.

[@benrecchi2880]

Dino, do you have any opinions on the Warp 9 started cap?

[@DinosTinkerShed]

I have never used one but there have been a few comments saying they work very well. Dino

[@azpattern]

Ok I looked and nobody said this. You took the battery cables off in he incorrect order. Always take the negative cable off first if you touch ground it won’t spark and once off the positive cable is safe. Put them on in the opposite order positive then negative. 40+ years ASE Certified Technician.

[@prairiegold6870]

You take the positive off first so it doesn't arc, ask anyone.

[@garysarizonaadventures2167]

@@prairiegold6870 as a 40 year ASE certified technician you take off the negative first especially in new computerized vehicles. Every class and school I ever went to made that a point. Go ahead and touch your tool from positive to a chassis contact and find out. I had to help someone to the eye wash after a battery exploded because he accidentally contacted the body.

[@davidle7807]

Dino, you inspire me to love my dr650 even more. Your content so excellent!

[@billhamilton2366]

You could take the armature out and clean the commutator while you are at it.

[@DinosTinkerShed]

Your right, I might do that in a later video if there is enough interest. Dino

[@theroads720]

My starter is making a screeching sound and it wont start the bike. Any ideas?

[@DinosTinkerShed]

Hmmmm, I'm not a mechanic but is the bike turning over or just making noise?

[@theroads720]

No, the bike isn't turning over. It's a very load grinding sound

[@andyb.1307]

Hello and thank you for the detailed tutorial. I am trying to diagnose an issue with the starter on my 1996 DR650. Most of the time it will not work. Occasionally it will turn over. I tested the wires and it seems that approximately 12 volts is being sent through all wires to the connection on top of the starter. My conclusion is that it is time for a new starter. Is there any way for me to test or analyze in my starter once it is removed in order to confirm that it is bad? Interesting observation, once the starter was removed there was no drain hole to be found. As you can imagine, the starter was sitting in a puddle of mud and debris. I hope to hear your perspective.

[@andyb.1307]

Also, can you recommend a replacement starter and a store to order it from in the U.S.?

[@DinosTinkerShed]

Hmm If you have taken the starter apart to lube it you can check for burned or damaged wires on the windings and look at the condition of the brushes and segmented armature. I am not sure on other testing methods for the starter. I would say given the age and the lack of water drainage it most likely needs replacement. As for a new motor, I would not discount Suzuki itself as an option, if not Pro Cycle does sell one for 149 us. Hope this helps. Dino

[@gtptvanbuuren3795]

Life good. Ta

[@billhamilton2366]

Where are yer old bark busters, upgraded headlamp, aux lights. I know . ...we all don't like riding at night unless we have to or we got caught with our pants down.

[@DinosTinkerShed]

LOL they are coming, Thank you Bill Dino

[@michaelvass1970]

I like, but you need to fix up your title. You’re robbing yourself of 90 cc. I’ve the same bike

[@DinosTinkerShed]

LOL thank you for the comment, all fixed up. Dino