LostInPA thats what i do.

Great tip. Have been doing that for years. And you can even put a strip of masking tape over the bolt heads to make sure they don't fall out when you accidentally step on them.

Glad you enjoyed it! Thanks for the feedback and views!

Awesome, glad the video helped out!

Great news. I'm opening my dr this weekend to do the job, looking forward to it!

Thanks for watching and for the feedback.

Yes. Procycle sells a kit for this job with safety wire. Loctite is fine, but wire guarantees the bolts will never move.

Yes, I did both…..blue loctite and a safety wire. Some say it’s overkill, but who cares? It’s easy and cheap.

As a aircraft machanic, you are right. Even planes like 787 uses this method in a lot of places

Thank you for that. May I ask you where you got this information? I have a 2019 but it still freaks me out thinking that such a small issue like this can wreck an entire motor!

4:02 wrongly specified as Philips instead of JIS. This is indeed a very good point that you made here

You bet! Thanks for watching.

Haha you got it *Danny!*

Thanks.

Better remove it. Soft sand paper the surface for improved contact.

i learned the hard way years ago trying to remove screws with a philips PH2 bit. JIS screw bits are a must have in the tool box. the Japanese screws and bolts are made of butter if you dont have the exact size tool, they will strip

The recovery tool kit that comes with the bike has the correct JIS bit.

I JIS every time I screw.

You would have thought he knew about JIS but maybe not!!!

Everyone should buy a JIS screwdriver if they own a Japanese bike or you WILL end up drilling out screw heads eventually.

Did you happen to replace your NSU? Mine appears to be the same and I'm wondering if it is something I could attempt myself.

this "known" issue.... well i had 96' DR did about 40k + 20k previous owner and never had that issue ... not that known issue i guess

Yes. It is. Strange wire protection. It's there.

I have to agree, that's a more permanent solution.

Sorry, I just saw this after making the same idea.

They did - they now use loctitie on the NSU bolts. Only 20 years late.

yes thread locker should suffice

You don't need to, Suzuki started doing it in 2017

It's possible those screws get caught in the transmission, the bike locks up, engine gets destroyed, the rider gets yeeted off a mountain.

Nothing more than a green neutral light :) ... Justin

I read somewhere else that Suzuki addressed this issue in 2017 models..

the drz 400 has separate concerns regarding the stator bolts that tend to need thread lock applied like the dr650 NSU bolts. i think this is suzukis way of making sure people keep buying bikes :) other known issues of the drz 400 are :steering stem bearings, wheel bearings, swing arm bearings, swing arm bolt tend to be left without hardly a drop of grease applied to them from the factory. these can be taken care of in a day. once a year apply grease and the bearings will last for years to come. Kick stand kill switch & Clutch kill switch should be removed once you are comfortable with the bike. these switches are silly and can leave you wondering why your bike wont start. the drz 400 petcock can potentially leak over the years, replace with a manual petcock (yamaha raptor will do) i may be forgetting another potential problem that can be fixed but thats the jist of it. the drz400 and dr 650 are great bikes with little maintenance and reliable machines.

So what does Suzuki say? What does the manual say? If you are correct then this important info needs to be shown or the vid changed.

I checked internet and best I come up with is tighten to 6Nm or 4.42 lbs/ft. Use loctite blue, and keep checking for a month for peace of mind. The NSU screws loosen due to the cover heating and enabling the screws to loosen, but whatever, just fix the issue and be safe.

@@johnrogers5825 In most cases, when a torque is needed, the manual says it in the section for that particular install, right next to the pictures. But in the case of the clutch cover bolts, there is no specified torque listed in the part of the instructions where it has you reinstalling the clutch cover, so you have to find the size and type of the bolt (standard m6) and find it in the general bolt size torque chart. Even there, there are two m6 type bolts listed, regular and hardened. The weaker or "standard" m6 bolt torque listed there is 4ft-lbs. Rocky Mountain ATV's dr650 ATV video says 7ft-lbs, which is for the stronger m6 bolts, not these standard ones. If you use 7ft-lbs like Rocky Mountain says, you'll break bolts. You have to read the manual carefully and discover it's a regular m6 bolt and use the chart correctly and only use 4ft-lbs. So technically, the suzuki manual is correct, but it's not very obvious and people such as Rocky Mountain often make the mistake of thinking it's 7ft-lbs which will break bolts.

@@johnrogers5825 Yes, 4ft-lbs on the clutch cover bolts would be safe. This video says 7ft-lbs but that snapped my bolts. The Suzuki manual is technically correct because it does not list a torque in the clutch cover install section....instead, you have to know it's a Standard m6 bolt, and you have to use the generic bolt torque reference chart in the manual which says those type bolts are 4ft-lbs. People mistakenly think its the "hardened" m6 bolts and try to torque it to 7ft-lbs and break bolts. But if you read the manual carefully and know what kind of bolts these are, you'll see the manually actually says to use 4ft-lbs not 7 like this video says. I was working off this video and snapped a clutch cover bolt at less than 7ft-lbs. I bought a new one and used 4ft-lbs and everything's perfect. No leaks. The manual was a little unclear, but techinically correct if you read it carefully and don't make assumptions.

@@steelmilkjug It is a shame that Suzuki doesn't explain and detail things exactly for the millions of dollars they make. Many companies are like this too.

Every mfg has it's little idiosyncrasies. Trust me this is an easy one to fix.

A tiny problem in an otherwise bulletproof bike.

If you get an 2017 model and up Suzuki finally started putting locktite on these bolts

Nah.

Problematic installing the clutch plates?

@@NirLouk No problems. The previous owner replaced the entire clutch a year ago. I think I made a mistake with the assembly. I just don't know where.

@@Unknown_Noise maybe the order of the plates? If they are not in the right order it can cause an issue. Other possibilities - weak springs. Wrong torque on springs.

@@NirLouk I was keeping an eye on the order of the plates. Wrong torque on springs - this could be it because I screwed on without a torque wrench. Many thanks for your interest. You helped me a lot.

The neutral sending unit is a device that sends a signal to the neutral indicator light on your dash letting you know when your bike is in neutral.

@@rmatvmc oh,do the older ones like 2007 or so have them?thanks

Yes, every DR650 will have one even going back to when they were first released in 1990!

That is a ratcheting wrench with a flex-head.

Sure you can!

If you don't mind not having a neutral light, you can remove the whole assembly.

@@rmatvmc I don't need neutral light. It will be safer if I delete everything:) Thanks. Cheers.

It's really not unless your impatient. You know what is a pain in the ass? A screw coming loose and destroying your engine