DR650 NSU Screw Fix - No Clutch Removal

The DR650 is known for having the Neutral Sending Unit screws back out, even on low mileage bikes. I had a scare with some weird neutral light issues, so decided I should stop chancing it and check them out. I'm glad I did.
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Intro 00:00
Remove Accessories 02:37
Remove Clutch Cover 04:06
NSU Location 04:42
Preventative Measures 05:13
Replacing top screw 05:43
Replacing bottom screw 08:45
Wrap it up 08:54

[@tsdmoto]

Great video, love the idea of fixing the NSU screw situation while leaving the clutch in place.

[@neiljarvis8911]

Wow! That was a super usefull video. I have a 2002 Sachs 650 Roadster with the Suzuki XF650 Freewind engine in it (basically a twin carb DR650 engine). I think this is some thing I will do at the next oil change. I can't believe you havent go thousand more views, with such good informative videos.

[@tvh300]

Great tutorial, thanks for sharing!

[@vitiatedvagabond9632]

this is the best video for nsu fix ive seen so far! thank you!

[@paulstevenconyngham7880]

Thanks for making this man

[@JustGresh]

Thanks for posting. Plan on doing this soon. My only recommendation is to add Loctite to the threads so there’s no chance of them backing off.

[@DustinRogersinMO]

Yep. I mention in the video to loctite the new bolts at 8:11

[@billsimpson2392]

Brilliant stuff Dusty 👍👍👍👍👍👍👍👍 ( a good nickname for a dirtbike rider lol)

[@mattg5585]

Glad you checked it! At least the bolts were still there. Props to you for getting the job done with the clutch basket on, I pulled mine.

[@Ryanhwelton]

Good job

[@Daverazzi]

My 2011 DR650 just started to act up today with the neutral light. Looks like I’ll be doing this to my bike this weekend. When I got the bike about a month ago it only had 49 original miles and now has 1800 miles on her. I was hoping I wouldn’t have this happen so quickly.

[@DustinRogersinMO]

Better to get it sorted out before it grenades itself

[@chrisbranco9866]

Great Video! I'm just about to fix my NSU. Do you think a strait ball end hex would work. I don't have the torch set up to bend a hex key.

[@DustinRogersinMO]

If it’s long enough, it may work for you. Mine was too short to have enough clearance to turn.

[@robertr9343]

Gotta use vises groups so they can lock onto the bit my boi

[@rabidwookie606]

Nice!

[@RandalAlvarez-by4mr]

Do you happen to have that allen tool for sale?

[@Asvmad]

Hey man check that oil gear for cracking it looks like mine and with more closer look check the teeth

[@got-to-wonder]

Did Suzuki fix this? And if so what year??

[@DustinRogersinMO]

I think so in 2016-2018 period. You’d have to Google it to be sure.