DR650 Fuel Filter Problem

In previous articles, we have discussed the few problems concerning Suzuki’s great
DR650SE. In each case we’ve suggested a fix. The Top Gun Secondary Air Filter is a
good example, especially for you dirt riders. The NSU problem and fix, originally posted
here, has found its way to many other sites dedicated to MSMs and dirt bikes.

Well folks, we have another filtering problem that can plague DR650 riders, especially
those who use aftermarket gas tanks and spend lots of time in the dirt.

Few DR650 owners seem to be aware that there is a small in-line fuel filter inside the
curved fuel intake pipe of the carburetor. It’s so small that it can clog the line easily,
restricting fuel flow.

Some aftermarket fuel tank petcock filters are not able to remove some of the smaller
material, so the fine stuff ends up in the in-line filter and eventually stops fuel flow. You
can sometimes clean this tiny filter, but if needed, a replacement will cost about $5!

A better fix will soon be available through MMP. It will be designed to fit a variety of fuel
tanks, will accommodate larger amounts of material before clogging, and will allow for easy
visual inspection. Stay tuned.

DR650 Start-up “Wheeze”

I often wonder how some of the so-called experts, who never ride the models they
comment on (or at least ride very little) know so much. Unless you put tens of thousands
of multisurface miles on your mount, weaknesses don’t often show up.

In the case of the DR650 for example, the header can sometimes disjoin from its flange at
the head, but not usually until 30K miles or more. The neutral sending unit screws can
sometimes loosen inside the engine (big trouble) but not usually before 20K miles. The
tiny in-line fuel filter may cause trouble at any time, but that is dependent upon fuel used
and riding conditions.

Another potential problem causer is the starter gear that is made like a clutch and will slip
in case of a backfire, thereby preventing crankcase destruction. In 1998 and some 99
models, this gear was solid and a number of engines failed when a backfire occurred.

The slipper starter gear used both before 1998 and after 1999 has to be replaced from time
to time just like clutch plates. It will probably never cause trouble, but you’ll know it needs
replacing when it begins to “wheeze” upon hitting the starter button on a cold morning.
There’s no rush, but if it wheezes when starting a warm engine, you’re getting close to not
being able to rotate your crankshaft mechanically.