The Iconic Suzuki DR650 Motorcycle Engine Gets A Massive Overhaul | Part 6: Barnett Clutch Install

What is going on, YouTube!

Today we’ll be rebuilding the clutch side of the engine and installing a Barnett Clutch Pack with its heavy duty clutch springs, perfect to keep up with the additional torque the 790 Big Bore Kit will be laying down.

If you plan on completely removing the Neutral Sending Unit the following information shared by @BergDonk over on the DrRider Forum is worth considering.

"Your NSU switch is the same as the Oz, and maybe other, market bikes, and have 3 wires. As best as I can tell, the other 2 wires tell the CDI, via a resistor under the front of the seat, whether 2nd or 3rd gear are selected. A limited test on one of my DRs, disconnecting the 2nd and 3rd connector yielded no difference in feel when riding, so no idea what the result really is. Much like the carb's full throttle switch.

The US NSU switch you pictured has only 1 wire, which is neutral.

None of the wiring diagrams in the factory manual, or the revised DRR version, are 100% with respect to the DRs I've worked on in Oz, especially when it comes to the NSU and CDI.

With the neutral wire disconnected from the harness, you'll need to make other electrical changes to get power to the CDI."



Once you've finished building up the clutch side, don't forget to remove the latex glove covering up the oil galley!

Coming up in Episode 7: I'll be taking care of the engines left hand side and installing the stator.

Go ahead and smash that like button, subscribe of course and stay locked in for the full DR650 790cc transformation, I have some awesome videos lined up!

Do hesitate to drop me any questions in the description, i'll get back to you in under 24 hours ;)

Let's get to work!

#dr650 #motorcycle #engine

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