Suzuki DR650 Electrical Page

 

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Suzuki DR650 Electrical Page

 

Suzuki DR650

 


Electrical

Electrical issues are the bane of many mechanics.  And if you have an old and pre-owned vehicle, you might have good reason to fear electrical mods and repairs.

 

For information on headlights see the DR650 Headlights Page.

 

For information on brake, running and turn signals, see the DR650 Signal Lights Page.

 

For information on heated clothing and grips, see the Riders Clothing Page.

 

 

Battery

Having a functioning battery is important if you have an electric start or like to run accessories while the engine in not running.  A battery may also decrease the load placed on stator and help prevent surges to your accessories and lights.  Plus at low RPMs, when your stator isn't putting out the 200Ws you were counting on, you lights won't get as dim as they would without a strong battery.

 

DR650  Battery

Stock Battery

 

If you are running a lot of accessories, and don't have a kick start setup, you may desire to upgrade your battery to a deep cycle bike battery.  These are often used by law enforcement agencies that need to run lights and communications systems for long periods while their bike is parked.

 

Odyssey PC310 Deep Cycle for 1996+ DR650s

Odyssey PC310 Dry Cell Deep Cycle for 1996+ DR650s

 

One nice investment is a battery charging system such as a Battery Tender.  This keeps your battery charged up to help with easy starts, prolonging the life of your battery and decreasing the load on your bike's charging system since it doesn't need to charge a half dead battery every time you go for a ride.

 

NiCd and other rechargeable battery packs are often used on off road to dual sport conversions.  These battery packs tend to be much lighter and more compact than lead acid batteries, which makes them easier to retrofit into a bike.  Suitable battery packs sometimes include those used in portable power tools, and remote control toys (planes, cars, etc).  For those looking to save some money or who have space limitations, they can build their own battery pack to their own special requirements.

 

Stock Battery Requirement '90-91 DR650:

Part Number: 33610-18010 - replaced by 33610-35400 YB5LB in 1991

Battery Type: YB5L-B

Mfg: Yuasa

Battery Family: YuMicron

Voltage: 12

Amps: 0.5

Capacity: 5
Dimensions: 4.75" x 2.375" x 5.125"
Metric Dimensions: 120mm x 60mm x 130mm
Weight: 3.5 lbs. 
Metric Weight: 1.6 kg

Acid Volume: 12.2

Battery Type: 12N5-3B
Mfg: Yuasa

Battery Family: Conventional
Voltage: 12
Amps: 0.5

Capacity: 5
Dimensions: 4.75" x 2.375" x 5.125"
Metric Dimensions: 120mm x 60mm x 130mm
Weight: 3.1 lbs.
Metric Weight: 1.4 kg

Acid Volume: 13.5

 

Stock Battery Requirement '92-93 DR650:

Part Number: 33610-14D00 - replaced by 33610-14D20 - then 33610-C14D2-0J000 (YT4L)

12V, 10.8kC (3 Ah)/10HR Capacity

1.320 at 20C (68F) Standard electrolyte S.G.

Battery Type: YTX4L-BS
Mfg: Yuasa
Battery Family: Maintenance Free
Voltage: 12

Amps: 0.4
C.C.A.: 50

Capacity: 3
Dimensions: 4 1/2" x 2 13/16" x 3 3/8"
Metric Dimensions: 114mm x 71mm x 86mm
Weight: 2.9 lbs.
Metric Weight: 1.3 kg
Acid Volume: 0.18

FT4L-BS

Mfg: Furukawa

Voltage: 12

Capacity: 3
Metric Dimensions: 113mm x 70mm x 85mm
Metric Weight: 1.2 kg
Acid Volume: 0.18

 

 

Stock Battery Requirement '94-95 DR650:

Part Number: 33610-17E00 or 33610-32C10- replaced by 33610-17E10 (YTX12-BS)

12V, 36kC (3 Ah)/10HR Capacity

1.320 at 20C (68F) Standard electrolyte S.G.

Battery Type: YTX12-BS
Mfg: Yuasa
Battery Family: Maintenance Free
Voltage: 12
Amps: 1.2
C.C.A.: 180
Capacity: 10
Dimensions: 6" x 3.4375" x 5.125"
Metric Dimensions: 150mm x 87mm x 130mm
Weight: 7.5 lbs.
Metric Weight: 3.4 kg
Acid Volume: 0.6

 

Stock Battery Requirement '96-97 DR650SE:

Part Number: 33610-10D00 - replaced with 33610-33E20 (FTX9-BS)

12V, 28.8kC (8 Ah)/10HR Capacity

1.320 at 20C (68F) Standard electrolyte S.G.

Battery Type: YB10L-B2

Mfg: Yuasa

Battery Family: YuMicron
Voltage: 12

Amps: 1.1

Capacity: 11
Dimensions: 5.3125" x 3.5625" x 5.75"
Weight: 7 lbs.
Metric Dimensions: 135mm x 90mm x 145mm
Metric Weight: 3.2 kg
Acid Volume: 27

(CN)

Battery Type: YTX9-BS

Mfg: Yuasa

Battery Family: Maintenance Free
Voltage: 12

Amps: 0.9
C.C.A.: 120

Capacity: 8
Dimensions: 6" x 3.4375" x 4.1875"
Weight: 5.4 lbs.
Metric Dimensions: 150mm x 87mm x 105mm
Metric Weight: 2.5 kg
Acid Volume: 0.4


Stock Battery Requirement DR650SE 1998-

Part Number: 33610-10D00 - later replaced with 33610-32C10 (prior 2001) - then replaced with 33610-33E20 (FTX9-BS) in 2006

Battery Type: YTX9-BS

Mfg: Yuasa

Battery Family: Maintenance Free
Voltage: 12
Amps: 0.9
C.C.A.: 120
Capacity: 8
Dimensions: 6" x 3.4375" x 4.1875"
Metric Dimensions: 150mm x 87mm x 105mm
Weight: 5.4 lbs.
Metric Weight: 2.5 kg
Polarity:
Acid Volume: 0.4

 

Related Links:

 

Charging and Battery Maintenance

Power Tender International

Power Tender International

 

If your bike is garaged a lot, if you like to leave your park lights on, don't want to worry about your bike not starting or just want your batter to last more than one season, you should look into getting a battery charging and maintenance system.  Battery Tender seems to have the corner on this market and their products seem to do a good job of maintaining your DR's battery.

 

Related Links:

 

 

Stator

The stock stator on new and old DR650s is 200 watts (@5,000 RPMs).  This isn't as good as some cruisers out there, but is good for a dualsport.

 

DR650 Stator

Stock DR650 Stator

 

These do burn out from time to time, leaving the bike dead after the battery is drained.  I am not aware of any higher output stators on the market, but if you are - please let me know.

 

webbikeworld  250-watt-stator

 

 

Regulator

This sits out on the front of the bike and generally doesn't give you any grief.  Upgrades are generally not necessary.  The regulator put out 13.5-15.5V @5,000 RPMs.

 

DR650 Stock Regulator

Stock Regulator

 

Fuses

Fuses are pretty straight forward and the DR 650 only comes with 4.

 

Main

20A

De-comp.

20A

Headlight (H)

10A

Headlight (L)

10A

 

If you add other fusible accessories, you may want to keep them near the other fuse to make them easier to find.

 

Auto fuses come in regular size and mini (as well as less useful large sizes).  The minis will fit into the fuse box on a DR, you if your accessories use mini auto fuses, you only need to pack extra fuses in that size.

 

Auto Circuit Breaker

Auto Circuit Breaker

 

The also make circuit breakers and other fancy resettable fuses and the like that will fit in the fuse box.  These are generally not necessary, and if they are, you probably have some electrical issues that need addressing.

 

Related Links:

Wrangler NW Power Products

 

 

Ways to Stretch your Juice

There are a few ways to stretch the 200 watts (@ full rev) your DR puts out.  This may become an issue if you have a weak battery with an electric start or wish to use heated clothing or grips and see at night.

 

 

 


Wiring Diagrams

There are a few differences in US, Canadian, Australian, and other DR650s.  This mostly pertains to the lighting issues (on/off light switch, passing light switch, and city light).

 

Wiring Schematics by Model Year and Country

'90-'93 USA + Canada

'90-'93 Australia

'90-'93 Others

Colorized Version by Peter De Ceulaer

These may not accurately represent 1990 and 1991 DR650s.
       

'94-'95 USA+ Canada

'94-'95 Others

   
       

'96-'97 USA+ Canada

'96-'97 Australia

'96-'97 Austria + Switzerland

'96-'97 Others

       

'98 on

     

 

DR650 Wiring Diagram

 

 


Power Outlets

The DR650 didn't come with any power outlets to allow you to plug in all our special accessories.  And like many things in this world, not all outlets and plugs are the same, but whatever outlet(s) you end up installing on your DR650, you can always use an adapter to hook up your choice of gadgets.

 

SAE Connector

These are generally used to hook up lights to towed trailers and make for great connectors for your bike's accessories.  It is an all-weather low-voltage, medium current connector that provides a very firm and secure connection and is far less cumbersome than auto power outlets or even BMW/Euro outlets.  The downside to its sleek size is that it can be a challenge to hook up with gloved or frozen hands.  And if the cable attached to the battery is just zip-tied to the bike, you will probably need two hands to the the connectors lined up, which isn't conducive to safe riding.  Then again, you shouldn't be trying to hook up your electric vest and zip up your jacket while entering the freeway.

 

SAE Connector End

SAE Connector End

 

This connection type uses both a male and female terminal for both the power source outlet and connection end of each accessory cord.  As long as you wire your accessory cable and your power source cables correctly the first time, you shouldn't have problems with this stet-up.  ;

 

The hot wire connected directly to the battery or other power source's  positive (red) terminal should be wired to the rubber-shrouded female side of the SAE connector.  Likewise, the positive wire on the accessory cord should be connected to the bare metal male plug end of the accessory cord.  If you use and extension cord, they you will need to wire it so that the male terminal goes to the female terminal. 

 

 

European DIN Sockets (also BMW style, John Deere, Bosch, Hella connectors, DIN standard connector, mini plug)

These European DIN (Deutsches Institut fr Normung - German Institute for Standardization) connectors are very popular outlet plug in the motorcycle community.  It is similar to the US 12V auto cigarette lighter outlets and adapters, but holds the adapter in the plug much more securely.  these allow for easy plugging and unplugging of accessories without too much worry of the plug vibrating loose during a ride.  It is also easy to plug in accessories with a gloved hand if the outlet is securely fixed to the bike.

 

BMW/Euro Plug End

BMW/Euro Plug End

 

This plug type is used by both BMW and John Deere and produced by Hella, Bosch and other aftermarket companies.  The surface mount Hella female socket provide a snug grab and the Kiwi ones are rated for 32A at 12V.

 

Some plugs are set up for use with both regular cigarette lighter outlets and the smaller BMW type outlets.  These may use a  plastic spacers that wrap around the end of the plug to allow them to fit into automotive cigarette lighter outlets.  Unfortunately many of these have poor power connections and low amperage ratings.

 

In regards to wiring, the center contact of the female outlet and the tip of the male plug should be wired as positive (+) leads.

 

Part numbers:

 

 

12mm Widder Style Connector

These were originally used as German antenna connectors.  Their design allows for a good amount of current and are used in Widder heated clothing. 

 

MANIC Salamander Zip 12mm Outlet

MANIC Salamander Zip 12mm Outlet

 

This uses a double male peg to double female peg, much like AC/DC outlets in most of Europe.  You will need to take note as to which side is positive and which s negative as the plug design is nonpolarized and you can plug it in backwards.  If you didn't use red and black wire or use them appropriately to identify which side is which, you may wish to paint, tape or otherwise mark the connectors to avoid erroneous connections.

 

These connector types can also vibrate loose and aren't the best connector type for most motorcycle uses.  They do allow you to switch polarity on power cords, just in case you have two bikes that are wired differently.

 

 

Auto Cigarette Lighter Adapter

This is the most popular outlet system used in the automotive world.  You can find all sorts of items to plug directly into these outlets as well as all different qualities of outlets and plug ends.  Unfortunately, many of the easy to find outlets are of poor quality, very in maximum current limits, allows for poor connections and are not always dependable.  The outlets themselves tend to be on the bulky side for motorcycle use.

 

12v Power Outlet

Marine Grade 12 Power Outlet

 

If you would like to avoid installing junk from the local auto store that will quickly rust on a bike, you might want to look into marine grade outlets and connectors.

 

Like the BMW outlets, the center contact of the female outlet and the tip of the male plug should be wired as positive (+) leads.

 

 

USB Port

12/24V to 5V USB

12/24V to 5V USB

 

With an explosion of computer and laptop peripherals, there are lot of devices that can run off of or get charged by a 5V USB port.

 

 

120/220V Inverters

Power Inverter

 

There are lots of inverters on the market these days.  Some are small enough to fit in your pocket and can allow you to power all sorts of items with in the middle of nowhere.  You can find one that plugs directly into a automotive power outlet or wire in to your bike with or without disconnects.

 

 

Related Links:

 

 


 

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