2010 DR650SE Oil and Filter Change - Page 3

Oil Filter Replacement

9. Tape some newspaper to the engine just below the oil filter cover to redirect any escaping oil to the drain pan. This helps to reduce the amount of mess.

10. Reposition the oil drain pan below the oil filter cover.

11. Remove the oil filter cover. With an 8 mm socket, a 3- to 6-inch extension and ratchet (I use a 1/4-inch drive), loosen the three bolts securing the oil filter cover on the right-side engine cover. Oil will likely run out. Completely remove the three bolts while holding the cover so that it doesn't slip off and fall. There is a spring between the cover and the oil filter; it usually comes off with the cover. Be careful not to lose the spring. There is also an O-ring set in a groove of the oil filter cover. The service manual states to use a new O-ring. Remove the cover.

12. Remove the oil filter from the engine and inspect it for debris. It's normal for it to look dark and contain very tiny metallic bits (sparkles) and sometimes a bit of sealant (grey or black). If you find other material or large metal bits, etc., it may be an indication of a problem in the engine. It may also be clutch material or debris left over from the manufacturing process. If you're unsure or concerned, take the oil filter and material to the service department at a trusted bike shop for their opinion.

There is an O-ring situated between the oil filter and the oil filter cavity back. The O-ring may stick to the filter or it may remain in position around the oil passage protrusion at the back of the cavity. The service manual states to use a new O-ring.

13. Remove the O-ring from the oil filter cover. Clean the groove that the O-ring sits in as well as the surface of the filter cover that makes contact with the engine. Wipe off the O-ring and inspect it. If it looks to be in good condition (no signs of damage or deterioration, and it is still pliable with a circular cross section), you can likely reuse it although the service manual states to use a new one. The service manual states to lightly apply oil to the O-ring. Insert the O-ring into the groove of the oil filter cover and set the cover aside.

14. If there is any debris or sediment in the oil filter cavity, wipe it out with a clean rag or shop towel. Wipe the oil filter cover sealing surface of the engine. Also clean the oil filter cover bolts and the bolt holes if oil seeped in.

15. Install the small O-ring over the protrusion at the back of the oil filter cavity.

16. Insert the filter into the engine with the hole facing inwards to the engine. Verify that the small O-ring is still in position before installing the filter. Before I install the new oil filter, I pour fresh motorcycle oil into the filter and rotate it so that the filter element is saturated with oil. Handling and installing an oil-filled filter is messier than a dry one, and oil will begin to run out if you take too long.

17. Ensure that the O-ring and spring are in position in/on the oil filter cover. Install the oil filter cover over the oil filter in the proper orientation (determined by the "Suzuki" label). Insert and hand-tighten the three (clean) bolts that secure the oil filter cover. I then tighten each bolt to 5.5 N.m (4 lb-ft) with a torque wrench. Generally, torque specs apply to clean, dry, oil-free threads (unless otherwise specified).

Add Oil To Engine And Check The Level

18. Remove the oil filler cap if not already. There is an O-ring which is attached to the cap. Clean around the edge of the cap and the oil filler hole. Also, clean and inspect the O-ring. Replace the O-ring if it's deteriorated or if oil has been leaking past it. Coat the O-ring lightly with oil.

19. Pour the recommended oil into the engine up to the full mark. Do not overfill the engine; if you do overfill the engine with oil by accident, remove the excess through the oil filler hole with syringe, or by carefully draining some oil out through the oil drain hole (remember to properly tighten the oil drain plug afterwards). If there is too much oil in the engine, it may become aerated (full of bubbles) and the oil lubrication system may be less effective. Also, crankcase pressure may become excessive leading to oil leaks. If the oil level in the inspection window is just a bit over the full mark, you're likely fine, especially if you replaced the oil filter as the oil level will likely drop a bit after running the engine.

20. Install the oil filler cap with its O-ring. Clean up any spills or mess on the bike.

21. Start the engine and run it at idle speed for about 15 seconds.

22. Stop the engine. The manual states to wait about one minute, and then check the oil level in the oil level inspection window. The motorcycle must be completely upright and on a level (horizontal) surface for accurate oil level determination. Add oil to bring the level to the upper (max) level if it's below it.

23. Start the engine and run it at idle speed for a few minutes to circulate the fresh oil and to check for oil leaks.

24. Stop the engine. The manual states to wait about one minute, and then check the oil level. Add oil to bring the level to the upper (max) level if it's below it.

25. Clean up. Pour used oil into containers. Examine the bottom of the drain pan for possible debris from the engine. Dispose of the used oil responsibly (take it to a recycling facility).

All done!