TDSA Rally

I've signed up for my second 2017 Dual Sport Rally. The 3-day Tennessee Dual Sport Adventure Rally is held March 31-April 2 in Hohenwald, TN (mid-State).

Devil's Creek Rally starts exactly one week from today!

DR650 Side Stand Switch

The side stand switch is a safety device integrated into the DR650 electrical harness. Be advised that its removal poses risks. Ask your dealer for more information and advice.

Onward...

We're only a couple weeks out now on the first Dual Sport Rally of the season (Devil's Creek) and I'm putting some final touches on the DR650 to have it ready for action. Today I removed the side stand safety switch.

The side stand switch is a safety device that prevents a motorcycle from being started and operated while the side stand is down. One can be found on virtually all contemporary motorcycles. However, they can be a real headache out on the trails. 

• The first problem is that loose branches from the forest trail can force the side stand down enough to engage the switch while on trails. 
• The second problem is that the switch itself is very exposed and susceptible to damage on the trail. You can pull the branches out and continue the rally, but if the switch is damaged the day is over, if not much longer as a safety switch problem can be elusive.

Here's a look at the side stand safety switch on my 2016 Suzuki DR650. As you can see it's a very exposed button-actuated momentary pressure switch.

Removal of the physical switch is as simple as removing a couple of screws. The connecting cable runs up the frame to a green quick disconnect directly behind the fuel tank.  

A quick, but somewhat flawed short cut to the side stand switch removal is to jump the two wires at the green connector and make a continuous open circuit at this location. However, the wiring harness that supplies current to the switch also includes a side stand switch relay. That relay should be disabled as it's an electronic device, no longer needed for side stand safety switch operation, that is susceptible to failure.The side stand relay (photo below) is located under the seat on the left side of the CDI unit.

The four wires to the relay are Orange x2, Orange/Black and Green.

The bypass to disconnect the side stand safety switch without otherwise interfering with the electrical flow in the wiring harness is to fuse either of the Orange wires to the Orange/black, thus creating a permanent open circuit. Fusing the wires can be done with a jumper wire or, as I have done, simply cut and crimp the wires.

It's an important connection so I soldered the splice before wrap.

Then I wrapped it up tightly...

...and returned the (now inoperable) relay to it's hanger. The motorcycle now can be put in gear with the side stand in the down position. The safety feature is gone.

I also went back and wrapped the green male-end of the quick disconnector to the side stand switch.

Lastly, some versions of the side stand safety switch removal include removal of the Neutral Switch diode (located behind the tank); another electrical component that could fail. However, that step isn't absolutely necessary to achieve the objective of the side stand safety switch removal. If the diode failed, in would simply render the neutral light on the dash inoperable. Just keep that in mind, should that light fail to come on while in neutral.

I believe that a record of the side stand safety switch should be made in our motorcycle's records and disclosed, along with all significant modifications, to future purchasers of the motorcycle. Consider doing so.

UPDATE OCTOBER 2021

As you now know I've acquired a 2012 model DR650 and was quick to remove the side stand safety switch, again only because of the potential problems that it may cause in my off road ventures. However, this time I did the bypass using blade connectors as shown in the following photos. Essentially this approach is cleaner from the standpoint that future road-focused buyers of your DR650  can more easily reincorporate the side stand safety switch into their models assuming, of course, that all relative parts and elements of the harness are retained.