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Old 12-08-2012, 11:53 PM   #71716
BergDonk
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Location: Snowy Mountains Oz
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Header Failure

It might also be caused by forcing in some way your midpipe and muffler fitting. If it didn't just slide together, and had some pressure on it on assembly, it may have stressed the weakest bit.
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Old 12-08-2012, 11:54 PM   #71717
Ren20
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guys, go check your NSU screws if you haven't. I just checked. one of them is so loose. I could turn it with one finger.

I did it without taking the clutch out. it was pain in the ass. they are now tighten and safety wired. I still consider myself lucky

bike has 7800 miles. 2001

Ren20 screwed with this post 12-09-2012 at 12:03 AM
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Old 12-09-2012, 12:04 AM   #71718
NordieBoy
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Joined: Dec 2006
Location: Kiwiland
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Quote:
Originally Posted by blk-betty View Post
Know nothing about machining. Are those welds "cleaned up" by hand or is it all mechanized?
By hand.
Before...


After...


Over 60% more surface area.
May be more prone to cracking on the edge of the weld, but I'm willing to risk it.

Oh, and that was 5 1/2 years ago.
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Old 12-09-2012, 01:12 AM   #71719
eakins
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Location: Fort Collins, Colorado
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so what ever happened to the rally fairing Safari was building?
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Old 12-09-2012, 01:34 AM   #71720
Phreaky Phil
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Quote:
Originally Posted by eakins View Post
so what ever happened to the rally fairing Safari was building?
Have you seen this update
http://www.advrider.com/forums/showthread.php?t=822511
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Old 12-09-2012, 02:01 AM   #71721
Mambo Dave
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Joined: Oct 2011
Location: 11 ft. AMSL
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Quote:
Originally Posted by Ren20 View Post
guys, go check your NSU screws if you haven't. I just checked. one of them is so loose. I could turn it with one finger.

I did it without taking the clutch out. it was pain in the ass. they are now tighten and safety wired. I still consider myself lucky

bike has 7800 miles. 2001
What type of screwdriver did you use to get in there?

I have about the same mileage and really need to do mine.
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Old 12-09-2012, 03:39 AM   #71722
greer
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Some folks use a screwdriver bit and a wrench. We used one of these with the back side of the "neck" filed down to give a bit more clearance. It's a little fiddley but works just fine, we've used it on three bikes now. Remove, degrease, and loctite one screw at a time or the whole assembly will want to pop out as it's got a spring under there.

Sarah

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Old 12-09-2012, 06:33 AM   #71723
victor441
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Joined: Jul 2009
Location: Sonoma, Calif.
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Quote:
Originally Posted by greer View Post
Some folks use a screwdriver bit and a wrench. We used one of these with the back side of the "neck" filed down to give a bit more clearance. It's a little fiddley but works just fine, we've used it on three bikes now. Remove, degrease, and loctite one screw at a time or the whole assembly will want to pop out as it's got a spring under there.

Sarah


good to know, need to do mine ASAP....BTW there is oil resistant threadlocker available, plan to use it when I do the job, especially if I don't remove the clutch basket

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Old 12-09-2012, 09:29 AM   #71724
Mambo Dave
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Quote:
Originally Posted by greer View Post
Some folks use a screwdriver bit and a wrench. We used one of these with the back side of the "neck" filed down to give a bit more clearance. It's a little fiddley but works just fine, we've used it on three bikes now. Remove, degrease, and loctite one screw at a time or the whole assembly will want to pop out as it's got a spring under there.

Sarah

Thanks man,

any chance there is enough room to get one of these in there?

http://www.sears.com/shc/s/p_10153_1...=31-59333379-2

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Old 12-09-2012, 10:20 AM   #71725
SkunkWizard
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Joined: Mar 2009
Location: "the Planet"
Oddometer: 685
I'm looking at getting a cover for the DR. I've been sharing the carport with Skunkwife and don't want her cooties to get on the bike.

so the question is, what size cover to get? XL/ XXL any body have a recomendation on brand?
needs to fit over soft panniers, no windscreen

thanks
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Old 12-09-2012, 10:47 AM   #71726
Fire Escape
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Didn't work for me

Quote:
Originally Posted by Mambo Dave View Post
Thanks man,

any chance there is enough room to get one of these in there?

http://www.sears.com/shc/s/p_10153_1...=31-59333379-2

I tried that and also one that had an angled handle, neither fit in there well enough to tighten anything. I only used it to take the old screws out though, got Allen heads and drilled them for safety wire to put in. I know that a lot of people have had great luck with Locktite but ... I was too lazy to remove the clutch and didn't figure that I could degrease the holes very well without better access, also I have seen plastic have a bad reaction to Locktite and disintegrate. I didn't want to have to be fishing pieces of the NSU out of the sump. So old fashioned wire was my choice, it is a real pia to do it underneath the clutch but I got it done. When all was said and done, it probably would have been quicker and easier to remove the clutch (doah, not like that hasn't been already said but sometimes you just have to try...)! The worst part of the job for me was the hours that I spent getting the old gasket off. Mine was in pretty good shape and I could probably put a bit of sealer on and been fine but I had a new gasket so ....
Neither of my NSU screws was 'loose' (as in falling out) but I could not detect ANY 'breaking torque' in turning one of them out, the other required very little effort to start turning.


Bruce
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Old 12-09-2012, 10:55 AM   #71727
dogjaw
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Joined: Jul 2008
Location: between the Ozarks and the Ouachitas
Oddometer: 2,851
Quote:
Originally Posted by blk-betty View Post
'09 DR650 just turned 6K miles today and about 20 miles from home exhaust got a little bit louder. About 10 miles got a whole lot louder. Figured it was a crack somewhere on the head pipe as that where the sound was coming from.

Thought about stopping and worried a little about doing engine damage but had no other way to get home so babied it the last 10 miles.

WTF! The head pipe is broken clean off at the flange where it bolts up and there is about 1/2" gap 360 degrees, actually looks like someone cut it off with a rough blade hacksaw.

Is this a common occurence?

Only motor mods are opened up breather box with DT-1 air filter, Pro-Cycle jet kit, and GSXR1000 muffler with Kientech mid-pipe on OEM header.

Anyone have a spare oem header or is there a better option.
I also have a stock header; just went to the FMF... PM me if needed
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Old 12-09-2012, 11:13 AM   #71728
Mambo Dave
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Quote:
Originally Posted by Fire Escape View Post
I tried that and also one that had an angled handle, neither fit in there well enough to tighten anything. I only used it to take the old screws out though, got Allen heads and drilled them for safety wire to put in. I know that a lot of people have had great luck with Locktite but ... I was too lazy to remove the clutch and didn't figure that I could degrease the holes very well without better access, also I have seen plastic have a bad reaction to Locktite and disintegrate. I didn't want to have to be fishing pieces of the NSU out of the sump. So old fashioned wire was my choice, it is a real pia to do it underneath the clutch but I got it done. When all was said and done, it probably would have been quicker and easier to remove the clutch (doah, not like that hasn't been already said but sometimes you just have to try...)! The worst part of the job for me was the hours that I spent getting the old gasket off. Mine was in pretty good shape and I could probably put a bit of sealer on and been fine but I had a new gasket so ....
Neither of my NSU screws was 'loose' (as in falling out) but I could not detect ANY 'breaking torque' in turning one of them out, the other required very little effort to start turning.


Bruce
Thanks guys.

I wonder if I ground that selector down if it would fit better?

Surely someone has to make an offset driver that would fit well enough... but then I haven't been in there, and it may be more complex than I'm thinking in getting up under the clutch plates.
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Old 12-09-2012, 11:42 AM   #71729
blk-betty
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Broken Header

Couple of pics.

This is what I found when I got home....





After removal....



Doesn't look like anyone has done any grinding...

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Old 12-09-2012, 11:55 AM   #71730
Fire Escape
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Location: Epsom, NH
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Quote:
Originally Posted by Mambo Dave View Post
Thanks guys.

I wonder if I ground that selector down if it would fit better?

Surely someone has to make an offset driver that would fit well enough... but then I haven't been in there, and it may be more complex than I'm thinking in getting up under the clutch plates.
It is 'really interesting' getting anything in there. One of those cases where you can see what you need to do but once you fit something in ... you can't turn the fastener much. I ended up grinding an Allen wrench, way down to where there was barely enough shank to fit into the screw head to replace my screws. Even if you grind everything off the back side of that driver, I am not sure that it will fit but obviously something will. I did get the screws out, I just don't recall what I ended up using as every 'screw turning thing' I had was out at the time. You will get it done but don't plan on it being quick or easy.


Bruce
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06 DR 650, Moose RS Holder, Handguards and Skidplate, ProTaper bars, Garmin 60CSx, Motech racks w/ 20mm Ammo cans, Renazco, TKCs summer/17" SM wheels winter 08 Scrambler, Conti Trail Attacks and BlackTiger Fork mod, 05 FSE 450, 03 KLR 250, 02 FXDX, 72 WR 250 (again), 72 SL 350 K2 (again), 72 TR6R, 06 XT 225
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