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Old 12-09-2012, 05:33 AM   #71731
victor441
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Joined: Jul 2009
Location: Sonoma, Calif.
Oddometer: 829
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, 08:29 AM   #71732
Mambo Dave
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Location: Pompano Beach, FL
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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, 09:20 AM   #71733
SkunkWizard
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Joined: Mar 2009
Location: "the Planet"
Oddometer: 656
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, 09:47 AM   #71734
Fire Escape
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Joined: Apr 2007
Location: Epsom, NH
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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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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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Old 12-09-2012, 09:55 AM   #71735
dogjaw
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Joined: Jul 2008
Location: between the Ozarks and the Ouachitas
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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, 10:13 AM   #71736
Mambo Dave
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Location: Pompano Beach, FL
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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, 10:42 AM   #71737
blk-betty
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Location: Charleston, SC
Oddometer: 2,315
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, 10:55 AM   #71738
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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Old 12-09-2012, 11:03 AM   #71739
ER70S-2
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Location: SE Denver-ish
Oddometer: 5,256
TREE used this. There are more photos and info in the link.

http://www.advrider.com/forums/showp...1&postcount=65

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Quote:
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"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 12-09-2012, 11:36 AM   #71740
Adv Grifter
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Location: Passing ADV Stalkers in California
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Quote:
Originally Posted by blk-betty View Post
Couple of pics.
This is what I found when I got home....

bummer.
My real concern here is for your valves. When the header is broken like that ... the head is open directly to cold air rushing in onto red hot valves.
In some cases the cold air can cause valves to warp a bit.

I know our Auto mechanic guys here know about this. Is this of concern?
Or would one need to run for hours and hours like this to have a bad out come on valves?

I ruined a Go Cart lawnmower motor once, header pipe broke off. 11 year old kids? ... cool! LOUD! We kept riding. Motor didn't run too good after that!
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Old 12-09-2012, 12:37 PM   #71741
Rusty Rocket
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Joined: Dec 2005
Location: Northcentral CT
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Quote:
Originally Posted by Fire Escape View Post
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.
same here
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Old 12-09-2012, 01:47 PM   #71742
procycle
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Location: Center of the DR650 universe
Oddometer: 2,161
Quote:
Originally Posted by Adv Grifter View Post
... the head is open directly to cold air rushing in onto red hot valves.
In some cases the cold air can cause valves to warp a bit.

I know our Auto mechanic guys here know about this. Is this of concern?
Or would one need to run for hours and hours like this to have a bad out come on valves?
I've always been skeptical of the old 'warp your valves' claim. I can't see how a little bit of cool air could do any harm. Especially since the exhaust valve heads get a blast of cool air on every intake stroke anyway.

My own opinion of where this old wives tale came from is this: If the motor had a restrictive exhaust and loosing the whole system caused the fuel mixture to become too lean - then you could easily damage the exhaust valves,
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Old 12-09-2012, 01:50 PM   #71743
sunthechip
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Paint job

Paint job

I did it myself instead of paying $40 for the decal.

Thanks for the help Tokyoklahoma.

Supplies:
-Krylon Fusion for plastic- White gloss and black gloss.
-Frog tape.
-Exacto knife

Painter's tape and an exacto:


Peeling away the stencil:


Prepping for paint (I had already done the white coating):


Painting:


Finished product:


Affixed:
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Old 12-09-2012, 01:54 PM   #71744
blk-betty
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Joined: Aug 2009
Location: Charleston, SC
Oddometer: 2,315
Quote:
Originally Posted by Adv Grifter View Post
bummer.
My real concern here is for your valves. When the header is broken like that ... the head is open directly to cold air rushing in onto red hot valves.
In some cases the cold air can cause valves to warp a bit.

I know our Auto mechanic guys here know about this. Is this of concern?
Or would one need to run for hours and hours like this to have a bad out come on valves?

I ruined a Go Cart lawnmower motor once, header pipe broke off. 11 year old kids? ... cool! LOUD! We kept riding. Motor didn't run too good after that!
Burning up the valves was the first thing I thoguht of and in the forefront of my mind while riding home.

I really babied it and it seemed to run fine at low rpms, albiet loud, never reved beyond half-throttle.

Debating on just picking up a take-off OEM or going with the FMF PowerBomb stainless header.

Anyone know if the PowerBomb will bolt up to the OEM sized midpipe from Kientech or will I need the larger diameter midpipe....if so I'll just go with another OEM.

And does the PowerBomb really do much for performance?
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Old 12-09-2012, 01:54 PM   #71745
procycle
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Location: Center of the DR650 universe
Oddometer: 2,161
Quote:
Originally Posted by Fire Escape View Post
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
Really! Removing the clutch isn't that big a deal. Nothing to be afraid of! Plus, it's an opportunity to inspect the steel plates for hot spots and the clutch basket fingers for wear. It doesn't take any more time to remove the clutch than it takes to dink around grinding tools and turning little screws 1/12 of a turn at a time. Once you have the clutch cover off it only makes sense to inspect everything you can while you're in there.
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www.procycle.us - Everything for your DR650 and lots of other great stuff!
DR900 Big Bore Stroker buildup
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