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Old 04-28-2013, 12:20 AM   #13126
sidetrack one
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Mucho easier with the clutch off, IMO, but you need to be tooled up a bit!


I reckon that top screw would be fairly fustrating, but I dont know, I took the clutch off!

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Old 04-28-2013, 12:42 AM   #13127
BergDonk
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My preference is to take the clutch off, it just opens up the access and it is a simple enough job, but like Dave says, needs a few tools, and an accurate torque wrench. 10 nm for the clutch springs and 50 nm for the 27 mm centre nut. The lock washer can be recycled with care, so no extra parts required. Doing it with the clutch on is tight and fiddly and will entail adapting a screwdriver of some sort. If you take one screw out at a time then the plunger and spring in the switch can't go walkabout. If you use Loctite, flushing all the oil out of the threads is not necessary, but nevertheless nice. I use aerosol brake cleaner. most evaporates off, but after its all buttoned up its due for an oil change anyway so any contamination is flushed out then. Stick it in fifth gear and you can hold the rear wheel to get 50 nm no worries.
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Old 04-28-2013, 06:34 AM   #13128
KIZ
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Nsu

Thanks for the replies guys , looks like another job to do soon, always looking to keep the DR in a good and reliable condition. Might be ready for the OCR next year. People keep worrying me with posts of explodeing 3rd gears. Keep the rubber side down Marty
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Old 04-28-2013, 10:32 AM   #13129
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Quote:
Originally Posted by BergDonk View Post
If you take one screw out at a time then the plunger and spring in the switch can't go walkabout.
Not my photo.
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Old 04-29-2013, 02:13 AM   #13130
rutsthematter
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Here is a pic of the genuine Suzuki CS retainer PN 24751-32E00. They should start installing them on new bikes.
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Old 04-29-2013, 03:10 AM   #13131
Croney
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Rotopax with Wolfman panniers

Has anyone strapped a set of soft panniers over some rotopax ?
Ive tried mine and the locking devise sticks out and into the pannier bag….is this normal.?
Can anyone share a photo for me please ?

Cheers..
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Old 04-29-2013, 03:30 AM   #13132
td42dan
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Want more comfort!!!!

so whats the best seat for comfort ?????
also wheres the best place / price to get one from???
ive a standard DR seat....
also after a seat thats comfy for a pillion....
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Old 04-29-2013, 03:41 AM   #13133
Sleepy John
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http://www.seatconcepts.com/products...358&id=7268100

http://www.seatconcepts.com/products...58&id=13933398
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Old 04-30-2013, 04:12 PM   #13134
Maso
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Rotopak solution

Quote:
Originally Posted by Croney View Post
Has anyone strapped a set of soft panniers over some rotopax ?
Ive tried mine and the locking devise sticks out and into the pannier bag….is this normal.?
Can anyone share a photo for me please ?

Cheers..
I have cut some thick dense foam spacer plates to build the bag out from the locks.
A slot cut in the middle for the lock to sit into.
Makes it a bit wider but gives a flat surface for the bag to sit on
I will take some photos tonight and post them up.
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Old 04-30-2013, 06:09 PM   #13135
0405canvet
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400 to 650

Hey maso, could you report on the good and bad going from your 400 to the 650 please?? Just thinking about doing the opposite.
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Old 04-30-2013, 08:09 PM   #13136
Maso
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The main reasons I went to the 650 is the 400 was struggling in my opinion once it was loaded up with gear and fuel especially on the tar at 100 KPH temprature would climb noticably.

The 650 handles the long tar sections a lot more comfortably.

Having had the suspension done on the 650 compared to the standard 400 suspension for the riding I do, you do not have to work as hard on the 650 so don't end up as tired at the end of the day.

I am not interested in single track anymore so the 650 was a better suited bike for my riding.
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Old 05-01-2013, 05:34 AM   #13137
Croney
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Thumb Rotopaks

Quote:
Originally Posted by Maso View Post
I have cut some thick dense foam spacer plates to build the bag out from the locks.
A slot cut in the middle for the lock to sit into.
Makes it a bit wider but gives a flat surface for the bag to sit on
I will take some photos tonight and post them up.
Cheers Maso thanks.
Pretty much what I had figured I needed to do....would be good to see it though.
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Old 05-01-2013, 03:23 PM   #13138
Maso
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Crony

I do not have them on the bike at the moment but here is what they look like.





They are a sheet of foam from Clark Rubber about 10 or 12mm thick glued togeather with contact cement then cut to shape.They did not have 20mm thick when I was there or I would have gotten that.
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Old 05-01-2013, 04:53 PM   #13139
DR Ozzy
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Where did you get your rotopax's from? ... US?
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Old 05-01-2013, 07:09 PM   #13140
Maso
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A group of us got togeather and did a bulk buy of all sorts of DR stuff from Procycle in US but Adventure Moto do have them.
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