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Old 03-18-2012, 02:19 PM   #61516
eakins
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Location: Fort Collins, Colorado
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Quote:
Originally Posted by TRAVELGUY View Post
All this posting about sprocket inside/outside and chain alignment got me thinking, which can be dangerous. Many mentions have been made in past postings that the snail chain adjusters may cause misalignment of the rear wheel. I checked this on my previous DR with a tool sold by KTM, a large set of dividers that measure from the center of the swing arm shaft to the center of the rear axle. On that bike it checked out to be parallel to within a few thousands. Use to measure this with a tape measure before finding the KTM tool. My idea/question now is why not grind off the indentations on the snail adjusters so that they would be micro adjustable? I didn't like before that one notch the chain was looser than I liked and the next was tighter than I wanted. A month from now I will be starting the build of my DR650 travel/adventure bike. First time I remove the rear wheel I think I will do the grinding on the snail adjusters.

TravelGuy
i only use this tool, not the numbers for alignment
http://pitposse.com/chalto.html
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Old 03-18-2012, 02:27 PM   #61517
joefromsf
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Thumb Lower Shock Mount Repair

Quote:
Originally Posted by joefromsf View Post
Unfortunately, I have bigger problems now. I just stripped the lower shock mount. I knew the specified torque of 55nm in the manual was wrong and had a note in the manual to use 37nm but that still over did it.
Well my weekend is ending on a better note than it started. I just finished repairing the threads on the lower mounting hole of my rear shock, and am very happy with the results.

First I was extremely lucky to already have a Time-Sert thread repair kit specifically for M10x1.25 threads, and the required tools. Pictured below, Time-Sert kit, tap wrench, tapping guide and cutting fluid. Note the tapping guide is extremely important as it helps keep the tool straight while drilling out and tapping the new hole.



Here's a close-up of the new thread insert that I used. I was concerned because it is 16mm long and the metal to be repaired was only 6mm thick.



Here is what it looks like loose fitted into the overbored and threaded hole:



I was trying to decide whether to cut/file the protruding section down after install or leave it that way as clearance would not be an issue. But then I wondered if those outer threads would be compatible with an M12 nut. Wow, perfect fit. Even better, the nut was 10mm thick so I still had a full 6mm that would be engaged in the shock.



After installing with red-loctite and press fitting the insert.



I was afraid of me forgetting or subsequent owner not knowing that the nut is fixed and not meant to be removed with a wrench like all of the other suspension bolts/nuts, so I applied some JB weld to it.



And a little yellow nail polish. Note that there is plenty of clearance.



Like I said, I am totally happy with this fix and don't think I'll need to send it off for repairs. I was even able to to all the work with the shock still mounted in the bike.
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Old 03-18-2012, 02:32 PM   #61518
eakins
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Quote:
Originally Posted by Albie View Post
Couple things. I've had IMS, Clarke and Acerbis tanks. Acerbis is easily the best of the bunch. I've never had an issue with the dual petcock setup, they just work. It's so much easier not having to bother finding a place you can lean that big pig of a bike over to get at the fuel much less laying it on it's side if you're stuck someplace flat. While I can't imagine why you feel you need to have that other lobe as another reserve, all you have to do is simply shut the petcock off on that side and you have the same situation as with the IMS. The IMS quality is just plain inferior to Acerbis. For $10 more the Acerbis is easily a winner hands down just based on the better quality. Now if I already owned an IMS then different story. I'd just keep the IMS. But luckily I haven't got around to getting a bigger tank till now, so I just ordered the Acerbis.
my IMS tank now hold 5.3 G after expansion (i'm sure the Acerbis will expand too). i've drained my IMS to the point of running out of gas and there was litterally a drible of fuel in the tank so this tells me the all the gas was getting over from the right side to the left and the petcock. i never once did tip the bike to the left just. thought i would need to but it all drained by itself.

for the same price i do know acerbis makes a better quality tank and it will expand some more too, especially if you use a locking cap as it does not vent out and heat expands the fuel. i have an acerbis locking cap on my ims and the hand feels hard at times (thus the expanding). i crack it open from time to time when riding in hot weather. i did have some concern that world put too much pressure on the tank itself or push air out the floatbowl valve (maybe it does), but after 2 years i've had no issues with the locking cap on an IMS tank.
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Old 03-18-2012, 03:04 PM   #61519
jon_l
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I find it odd to have inside-threaded end on the front axle:


DR650 front axle

At first I thought I was missing something, but Wifey's Sherpa looks the same. Is something missing? If not, does anyone know the purpose of the threaded hole? It holds dirt, seems like it should have a screw in it.
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Old 03-18-2012, 03:10 PM   #61520
jon_l
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Quote:
Originally Posted by eakins View Post
yes, i knew i remembered that. thanks for the visual.

anyone with a new PBI, that is bevel is not there correct?
they fixed the problem?

if it's still there then stay away. hopefully they fixed it.
Eakins - this is the 14T I am about to install, bought from Procycle in November.


PBI sprocket 001


PBI sprocket 002

I am waiting for Jeff to advise before I install it, since the collective are not unanimous regarding which way the raised shoulder is supposed to go.
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Old 03-18-2012, 03:21 PM   #61521
Nibis
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Quote:
Originally Posted by jon_l View Post
I find it odd to have inside-threaded end on the front axle:


DR650 front axle

At first I thought I was missing something, but Wifey's Sherpa looks the same. Is something missing? If not, does anyone know the purpose of the threaded hole? It holds dirt, seems like it should have a screw in it.
It's probably used in the machining process on the lathe
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Old 03-18-2012, 03:36 PM   #61522
maynard911
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Quote:
Originally Posted by AdventureChick View Post
You said you ended up putting the cee baileys on the shelf.
Did you end up trying any other one that you might recommend?
I ended up cutting down an old aftermarket lexan headlight fairing that was on my old Moto Guzzi. I've forgotten the maker. I searched around the internet and have not been able to find one for sale, so they are probably no longer made. As you can see in the picture it has an angle of attack similar to a sportbike fairing. The wind hits me just below the bottom of my helmet, is completely smooth, and it takes all the pressure off my chest. The low angle is never in the way, even standing leaning way forward on a steep ascent you are over top of it. If you did contact it in a get off it is flexible 1/8 lexan, has all rounded edges, and installed with nylon bolts, so unlikely to cause harm. On my first DR I used an upside down EX500/Ninja 600 shield with a little trimming of the upper edge and that worked pretty good also.

http://imageshack.us/photo/my-images/594/dscf0015gs.jpg/
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Old 03-18-2012, 04:10 PM   #61523
Involute
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Probably be a DR owner buy the end of the week

More money than brains but not much of either. I've got the bug to add another bike the the stable (currently holding an 08 DL1000 and an 06 CBR1000RR) and I think I've talked myself in to a 2005 DR650 with 4700 miles on it even after reading all about the dreaded 3rd gear problem. If I ever quit talking about an Alaska ride and quit spending the money I have for it I'll probably use this bike for that if I get it, even after spending a bunch on my Strom to set it up for the ride. It's got a Supertrapp slip-on and what appears to be a Suzuki Alum skid plate on it. Nice shape (blue/white). Once we get it started (dead battery) and I take her for a spin I'll probably pick it up. The dude is a fellow MSF Instructor I've taught with a few times so I'll feel bad about offering $2k rather than the $2500 he's hoping for but I told myself prior to looking around that $2k is the most I'll spend. Of course I'll most likely spend another $1500 on the crap I need to set it up for my fat ass to back country tour on not including the rest of the misc crap I feel I can't live without. I'll probably spend a few months riding it mostly as is before I start dumping $$ in to it though. If I don't like it I figure I can turn around and sell it and not lose much, if anything. I ran out of pavement worth exploring in UT quite a few years ago, and I can't make it to other states every other weekend to explore new stuff there so I might as well hit the dirt again on something less beastly than the Strom. I had a 98 KLR650 years ago and had a great time on it hitting some light trails and backroads so what the hell right? I could probably take my Strom on a lot of the stuff I plan on riding but it'd be too much work to be enjoyable and I don't like the idea of it tipping over all the time and getting banged up.

Nothing much else to say other than thanking you folks for posting the informative things you have. I'm sure I'll have questions. Oh, and another thing, if I lose the engine due to the tranny disintegrating I'll hunt all you people down that go on about the reliability of this thing on my Strom and take a big, big ol poop in your driveway.
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Old 03-18-2012, 04:13 PM   #61524
ben2go
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Quote:
Originally Posted by Involute View Post
Oh, and another thing, if I lose the engine due to the tranny disintegrating I'll hunt all you people down that go on about the reliability of this thing on my Strom and take a big, big ol poop in your driveway.
Please do.It may help the grass that's growing in it.
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Old 03-18-2012, 04:33 PM   #61525
ilragazzo
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new owner of a slightly used DR.

I bought discoganya's 2005 DR650se. For a good price. I love it. a little twitchy on the freeway compared to my katana, and more uncomfortable than my kat. but alot more useful when the pavement ends.
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Old 03-18-2012, 05:52 PM   #61526
eakins
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shoulder goes in, but it looks like that PBI is similar to than the 1
trailrider383 posted above. it still has the bevel in the shaft mount area.

maybe it's much less. hard to tell how much unless you take an angle pic. trailrider had output shaft damage from that design as he reported in 2008 as there is less support area on the output shaft than the JT or oem CS (which are 90 degree cuts on both sides). look at the pics above and see if your PBI looks like the one above. Jesse was suppose to contact PBI back then and find out why they add a bevel when the oem one does not have that bevel? guess that never got resolved.

...sorry jeff @ PC if this is an issue.

edit:
i have a spare 14 JT so i just took some pic.
i thought HT was 90 deg cuts but it slightly beveled on each side.
bevels are 1mm deep and the overall center width is 10mm so there is 8mm on these CS that contacts the motor output shaft. no one has reported wear issues w/ JT. I'd say if you have atleast 8mm of contact those PBI are good but if that bevel is deeper than it has less.






Quote:
Originally Posted by jon_l View Post
Eakins - this is the 14T I am about to install, bought from Procycle in November.


PBI sprocket 001


PBI sprocket 002

I am waiting for Jeff to advise before I install it, since the collective are not unanimous regarding which way the raised shoulder is supposed to go.
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eakins screwed with this post 03-18-2012 at 06:05 PM
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Old 03-18-2012, 06:48 PM   #61527
zdiver1
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Location: Peoria,Arizona
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About time!

Well it was raining and hailing out today so I finally got around to installing my HID light kit and battery charger that I bought on a black Friday sale in November! all I can say is it is very crowded in the wiring area.
Next project Acerbis 5.3 tank I ordered white so I should get it soon.


Eakins, I already have the new locking gas cap and it looks like it has a built in vent?
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Old 03-18-2012, 07:40 PM   #61528
TaZ9
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Quit beating a dead horse...

[QUOTE=sagedrifter;18243781]Shoulder goes in. The flat side is were the retainer fastens too. That's the way its been from day one on my bike.

If you want to put it on backwards, go for it. It doesn't matter much, it will still work. The drive line is not perfectly straight anyway. If you want it to be more flexible, run the clip, many do.

Nothing to worry about. Many of us have ran 520 set ups for many miles.

---------------------------------------------------------------------------------------------------------------------------------------------------------
Sagedrifter is right...the shoulder goes inward. So get over it and ride!

Just for discussions sake, motorcycle guru Elden Carl at www.topgunmotorcycles.com has ridden over 1,000,000 miles on various motorcyles including over 180,000 miles on his DR650's. He and his friends ride a variety of motorcyles and they prefer (and sell) the JT sprockets saying, "They (JT sprockets) lasts longer than anything else we have tried".

I too prefer them over the PBI.

Ride safe

Taz9

TaZ9 screwed with this post 03-18-2012 at 07:42 PM Reason: grammer
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Old 03-18-2012, 07:51 PM   #61529
shaddix
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So I bought my 09 DR650 last night. First bike. Finished my BRC today. Then I came home and goosed the rear wheel out from under me in the front yard. Landed flat on my face! Broke the rear left blinker off but no damage to me. I'm gonna try to keep that as my only wreck ever XD!
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Old 03-18-2012, 08:00 PM   #61530
thumpididump
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Congrats.


You got it on video, right?


Quote:
Originally Posted by shaddix View Post
So I bought my 09 DR650 last night. First bike. Finished my BRC today. Then I came home and goosed the rear wheel out from under me in the front yard. Landed flat on my face! Broke the rear left blinker off but no damage to me. I'm gonna try to keep that as my only wreck ever XD!


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