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Old 02-21-2013, 12:43 PM   #73951
Escaped
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Location: Northern California
Oddometer: 488
As a side note, I once dumped the bike on the right side hard and after I picked it and myself up, the bike would not shift or come out of gear. To fix it, I just took the clutch apart (just the plates) put it back together and it was good to go.

Quote:
Originally Posted by Icecold Dan View Post
Hey all,

I have a major issue with my DR. Yesterday as I was down shifting to stop at a light, there was a clunking noise going from 2nd to 1st. When the light turned, the bike wouldn't move. I got it into neutral and pushed it to to the nearest sidewalk. I thought at first that I had thrown the chain, but when I opened the front sprocket cover, I found that the chain was still in place. Uh oh...this isn't good. I ended up calling for a ride and when I got home I started to disassemble things starting at the gear shift mechinasim. Everything there looked good so I moved over to pulling off the right side cover where the clutch is. Everything looked good with the clutch plates but I haven't actually checked tolerances yet. I had to stop when I got to the the large nut on the clutch hub. I believe it is 26mm but wasn't able to confirm as I don't have a socket that big and I couldn't get my wrench in there to test for size.

I'm starting to get nervious that the problem may be in the transmission itself but am not really sure how to troubleshoot any further. I'm not sure what my next step should be. Any advice would be greatly appreciated. I already think I'm in a bit over my head.

It's an 09 with 15k miles.

Thanks,

Dan
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Old 02-21-2013, 12:54 PM   #73952
FlowBee
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LUCAS Headlamp switch

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Originally Posted by poppawheelie View Post
Good one! I'll send that on to a couple friends.


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Old 02-21-2013, 01:10 PM   #73953
BergDonk
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Quote:
Originally Posted by Rusty Rocket View Post
Lucas; what ever are you talking about??

Quote:
Originally Posted by FlowBee View Post


The FIX

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Old 02-21-2013, 01:37 PM   #73954
Rusty Rocket
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Originally Posted by BergDonk View Post
The FIX

I had the misfortune of helping my friend work on his 1974 Triumph TR6 sports car. Always something with the electrics. Wish we had some of that back then.
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Old 02-21-2013, 01:58 PM   #73955
dljocky
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Chain Tool?

I was wondering how many folks carry some sort of chain tool, breaker/press on their DR for trail side repairs? I'm thinking of getting something and would appreciate any advice on this matter.
Thanks all
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Old 02-21-2013, 02:02 PM   #73956
Rusty Rocket
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Quote:
Originally Posted by dljocky View Post
I was wondering how many folks carry some sort of chain tool, breaker/press on their DR for trail side repairs? I'm thinking of getting something and would appreciate any advice on this matter.
Thanks all

I have been carrying this style since the '70s.



I also now(with the advent of press fit M/L) drill out the plate of the spare masterlink so it is slip fit, like back in the '70's.
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on one side the sign it said "Private Road", but on the other side it didn't say nothin'
2009 DR650
..1972 Penton Six-Days ..1971 Suzuki TS185.. 2005 KTM 400exc
Member of: AMA, NETRA, Blue Ribbon Coalition, CCCofVT, Berkshire TR, CT Ramblers
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Old 02-21-2013, 02:11 PM   #73957
FlowBee
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Quote:
Originally Posted by Rusty Rocket View Post
I have been carrying this style since the '70s. (pic) ... I also now(with the advent of press fit M/L) drill out the plate of the spare masterlink so it is slip fit, like back in the '70's.
I recently bought a Motion Pro PBR press tool kit for inclusion on the DR for out of state trips. Dead weight, yes, but I'll admit I'm relatively newish to chains - my last chain driven bike was a CBR1100xx and I didn't take that thing on long trips.

Can you elaborate a little on what you mean by this? Do you then mount it like a clip and wire it?

Thanks.
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Old 02-21-2013, 02:20 PM   #73958
dljocky
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Thanks Rusty,
Flowbee, I'm new to learnng how to work on bikes, and if I had a chain problem out in the wilderness, I might not know exactly how to fix it, but I at least want the right tools!

More suggestions please.
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Old 02-21-2013, 02:21 PM   #73959
Rusty Rocket
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Quote:
Originally Posted by FlowBee View Post
I recently bought a Motion Pro PBR press tool kit for inclusion on the DR for out of state trips. Dead weight, yes, but I'll admit I'm relatively newish to chains - my last chain driven bike was a CBR1100xx and I didn't take that thing on long trips.

Can you elaborate a little on what you mean by this? Do you then mount it like a clip and wire it?

Thanks.
I carry a spare that looks like this


I believe I have a DID 520 o-ring chain

I drill (with a #7 drill, .201 inch dia) the plate so it fits snugly, but is free fitting so I can put it together without a chain press. Old school.
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on one side the sign it said "Private Road", but on the other side it didn't say nothin'
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..1972 Penton Six-Days ..1971 Suzuki TS185.. 2005 KTM 400exc
Member of: AMA, NETRA, Blue Ribbon Coalition, CCCofVT, Berkshire TR, CT Ramblers
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Old 02-21-2013, 02:22 PM   #73960
BergDonk
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Quote:
Originally Posted by dljocky View Post
I was wondering how many folks carry some sort of chain tool, breaker/press on their DR for trail side repairs? I'm thinking of getting something and would appreciate any advice on this matter.
Thanks all
I carry one of these:


http://terra-x.com.au/chainbreaker/
Check the video to see what it can do.

Best to use, and lightest and smallest I know of, and I've tried a few over the years, including one like Rusty's above.

We not long did a group buy on the Oz sub forum. They are not cheap, but they will not let you down, they just work. They may or may not be available ATM.

I also carry a few masterlinks and some spare chain.
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Old 02-21-2013, 02:25 PM   #73961
Rusty Rocket
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Quote:
Originally Posted by dljocky View Post
Thanks Rusty,
Flowbee, I'm new to learnng how to work on bikes, and if I had a chain problem out in the wilderness, I might not know exactly how to fix it, but I at least want the right tools!

More suggestions please.
I also carry a spare length of chain, about 4 links, in case a section is damaged/twisted so I can cut out the offending links and fix with the piece of chain and 2 masterlinks.

I carry too much stuff. My fannypack weighs at least 20lbs. Guys in my club are always looking for me when they break down.
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on one side the sign it said "Private Road", but on the other side it didn't say nothin'
2009 DR650
..1972 Penton Six-Days ..1971 Suzuki TS185.. 2005 KTM 400exc
Member of: AMA, NETRA, Blue Ribbon Coalition, CCCofVT, Berkshire TR, CT Ramblers
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Old 02-21-2013, 02:32 PM   #73962
shaddix
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I am having an issue with the starter button on my 09. Sometimes the button doesn't do anything, it acts like the kickstand is down and in gear, but the kickstand won't be down and it will be in neutral. I try feathering the clutch a bit to see if maybe it's that switch but it just seems to be random..... Is this a common issue with an easy fix?
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Old 02-21-2013, 02:40 PM   #73963
Rob.G
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Quote:
Originally Posted by shaddix View Post
I am having an issue with the starter button on my 09. Sometimes the button doesn't do anything, it acts like the kickstand is down and in gear, but the kickstand won't be down and it will be in neutral. I try feathering the clutch a bit to see if maybe it's that switch but it just seems to be random..... Is this a common issue with an easy fix?
Check the kill switch on the right handlebar pod.

Rob
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Old 02-21-2013, 02:41 PM   #73964
FlowBee
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Quote:
Originally Posted by Rusty Rocket View Post
I also carry a spare length of chain, about 4 links, in case a section is damaged/twisted so I can cut out the offending links and fix with the piece of chain and 2 masterlinks.
I think I get it now. You modify the rivet fit kit enough so that it barely works like a master link kit. Gets you back to civilization.

When you're in BF Egypt it's better to be looking AT it than looking FOR it. Beats walking!


Quote:
Originally Posted by Rusty Rocket
My fannypack weighs at least 20lbs. Guys in my club are always looking for me when they break down.
Like having a Safari tank on a DR. Suddenly you're OPEC 1973 .....
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Old 02-21-2013, 02:52 PM   #73965
NYTrainer
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Starter switch

Mine did the same thing for a few times, then quit working altogether at the worst possible time. It is a poor design as the "button/lever" hangs down in harm's way. Check the kill switch & all connectors, if it then does not work consistantly, buy a new one!
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