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Old 04-26-2009, 03:25 PM   #2041
Ladder106
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Joined: Jan 2005
Location: Davis, CA
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Quote:
do not drink Bud or anythin that resembles it for a beer
Trust me on this.....even though I'm a Yank I firmly believe that the only thing that resembles Bud is excreted from the bladders of felines.

I am, admittedly, pretty much a "lightweight" when it comes to alcohol but I DO like a GOOD beer....but just one (well, OK, sometimes two). We have a wide variety of "microbrews" here in N. Cal. Some are nice.

On the whole, I prefer English beer, usually Boddingtons. A few shops here carry it.


I ordered a new gasket from Stefan along with my other parts. I amazed myself by actually planning ahead on this one. I purchased some gasket paper from the local auto shop and have used the new one for a pattern so I can produce my own from now on. Shockingly efficient, that.
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Old 04-26-2009, 03:29 PM   #2042
bluesman
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Quote:
Originally Posted by Ladder106
Trust me on this.....even though I'm a Yank I firmly believe that the only thing that resembles Bud is excreted from the bladders of felines.

I am, admittedly, pretty much a "lightweight" when it comes to alcohol but I DO like a GOOD beer....but just one (well, OK, sometimes two). We have a wide variety of "microbrews" here in N. Cal. Some are nice.

On the whole, I prefer English beer, usually Boddingtons. A few shops here carry it.


I ordered a new gasket from Stefan along with my other parts. I amazed myself by actually planning ahead on this one. I purchased some gasket paper from the local auto shop and have used the new one for a pattern so I can produce my own from now on. Shockingly efficient, that.
Well, then you totally settled! :) it will be an easy and rewarding work on the bike, believe me. You not going to regret that planning for many more cases, that's was very wise move!
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Old 04-26-2009, 04:43 PM   #2043
jabroka
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Quote:
Originally Posted by Ladder106
I ordered a new gasket from Stefan along with my other parts. I amazed myself by actually planning ahead on this one. I purchased some gasket paper from the local auto shop and have used the new one for a pattern so I can produce my own from now on. Shockingly efficient, that.
I have vector-based corel draw files of the generator and clutch cover that can be used in any cutting plotter.. I went to a graphic shop and they charged me $10 to cut a 1m x 1m piece of 0.6mm gasket paper. they came out perfect! if anyone wants them I can zip the files and upload them to rapidshare...






jabroka screwed with this post 04-26-2009 at 05:20 PM
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Old 04-26-2009, 07:49 PM   #2044
robmoto
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Thumb looks great

Hi Beaky now thats a bike colours are great and I like the headlight you already have just sraighten it up a bit better globes and she,s a goer mate good job on panniers the size of them suits the bike to a T regards, Rob,
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Old 04-26-2009, 07:57 PM   #2045
robmoto
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gaskets

Jabroka, thanks for the offer about the gaskets they turned out really well but that computor talk has got me buggard.
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Old 04-26-2009, 10:32 PM   #2046
Ladder106
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Quote:
can zip the files and upload them to rapidshare...
Yes, please.

Robmoto....we'll 'splane later.


I finished the balancer chain adjustment without too much bad language. I was worried when trying to loosen the two allen headed screws that hold the idler wheel. The PO had these really-really tight. Had visions of stripped allen heads and then flywheel removal and all kinds of ugliness to get the stripped screws out. They broke loose with a "pop" in the end with no damage....whew! The manual doesn't tell you to watch out for the starter gear train to wander out of the case with the cover. Good Grief - it looks like a damn transmission in there with so many gears. Got all those sorted out but it kinda scared me at first with a "Where the hell did THOSE come from" moment.

There was a bit of slack at the bottom of the timing chain run. I read the post about using wrenches to put tension on the top of the balacer chain run. When I did this there was about 5-6mm of up and down movement in the run of chain from the front balancer to the idler wheel. Is this alot? When I loosened the two allens, the spring sucked up all that slack so now there's really no slack to speak of at all in the system. Is that corect?

I realized early on that the shift lever and near side footpeg had to come off. When removing the peg, I noticed that the treads on the ends of the peg mounting bolts looked a bit beat up.......corrosion inside the threaded tubes welded into the frame. Got out the taps and some thread cutting oil. Cleaned up the frame threads and slide the bolts through a die to get those threads back into shape.

With the side cover off, I checked the three bolts holding the stator to the cover.....loose - yikes I removed the stator and ignition coil, cleaned the side cover up well and then reinstalled the stator with locktite. I've heard on Thumpertalk that some DRZ400s have had their stators come adrift due to improperly torqued bolts. I removed and locktited (can that be a verb) the bolts on my 400 so maybe we should be checking these on the 750s also. You'll have the cover off to check balancer chain tension so do this at the same time.

Waiting overnight for locktite to set up then I'll add oil and start her up.

Forks and cartridge emulators are next.
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Old 04-26-2009, 10:58 PM   #2047
bigS
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Greeting from Thailand

Hello to you all, just sold my f650 funduro to a friend and bought this one. Very nice bike, but it's taller than my old BMW. I need to lower it a little, so any suggestion would be appreciate.

thank you,

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Old 04-26-2009, 11:10 PM   #2048
robmoto
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good stuff

Ray sounds right to me good work, all my starter coggs fell out on me as well they show a good detail veiw and what to do in the manual as well.I did not know about letting locktite set maybe I better read the instructions next time another way to make sure there tight is do them up till they strip then back off half a turn Ihave been cleaning, rubbing back the barrell and head and using a scotchbrite to get in beteen the fins going out to paint them now, I got more parts from cnsml 2 new oil lines and head gasket today and just waiting for the valves and other trick stuff from stefan it is on its way he posted them on the 20th.I pulled one carb apart last night just have a looky see and the c clip on the needle is not there I think lots of carbs use the same bit and size so shoud be easy to get another. regards, Rob.
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Old 04-26-2009, 11:18 PM   #2049
Ladder106
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Joined: Jan 2005
Location: Davis, CA
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Hi BigS

Others here have, I think, lowered their bikes as well. I'm sure they'll let you know what works. Since this is such an international site, you have to get used to waiting around until other people get out of bed and start their day.

Quote:
the c clip on the needle is not there
Geez, Rob. Good thing you looked. It would have been frustrating trying to figure out why your bike wouldn't start after all that work.

A scotchbrite between the fins??? You're gonna have to call it DR. OCD.
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Old 04-26-2009, 11:28 PM   #2050
Ladder106
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Location: Davis, CA
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I use Blue Loctite 243. For threads with oil contamination.

Full cure time is 24 hrs.
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Old 04-27-2009, 12:01 AM   #2051
bluesman
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Quote:
Originally Posted by bigS
Hello to you all, just sold my f650 funduro to a friend and bought this one. Very nice bike, but it's taller than my old BMW. I need to lower it a little, so any suggestion would be appreciate.

thank you,


That's good looking DR you have! Congratulations! :)

SR43 series (one you have) is actually lower than older 2 models (750 and 800). I am really short guy but I did not bother with lowering. BUT I had to figure out (and I did) that previous owner of my DR set rear spring preload to almost max. and that raised bike height a lot, really a LOT. So, when I set spring preload to factory standard - all issue with seat height dissapeared. I never even thought about lowering it anymore.

You may try to set preload to lower factory limit, but then you need to raise forks in the top yoke/clamp to reflect geometry change of rear.
If you want to lower your DR even after rear preload set to lower factory setting then best is to tackle seat. Stock DR seat is way to hard for long distance anyway.
Just do not touch rear suspension links. Usual sportbike rising/lowering methods (changing suspension links) in application to DR is really bad idea because of suspension trave range.
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Old 04-27-2009, 12:04 AM   #2052
nave
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Replacing the power/ignition coils.

"O God +tax" that’s what the salesman at the Suzuki dealership warehouse answered me when I asked him what's the price for new ignition coils.
He knew what he was talking about… (760 euro!!! )

I'm used to the very high prices here in Israel for parts, so usually I google or looking at Hessler site. This time I remembered I bump somewhere on this thread ona link…
So I bought it from that guy and now I recommend him warmly!

So thank you all and Keep on the information, experience, knowledge, stories, pictures and so on, coming!!!

O.K now lets get our hands dirty…
First you have to be sure the coils are bad by using an electro tester as shown here:


If they are bad and you're sure the problem is not the CDI it's time to replace them…
To make things easy I take off the gear lever and the (left) foot peg and disassemble the engine guard. A good opportunityto clean all the mud…



Don't forget tp drain the oil...

Time to open the 12 case bolts..
.

Small tip- the bolts are in different length, to know which one goes to what hole you just posh them in until they reach thethread. They should all stick out the same. If they stick out more or less you're wrong.
I once happened to see a mechanic organize them in the order of disassembly. Now, what will happen if someone (like your kid…) will mix them???


Time to take off the case…
The case is magnetic and you can use your hands or a heavy hammer. Just kidding, use a plastic one…

If your bike is leaned against the side stand what will probably happen is that the starter driven gears will fall off…
If this happens and you don't have the manual book and you didn’t see it before you're going to have a nice assembling game… (As it happened to me the first time I opened it many years ago…)


Out with the old in with the new!
Don’t forget to apply a small quantity of thread lock the bolts and some silicone to the rubber seal.



Now it's a good time for a coffee/beer/smoke break, or in my case- running after the kid…

As always,assembling is the same only backward
One more tip- when you pot on the new case seal- spread on it with your finger some engine oil on both sides. That will make it easier to take off next time.

Tighten the bolts with atorque wrench or by feeling.
Now it's a good time to recheck that all the bolts are in and tighten well and no bolt is left alone on the plate.

A short prayer
Push the start…
Hallelujah! It's a live!!!!!!!

Put back the gear lever, foot peg and the engine guard and hit the road!

Drive safely.
Nave.


nave screwed with this post 04-27-2009 at 07:02 AM
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Old 04-27-2009, 12:20 AM   #2053
nave
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Welcone BEAKY!
Great looking BIG you got there
my best advice for you is- check the oil level in high frequency (about yevrey 400km) and do the service on time (use good oil)
I bought mine with 55,000km on and rebuild the engine on 85,000km
now the bike has about 250,000 on the same engine and the same clutch!!!

It's hard to keep up with you guys...
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Old 04-27-2009, 12:41 AM   #2054
DrBigEd
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Location: Cape Town, South Africa
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Quote:
Originally Posted by Ladder106
I just tell mine that I could be spending several times this on alcohol and other women.....it doesn't completely work but it does make for some sobering thoughts on her part and seems to reduce the "backlash"
Surprise, surprise. She took it in her stride! No problems.

I use that line regularly, but she knows me too well. I don't drink any alcohol (had malaria twice) and I don't much care for other women except Angelina Jolie and Cindy Crawford

I also realise I should stay away from eBay for a little while.
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Old 04-27-2009, 12:46 AM   #2055
DrBigEd
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Great job there Nave! That's way beyond me, but I always appreciate a good craftsman.

You said check the oil level in high frequency. I'm a little lost here (should come as no surprise). Did you mean to check it regularly?
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And smiles you'll give and tears you'll cry
And all you touch and all you see
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