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Old 07-07-2008, 04:26 PM   #15016
scootertrash
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Location: "My leg's tired, let's live here."
Oddometer: 2,074
Did the neutral switch thang..

Had some extra energy yesterday so I opened up the clutch case on the DR and checked the screws.

Turned off the gas and made sure the float bowl was dry:



Marked the clutch lever on the splined shaft before removing. Found out later it was unnecessary as the shaft will move when you R/R the clutch cover. Just make sure to move the lever as far back as you can by hand before putting it back on the shaft:



Laid the bike over on towels as I was too lazy to drain the new oil out of it:



Removed the footpeg with the mount:



Disconnected the master cylinder clevis pin and two springs, then swiveled the brake pedal down:



Note the washers stacked above and below the oil line, also the case bolt below and left of the oil line is the only one with a washer:



Finished removing the case bolts:



There's the neutral switch. I locktited the lower screw and removed the upper screw with a flat screwdriver and hammer as a chisel. It wasn't loose, but it came out real easy. I will eventually replace with a hex bolt, but for now, the lower screw is holding it in and is securely locktited.



Notice large oval hole below clutch basket, make sure you stuff a rag in it, because if a screw goes down there, you are in for a lot of work! Also, note the oil cooler line to the right, it has to be removed before the cover can come off. I did not have to remove the skidplate, just had to loosen it up for clearance. Tap on the cover and rotate it slightly as you lift it off.



It was probably a 1 to 2 hr job tops and a lot shorter when I go back in the next time with the hex bolt. No gaskets were needed and no oil was lost. Be careful to choke up on the ratchet handle when you tighten up the case bolts, you don't want to put too much torque on them. No issues, no leaks..
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scootertrash screwed with this post 07-07-2008 at 04:33 PM
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Old 07-07-2008, 04:57 PM   #15017
DevilofSky
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Joined: Jul 2008
Location: Italy
Oddometer: 78
Quote:
Originally Posted by pc1222
I think the word you are looking for is windshield
yes!! i can't find that here in italy...

there's some store/shop there where i can find it quite cheap?

ps. for the 2°question there is something?

thanks a lot!
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Old 07-07-2008, 05:20 PM   #15018
judjonzz
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Joined: Mar 2002
Location: Not Fargo, not Butte, not Cheyenne
Oddometer: 1,998
There is a product called Dirt Bagz, soft bags with minimalist frames, available for the DR650

happy-trail.com makes aluminum panniers for the DR650.
http://happy-trail.com/category.aspx?categoryID=781

Eurotech Motorsports lists bags and mounts for the DR650SE.
http://www.eurotechmotorsports.com/f..._StartRow=1301

I am sure there others. I hope this helps.

Try a Google search on "DR650 saddlebag mounts".
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Old 07-07-2008, 05:35 PM   #15019
PhL0aTeR
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Location: Color-red-o
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Quote:
Originally Posted by rivercreep
All I'm going to say is this....................
In theory, what's happening is that the unburnt gasses that are making their way into the exhaust system unburnt, are being ignited when you turn your ignition back on and create the "backfire" when hot carbon/partial flame is making it's way out through the exhaust and igniting that unburnt mixture.
Again, in theory, there can be enough pressure build up within the exhaust system to force an exhaust valve open and slam it into your piston.

That being said...........my 97 hit the 50,000 mile mark without any engine damage occuring from the same practice. (it was a little old lady in a Subaru that took it out!)
Sure is fun waking up the cagers though!
Well im glad.... lol.... cuz i did it today and nearly fell off the bike laughing so hard at how loud it was...... i figure next time someone is an idiot and talking on their cell phones ill hold the kill switch in for a few seconds then let it out KAPOWWWWWWWW
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Old 07-07-2008, 05:36 PM   #15020
DevilofSky
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what a prices!!


i can't
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Old 07-07-2008, 05:44 PM   #15021
adriftAK
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Location: Anchorage, AK
Oddometer: 50
Quote:
Originally Posted by speedwobble2
Taking the brace off the Safari tank takes all of about 30seconds and I have not found it a problem. The RHS of the tank covers nearly half of the length of the oil cooler and gives protection especially if you drop it.
The slim design of the 30l Safari tank makes moving around on the bike quite easy, you don't even notice it after a while. The only problem I had was when fitting it from new and had trouble getting the 2 rear bolts in but now that it has bedded in it's no trouble........I'm happy!
Installed my safari this weekend and had a similar experiance. Those 2 bolts gave me some fits initially but very easy install otherwise.
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Old 07-07-2008, 05:52 PM   #15022
Brewcelero
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Hey!

Hey, I'm a brand new member and since I'm been lurking this thread for many moons I thought I'd make my first post.

I have a 2008 DR I got in February. The only mods so far: lower it and add the gel seat plus the stock luggage rack.

Let's see if I can post a few pics.

Hmm, it says I have uploaded the max of one pic.

Well...
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Old 07-07-2008, 05:53 PM   #15023
adriftAK
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Location: Anchorage, AK
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Quote:
Originally Posted by Chuck Chiodini
Lewy wrote "Looking into using a vacuum or electric pump to use up the last little bit."

If you rotate the fuel inlet on the carb to the 8 o'clock position you will be able to use all the fuel less an ounce or two. Same setup I run except I have a small bronze in-line fuel filter from a bike shop in the "common" line to the carb. I removed the OEM white plastic fuel strainer from my inlet tube when I rotated it. No need for a pump IMHO or experience.

Good luck!
Can the inlet be safely rotated with some force or do you mean actually bending it? Don't want to break it
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Old 07-07-2008, 05:56 PM   #15024
Brewcelero
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2nd Try

Hello, I couldn't figure out how to post them, so here is a link to my pics:

http://www.photoshow.com/watch/Sx6HE2HN

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Old 07-07-2008, 07:40 PM   #15025
Krusty ...
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Location: Richardson, TX
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Quote:
Originally Posted by adriftAK
Can the inlet be safely rotated with some force or do you mean actually bending it? Don't want to break it
It will rotate. Use a vice if the carb is off the bike.
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Old 07-07-2008, 08:40 PM   #15026
macdesign
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Location: Melbourne, Australia
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KTM USD's on a DR650

Quote:
Originally Posted by LukasM
Yeah, some people have done it and posted in this thread. I am one of 'em! Check out the link in my signature (yeah I know I have to update the log...).
Thanks Lukas you have saved me a bunch of time measuring stuff.
I'm onto it asap.
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Old 07-07-2008, 10:43 PM   #15027
El Toad Man
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Location: Cairns, Australia
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Quote:
Originally Posted by adriftAK
Can the inlet be safely rotated with some force or do you mean actually bending it? Don't want to break it
It will rotate with enough force. The trick is to not crush the elbow before it rotates.
Shown here:
http://www.advrider.com/forums/showthread.php?p=5121717
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Old 07-08-2008, 02:55 AM   #15028
DRjoe
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Location: Sunshine coast qld
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Quote:
Originally Posted by PhL0aTeR
Well im glad.... lol.... cuz i did it today and nearly fell off the bike laughing so hard at how loud it was...... i figure next time someone is an idiot and talking on their cell phones ill hold the kill switch in for a few seconds then let it out KAPOWWWWWWWW
watch out it can fairly mess with the packing in your silencer.

I had a d*!k head of a mate who used to do it with his car, every time he did it a big chunk of smoldering packing would fly out of the exhaust.
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Old 07-08-2008, 04:43 AM   #15029
svwayne
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Location: Lawrenceville, Jawja
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Quote:
Originally Posted by scootertrash
There's the neutral switch. I locktited the lower screw and removed the upper screw with a flat screwdriver and hammer as a chisel. It wasn't loose, but it came out real easy. I will eventually replace with a hex bolt, but for now, the lower screw is holding it in and is securely locktited.

I'm tempted to remove the switch while I'm in there. Will it come out at this point or am I going to have to pull the clutch basket?

Thanks for taking the time to post the pics.
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Old 07-08-2008, 05:08 AM   #15030
dedsmurf
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Joined: Feb 2008
Location: Austin
Oddometer: 391
Quote:
Originally Posted by Brewcelero
Hello, I couldn't figure out how to post them, so here is a link to my pics:

http://www.photoshow.com/watch/Sx6HE2HN

right click the pic on your site, select "copy image location" (link) and then when posting click the "insert image" button in the wisiwig toolbar and paste the link. the pic stays on your site but is simply linked to the forum page.
no uploading.
just dont remove the pics or the link will be broken and ppl wont see your great ride(s)/tool/mod/oops....
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