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Old 10-23-2012, 06:46 AM   #691
Bronco638
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Quote:
Originally Posted by Willwilkins
Sounds like a duck with a sore throat? Perfectly normal, they've been doing it for years
More like a pig that's being violated............

Quote:
Originally Posted by ER70S-2 View Post
I don't recall that removing the oil line is part of the procedure but you do have to remove the cam chain tensioner, the pipe and the clutch cable/arm (IIRC).

So, disassembling the starter on the bike, eh? Sounds plausible. What did you use as a lubricating agent?
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Old 10-23-2012, 11:01 AM   #692
ER70S-2
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Quote:
Originally Posted by Bronco638 View Post
More like a pig that's being violated............
Insert banjo music here....................


Quote:
Originally Posted by Bronco638 View Post
I don't recall that removing the oil line is part of the procedure but you do have to remove the cam chain tensioner, the pipe and the clutch cable/arm (IIRC).

So, disassembling the starter on the bike, eh? Sounds plausible. What did you use as a lubricating agent?
I removed the oil line and CCT, but not the pipe. The clutch cable bracket is secured by the two starter thru bolts, so it comes off. Doing it on the bike is possible, but very tight, and for whatever reason, that's the way I did it. I used marine grease.

At the time I was unaware of the CCT complications if done wrong, I got lucky.
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Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 10-23-2012, 11:26 AM   #693
Adv Grifter
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Quote:
Originally Posted by Bronco638 View Post
It's stamped steel is it not? Are those support pieces that heavy? I'm going to guess that any other metal may not handle the vibrations as well (stress fracture). I suppose you could weld a section of .75" square tube to the head bearing tube so you could bolt a structure to that. Then, you could remove all of the stuff that's attached to the forks/triples.
Correct, stamped, thin steel supports. Not heavy (but it all adds up) The turn signal brackets are steel too.

You definitely could fabricate a lighter, alternative mounting system to simply the whole arrangement. Hope you can come up with something elegant and functional!
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Old 10-23-2012, 11:35 AM   #694
Adv Grifter
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Originally Posted by GSF1200S View Post
Yeah, definitely need to worry about protecting all the wiring. I have seen mention of the buell headlight mod, but im not sure exactly how much weight it saves- you have any clue? If it saves alot compared to stock, Id do it. If it only saves a little I might as well stay stock and buy an HID kit. This is why I was looking at KTM headlights and aftermarket ones- weight. Of course, as an adv bike the light needs to actually work.

Never considered anything in the forks. I need to get it all apart and take a look, but I also need to get it back on the road! Im a huge believer in doing smart things to reduce weight. When the price gets ridiculous then I stop. I did the same with my 1200 bandit and it made a huge difference in tight twisties throwing it from side to side.
I've not weighed the Buell headlight. One was for sale a while back ... cheap. I didn't buy it. The Buell headlight and shroud is probably light, weight comes with how its mounted and what materials used. There are several alternative headlight fairings on the BIG DR thread, if you can find them!

I mis-spoke, upper triple is Alu, but has steel brackets and steel turn signal mounts. Upper triple HUNKY, as it houses ignition, rubber bar mount system and incorporates idiot light module. An aftermarket upper triple might be stronger, lighter, stiffer?

I totally agree regards Price vs. weight savings: It only makes sense to do relatively cheap and easy weight saving methods. Plus One on the Bandit.
A good riding buddy has one ... tricked out an lightened. More like a GSXR than a Bandit now. What a great bike.
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Old 10-23-2012, 01:37 PM   #695
Bronco638
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Quote:
Originally Posted by ER70S-2
Insert banjo music here....................
Pretty much.

Quote:
Originally Posted by ER70S-2
I removed the oil line and CCT, but not the pipe. The clutch cable bracket is secured by the two starter thru bolts, so it comes off. Doing it on the bike is possible, but very tight, and for whatever reason, that's the way I did it. I used marine grease.

At the time I was unaware of the CCT complications if done wrong, I got lucky.
I'd prefer to keep things as simple as possible. So, I think I'll leave the CCT alone. Perhaps I can remove the starter far enough, with other things in-place, so that I can lube that bushing and then re-install it.
Quote:
Originally Posted by Adv Grifter
Correct, stamped, thin steel supports. Not heavy (but it all adds up) The turn signal brackets are steel too.

You definitely could fabricate a lighter, alternative mounting system to simply the whole arrangement. Hope you can come up with something elegant and functional!
I just had the head bearings replaced, frame powder coated and got the DR completely re-assembled. I'll not be welding anything to the head tube any time soon. But, if/when the opportunity presents itself, I may look into it. In retrospect, wouldn't the lock 'rack' interfere with something welded longitudinally to the head tube? I'm thinking it would (not that that's a shop stopper but it would be a consideration).
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Old 10-23-2012, 08:30 PM   #696
ER70S-2
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Quote:
Originally Posted by Bronco638 View Post
I'd prefer to keep things as simple as possible. So, I think I'll leave the CCT alone. Perhaps I can remove the starter far enough, with other things in-place, so that I can lube that bushing and then re-install it.
Simple is why I did mine on the bike. Post back, inquiring minds will want to know if it can be done with the CCT left in place (a very important point for the less mechanically inclined and future information).

edit: this is incorrect, there's a bearing on the left end of the armature.
OBTW: There are two bushings, one on each end of the armature.
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Quote:
Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -

ER70S-2 screwed with this post 01-27-2014 at 01:49 PM
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Old 10-23-2012, 11:42 PM   #697
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Can't eat your bicycle in a pinch.
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Old 10-24-2012, 06:54 AM   #698
Bronco638
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Quote:
Originally Posted by ER70S-2
Simple is why I did mine on the bike. Post back, inquiring minds will want to know if it can be done with the CCT left in place (a very important point for the less mechanically inclined and future information).
OBTW: There are two bushings, one on each end of the armature.
I won't be getting to this until deep in the winter "off-season" (probably January) but I'll be happy to let everyone know if it's possible and how to do it.
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Old 10-24-2012, 06:59 AM   #699
greystoke
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Quote:
Originally Posted by ER70S-2 View Post
Simple is why I did mine on the bike. Post back, inquiring minds will want to know if it can be done with the CCT left in place (a very important point for the less mechanically inclined and future information).
OBTW: There are two bushings, one on each end of the armature.
Timely. I just fixed mine as starter had completely seized and did a little write up http://www.advrider.com/forums/showthread.php?t=832297

I'm not a mechanic and was shitting myself at the idea of removing the CCT but it turned out to be fairly painless. The hardest part was finding the correct TDC for the first time. That and unbolting everything else which was just a pain.
I can't see how to get the starter out without removing it unless you're skilled with chopsticks.
If you do remove the CCT, buy a new gasket $4.00 before hand.
The first time took me an hour checking and rechecking but I ended up having to do it twice and the second time took 15 mins max

PM me if there's anything else you need

P.S. looking back i'm pissed I didn't have a crack at it when my CCT gasket started leaking a couple of years back. The mechanic I used took me for a ride and didn't even get a new gasket. Just lathered silicone on the old torn one. If I was as broke then as I am now I might have learned something :)
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greystoke screwed with this post 10-24-2012 at 07:07 AM
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Old 10-24-2012, 10:54 AM   #700
ER70S-2
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Greystoke:
Nice write-up.
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Quote:
Originally Posted by Threewheelbonnie View Post
"BTW, I don't do style. It's a dirt bike, not some girlie dress-up thing." -
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Old 10-24-2012, 11:06 AM   #701
Adv Grifter
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Thanks for the great write up. Hope it makes it to the DR650 thread index.
Very important service to do once in a while. Most forget the starter until it's too late. Thanks!!
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Old 10-24-2012, 06:35 PM   #702
Bultaco206
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Originally Posted by AST236 View Post
Sweet, Bultaco206. Keep us updated.....
Well, I've got a lot of stuff (a lot) ordered but I've done nothing to the bike yet since I bought it last Saturday. But I did do about 40 miles of gravel on it today...what they're calling the last 80-degree day until next summer.



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Old 10-25-2012, 06:15 AM   #703
Bronco638
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Quote:
Originally Posted by ER70S-2 View Post
Greystoke:
Nice write-up.
+1
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Andy holds the lead. And he will, all the way to the Highway. Today is his day.
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Old 10-25-2012, 08:41 AM   #704
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Originally Posted by ER70S-2 View Post
Greystoke:
Nice write-up.
Cheers fellas. No way i was forking over AU$800... Hope it helps
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Old 10-25-2012, 09:28 AM   #705
Bronco638
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Quote:
Originally Posted by greystoke
Cheers fellas. No way i was forking over AU$800... Hope it helps
It does help (a lot!). No way I would pay that amount either.
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There are some simple thruths......and dogs know what they are - Joseph Duemer

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