DR750 & DR800 owners thread

Discussion in 'Thumpers' started by MCmad, Jul 14, 2008.

  1. Resi

    Resi Been here awhile

    Joined:
    Jul 5, 2011
    Oddometer:
    211
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    Ray, I use a selfmade tool for fixing the sprockets.

    Flat steel with two pins for fixation and a hole in the middle for a socket.
    The counterholder fits straight into the block.
    I'll take a photo later when I finished work.

    Cheers,
    Lars
  2. robmoto

    robmoto Long timer

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    Ray a rattle gun used correctly is your best freind and blue locktite.
  3. Ladder106

    Ladder106 It's a short cut, really

    Joined:
    Jan 31, 2005
    Oddometer:
    5,142
    Location:
    Davis, CA
    Once again, thanks for the assistance guys.

    Mait, my angle grinder holder was much to cheap and wimpy to even begin to hold the sprockets. Thanks for the idea though.

    Resi, Looking forward to seeing the tool you made. It appears that it would be difficult to get any tool into the space for the upper balancer sprocket.

    Rob, I know, power tools are your friend. I have an electric impact wrench that's old but remains reasonably functional. I keep telling myself that someday I'll buy an air compressor and a few pneumatic tools to make all that bolt twisting go a bit more quickly.

    Anyways.....here's what I did:

    I discovered that one can use the flywheel bolt on the crank and the installed balancer chain to hold the balancer shaft sprockets.

    Fit a tubular spacer about 25 mm or so behind the flywheel attachment bolt on the crank shaft. This keeps the bolt from bottoming in the crank threads and makes it easier to remove at the end.

    Tension the balancer chain....this is IMPORTANT since with no tension on the chain system, the chain will slip over the crank sprocket teeth and throw off your balancer timing.

    Since the crank and the balancer shafts rotate in opposite directions you can now hold the 17mm crank bolt while applying a torque wrench to the balancer bolts.

    NOTE: Be careful here and observe the chain slack. Slack still develops in the chain run between the crank and the upper balancer sprocket. Too much slack and the chain will slip......Incrase the tension in the system.

    Then you can use an impact wrench (either powered or hand held) to remove the bolt in the crank shaft. You have to do this in order not to disturb the balancer shaft bolts. A few taps and the crank bolt comes out and you can now continue to assemble the rest of the left case bits.

    ......and , if you're like me, you will put everything together, stick a new gasket onto the left outside case and as your gathering the case bolts you'll notice that the long chain guide that goes on the upper part of the balancer chain is still on your bench....:baldy

    ...then you get to take everything back apart again to install the chain guide..

    So, the bike is back together, oil added and running. I ran out of daylight to actually test ride it other than just up and down the street.

    Sure sounds different at least. In place of a bit of rattling noise, there is a nice pleasant "whine" coming from the left case. At least it SOUNDS smoother.

    More after it warms up a bit this morning.
  4. aapo

    aapo aapo

    Joined:
    Aug 13, 2008
    Oddometer:
    175
    Location:
    Finland
    Yes, it really makes the engine sound good :). When i did the same for my 750, i noticed later i should have taken the balancer sprockets also from the donor 800 engine. I don't really remember after how many km's, but noise was back and i need to adjust the balancer chain again few times. But then i decided that it's just noise. Or one should just go to sit next to 640 lc4 :)
    But ok, mine has some 100 000 on clok and think there is not all. I'm building the top end second time now... Lapland kils bikes or something.

    And hello again, it's been a while i was here :) Had to do all sorts apartment renovation,new job, new baby etc :)
  5. Resi

    Resi Been here awhile

    Joined:
    Jul 5, 2011
    Oddometer:
    211
    Location:
    Nassau Area
    Mates, this is my selfmade counterhold for balancing chain wheel:

    [​IMG]

    [​IMG]

    My usefull friend for many years and engine build up's :clap

    Cheers,
    Lars
  6. Ladder106

    Ladder106 It's a short cut, really

    Joined:
    Jan 31, 2005
    Oddometer:
    5,142
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    Thanks Lars,

    Are the two pins that engage the sprocket different diameters? Or is this just a trick of the photo?


    Also, in making this work, is it sized so that the plate contacts the crankshaft to prevent it from spinning or sized to contact the inner part of the engine case?


    Any tricks to having it engage the upper/rear balancer shaft sprocket. With the cam drive sprocket also there, this one seems the most difficult.
  7. Resi

    Resi Been here awhile

    Joined:
    Jul 5, 2011
    Oddometer:
    211
    Location:
    Nassau Area
    Ray,

    these two pins are at 6mm diameter.
    The flat bar is just fitting into the case on both balancer chain wheels, the inner diameter is large enough to get an impact driver socket through.

    Cheers,
    Lars
  8. robmoto

    robmoto Long timer

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    Sorry for the delay Lars, this is the airbox cover I made about 6 months ago works a treat I am still using the original battery box holder so there is no relocating the electricals.
    The CDI unit is where it is because the bike had a drum brake and now a disc brake and I needed to move the CDI to mount the rear brake resivior.
    I am using a small battery under the air filter ,
    [​IMG]
  9. robmoto

    robmoto Long timer

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    whoops wrong picture Lars that was a pic of your mesh insert and new end I made for that muffler we got of ebay. :D.
    Here are the right ones I am a bit rusty at doing photo,s sorry you blokes,
    [​IMG]
  10. robmoto

    robmoto Long timer

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  11. robmoto

    robmoto Long timer

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  12. robmoto

    robmoto Long timer

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  13. robmoto

    robmoto Long timer

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  14. robmoto

    robmoto Long timer

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  15. robmoto

    robmoto Long timer

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    Here are a few pic,s of Old Blue getting the restore make over treatment, Robmoto style :lol3.
    [​IMG]
  16. robmoto

    robmoto Long timer

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  17. robmoto

    robmoto Long timer

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  18. robmoto

    robmoto Long timer

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  19. robmoto

    robmoto Long timer

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  20. robmoto

    robmoto Long timer

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