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PostPosted: Fri Jan 03, 2014 1:48 pm 
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Trail Rider
Trail Rider
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Joined: Thu May 02, 2013 10:35 am
Posts: 107
Location: Greensboro, NC
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mxrob wrote:
Man, you are strong... That looked so effortless. :sarcastic: Suzuki should have had Mikuni install the screws in the NSU for them. :rofl:


^^^ The years of not working out and drinking are really paying off :rofl: ^^^

As for removing the 27mm nut, I used a cordless impact drill. This thing is worth every cent!

http://www.porter-cable.com/Products/ProductDetail.aspx?ProductId=28652

The screws on my oil deflector stripped when I tried to remove them so I just left it on.

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PostPosted: Mon Apr 28, 2014 12:48 am 
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Joined: Sun Feb 09, 2014 4:39 pm
Posts: 4
Location: Port Townsend, WA
Location: Port Townsend, WA
Thanks fellas for all of the posts in this thread. I have an '09 with 6k miles and did mine this evening. The screws were not loose but an energetic 2yr old would have had them out 'first try. Used the motionpro clutch holding tool ($20) and it worked great. Thanks again, dd


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PostPosted: Sun Jun 22, 2014 5:23 pm 
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SuperMoto Dude
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Joined: Thu Jun 05, 2014 11:29 am
Posts: 384
Location: South Conway NH
I'm getting ready to do my 1st oil change @ 500 miles and was going to check mine out.
Stupid question, can I reuse the clutch cover gasket or should I buy new?
And do you use any sealant on the gasket ?

This is on my 2011 with 480 miles.
I will post results of what I find.

Thanks.

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Florida Cracker in the Whites Mountains of NH
2011 DR 650.
upper chain roller,clutch,side stand switches=removed,Craftsman $10 tool box,$10 eBay tachometer,NSU mod,raised needle, de-snorkled, Scaggs Rack,Ricochet skid plate,homemade 6061 peg lowerers,14T c/s,Garmin 60csx GPS,Moose Handguards,DRZ 250 footpegs,ProCycle seat,mid-pipe,engine armor,DR250 taillight,GSXR600 muffler,ProTaper CR1 1/8 bars, Acerbis 5.3,Dunlop 606 rear, IRC TR-8 front, Countershaft seal retainer, carb mounted choke knob.


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PostPosted: Sun Jun 22, 2014 5:56 pm 
cragantler wrote:
I'm getting ready to do my 1st oil change @ 500 miles and was going to check mine out.
Stupid question, can I reuse the clutch cover gasket or should I buy new?
And do you use any sealant on the gasket ?

This is on my 2011 with 480 miles.
I will post results of what I find.

Thanks.


I'd replace it, if its not damaged you might get away with reusing it. It shouldn't require sealer or liquid gasket.. I'd wet it with some oil before installing the new one... And tourqe to spec.


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PostPosted: Wed Oct 01, 2014 3:10 pm 
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MSF Student
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Joined: Wed Jul 30, 2014 5:39 am
Posts: 63
Location: Bristol, England
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I did mine today, both screws were only finger tight. Mine is a 1996 bike but fairly low mileage (17,000). Removing the remains of the old gasket was a total pain in the arse.

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PostPosted: Wed Oct 01, 2014 6:46 pm 
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Adventure Rider
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Joined: Thu Oct 17, 2013 10:53 am
Posts: 1057
Location: Calgary, Alberta, Canada
If you have a look at this post, you can fix the NSU screws and leave the clutch in place.

It just takes a little more time and the right tools to get at the one screw behind the clutch.

topic3547.html

It's worth a try and if all else fails you can still remove the clutch.

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Ride to work, work to ride.
- 2014 FZ-09 for the pavement.
- 2013 DR650SE for everywhere else.


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PostPosted: Sat Oct 25, 2014 10:22 pm 
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I've referred to this thread so many times I decided to add my own pics.
This is how I dealt with the DR NSU issue.
Pulled the clutch cover. Removed clutch disk/basket. Removed Oil deflector. Removed stock NSU screws. Lower one was hand tight the upper was snug. Replaced with 5mm Cap head screw, drilled for safety wire. Installed with permatex blue.

Attachment:
File comment: Before
IMG_0005.JPG
IMG_0005.JPG [ 623.24 KiB | Viewed 1431 times ]


Attachment:
File comment: After
IMG_0006.JPG
IMG_0006.JPG [ 601.57 KiB | Viewed 1431 times ]


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PostPosted: Fri Jan 09, 2015 3:06 am 
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SuperMoto Dude
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Joined: Sun Mar 23, 2014 11:07 pm
Posts: 428
Location: Poverty Flats S.W. Idaho
Porterwm1976 wrote:
2007 DR650 just under 8,000 miles...



I was killing some time this past week and stumbled upon this post. We've all read the warnings about the nsu terror but the whole "8000 miles" thing hit home since my bike is at 7400. Bought it new, and really wasn't too worried about the NSU problem.

We have had this real awesome weather called winter and now freezing fog, so I cracked open DR Zoidberg tonight to have a look. The lower of the two screws was maybe a bit snugger than the one in the video, but not a hell of a lot. So about two hours from start to finish with getting sidetracked, and I feel a great relief! It is slightly horrifying to think of that 15 cent screw destroying my bike. :bad:

I only did the blue loctite,no wire, and did not have to pull the clutch. I just shaved a allen wrench.

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PostPosted: Thu Jan 22, 2015 1:42 pm 
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Joined: Sun Dec 22, 2013 6:12 am
Posts: 3
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I plan on doing my NSU unit soon. Some of you have used both the blue locktite and safety wire for added insurance….but how about just using blue locktite alone? If the screws worked their way out wouldn't safety wire plus the two bolts cause more damage? Just asking. :sad:


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PostPosted: Thu Jan 22, 2015 5:34 pm 
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Trail Rider
Trail Rider

Joined: Sun Sep 28, 2014 8:16 pm
Posts: 144
Location: Mt Vernon, IN
MadMax wrote:
I've referred to this thread so many times I decided to add my own pics.

Image


I see you are smarter than I am. I did not plug those two bottom holes with rugs and, of course, I had to fish with a magnet to get a screw out of the oil reservoir. Luckily it was right there and no harm was done.


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