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PostPosted: Wed Feb 01, 2012 12:43 pm 
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I have done this fix twice now on two bikes, it was faster this time with a different tool.
If you don't want the hassle of taking off all the clutch crap I think this is the best way to do it.
Well, it works for me so what can I say, twice now and no clutch disassembly = happy. :drinks:

I have a new 2009 DR with 12K kms and don't want to grenade it with a ten cent screw the factory can't design better.
This time I used the pliers on a gyprock bit to twist the upper bolt loose, only took me about 10 mins of flailing but much faster than last time. The gyprock shape goes into the head deeper and is easy to torque out,
but you have to hold the pliers real tight, come onto her and don't be wimpy. :aggressive:

The new drilled allan bolt is easy to insert with the pliers, then using a long ballpoint allan key it's a breeze to turn it in all the way and tighten.
The hex bolt is an 8mm head. I use it cause it's easier to drill than the allan. ( both bolts should be 15mm long ).
A tip if you drill the allan, do it once from each side only into the middle or you'll snap the bit.
It also helps to sand the side flat a touch on a belt sander then center punch the flat, the bit will drill a lot easier into the flat surface.

Maybe this saves someone else time down the road.

Image

Image

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BIKE TRIPS - Alaska, Labrador, Himalayas, Oz - http://callmetree.com

2009 DR - Intiminators, prog springs, DRZ shock with a Summit racing 450lb QA-1 spring, Vibranators,
Oxford grips, IMS, Corbin, 1520 bags, ScreensForBikes . . . it's only money eh ?


Last edited by TREE on Sun Apr 13, 2014 10:36 am, edited 1 time in total.

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PostPosted: Wed Feb 01, 2012 1:43 pm 
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Great posting, (always a fan of pics when it comes to this stuff, I'm a visual learner myself). If one is diving in there, they might as well try to do it without messing with the clutch, it can't hurt. I will for sure be trying it this way when I do muster the courage and ambition to crack open that side case. Thanks for the post.

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PostPosted: Wed Feb 01, 2012 6:27 pm 
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That's a keeper... moving it to the How To section....

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PostPosted: Thu Feb 02, 2012 8:02 pm 
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Hi Rob. I would like to add this tool to the NSU thread I started.
(Thanks for moving it to the new location.... nice.)

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It looks like it would work better than the pliers !
They are at Canadian Tire here but not sure if / where in the USA.

cheers. Tree

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PostPosted: Wed Jul 03, 2013 11:56 am 
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F'ing Brilliant TREE!!!! :clapping:

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PostPosted: Wed Jul 03, 2013 12:47 pm 
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Oh, yeah I still need to do the NSA check, gonna have to do it next oil change (4800m)

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2012 DR650~ FMF-Q4,power bomb, DJ kit, modified Carb, modified air box, Twin Air filter, Pro-taper CR high bend bars, Acerbis 5.3 gal fuel tank, Vapor Tach, PWC skid plate, UNI breather filter, Moose racing hand guards, Pat Walsh rear rack, Super moto fender, 12v outlet, 14 tooth CS sprocket, Xring chain, Full cogent suspension, Runnin on Royal P.


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PostPosted: Wed Jul 03, 2013 6:22 pm 
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I use this mini ratchet set from Newmantools.com Worth it's weight in gold for tight access jobs. :good:

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PostPosted: Mon Jul 22, 2013 4:41 pm 
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Checked mine today, 2008 with 9600 miles. Didn't even have to use the pliers/bit combo as I could loosen the upper screw with just my fingers. The bottom screw was only slightly tighter. I replaced both with loctited allen head bolts. The lower bolt was easy to reach but the upper one gave me trouble. After threading the upper bolt in by hand (one finger behind the clutch basket and another behind the oil deflector), I tried a ballpoint allen to tighten it but wasn't able to get it into place. Ultimately, I ground down the smaller end of a short 4mm allen wrench by about 1/4" and was able to snug it up. Be careful and plug up the hole at the bottom of the crankcase, or you'll be fishing your bolt out with a magnet like I did.

:sad:

Good luck and get it done!

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PostPosted: Fri Jul 26, 2013 8:40 pm 
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I'm a big fan of lockwire for this job mainly because you can set it and forget it.
Now I can drive without wondering if the screws are ever going to loosen.
Great peace of mind when you're on the Trans Lab hwy or the Brisay Road.!

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BIKE TRIPS - Alaska, Labrador, Himalayas, Oz - http://callmetree.com

2009 DR - Intiminators, prog springs, DRZ shock with a Summit racing 450lb QA-1 spring, Vibranators,
Oxford grips, IMS, Corbin, 1520 bags, ScreensForBikes . . . it's only money eh ?


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PostPosted: Fri Jul 26, 2013 10:16 pm 
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mxrob wrote:
I use this mini ratchet set from Newmantools.com Worth it's weight in gold for tight access jobs. :good:

Image


My offset driver collection, they work good,, the angel driver attachment works great on car stereo speaker installs with a stick driver, wouldn't do much good on the neutral switch but the one that takes regular screw tips did the job for me.

Image

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2 nuts, 2 wheels, 2 beers...
OK, so what's the speed of dark?


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