DUDE, YOU ROCK! I've been wrenching all my life and I would have never have thought of using the cardboard as a holder for the screws. I like how you made a template of sorts so you would remember where the screws go. Learned something new!
The cardboard template is definitely the way to go for something like this. Also, if you're in a pinch and don't have time/desire to do the cardboard thing, take a piece of duck tape (masking tape, etc) and put it sticky side up on your work surface. Then, just take every bolt starting from a known point and attach it in order to the tape. That way, you don't get them mixed up and can just work backwards to put it back together. Alternatively, if you're ghetto like me, you'll just take a sharpie and number each of the bolts as well as the spot on the case where you got it from. Looks a little weird for a few days, but it wears off.
Duals. Sorry for not replying earlier but had a computer melt down a while back and missed a lot of stuff on youtube etc. Just saw your comments now. Happy you learned some-thing new.
I am in the process of replacing a cracked clutch cover and your video is perfect. I thought I'd check those screws.Thanks man. I'm 66 and still working in my driveway, sucks but so it goes.
Robert Shaffer Thanks Robert. I'm still working in an unfinished garage but at least its dry. The old video quality wasn't so good when I posted this one. Mind you I still forget to turn the camera on half the time. Anyway take care out there.
This video helps a lot, but I wish you would have videoed the steps you used to loosen up the clutch basket (you wrote you used wood - would simply sticking a post through the back wheel hold the clutch enough to loosen and re-torque the bolts?).
Lots to learn for me ! I know it's just undoing bolts ,but there's a lot of knowledge here I don't have ,that would give me the confidence to attempt this I become confused doing this kind of strip down for fear I cannot put it back correctly but it's fascinating all the same 👍
Love your videos. at 4:00 is that you tapping that retaining wire that hold back the first steel plate (not sure what its called exactly) back into the grooves? Admittedly, I'm new to mechanics. I'm having a hell of a time getting that back in. I actually broke one already ha. Is there a secret to getting that darned thing on? Btw. 08' Dr650, 4100mi, found the top NSU screw loose as a goose.
+Logan Stark Just tapping the tab over on the retaining washer that stops the nut undoing. Make sure the clutch basket is fully home before tightening the retaining nut.
Reason I watched this was because I noticed while driving mine that the neutral light would be flicking on and off at random while in gear, HOWEVER, while it is in neutral, the light was on steady like it normally should. Could the light blinking while being driven be a sign that the NSU screws are coming loose? Its a 2005 and has a good number of kms on it. Just wondering if that could be it before taring everything apart. Cheers
Do you know the tourque specs? Any sugjestions for a 92 dr650, nsu may be malfuntioning i removed the cover and it appears to be in good shape i havent removed the clutch plates if you could give me alitle more verbal advice about electrical issues that could be maybe my cluster pannel light has burnt out... Have to get a new gasket now so i have a few days to leave the cover off please respond it would be good to have some experiemced advice
Christopher Miller Christopher I don't know much about the pre-96 DRs'. Torque specs may differ but on the post 96 models the clutch cover bolts are only torqued between 1.5 to 2.3 Nm. I do it by feel. Try a new bulb for the neutral light and see if thats the problem. Good luck.
My 14 dr650 died on me while on a trail..got jump started twice and still stalled while riding, ended up towing it back... Lights still work when I turn it on...but just wont start. Think its the battery?Going to have it checked tomorrow. Don't have a charger kit just yet. Advise would be helpful, thanks. has under 400 miles
I lose my unit into the case at 4300kms and thankfully I noticed my light didn't work for neutral any more. the screws where a couple cm away from going into the trans when I popped the side cover off. I didn't want to take it apart so I cut the wires and plugged the rubber gromet and its still good at almost 8500km
Just fyi to anyone following this, the clutch cover hangs a bit on the top left corner because of a little tube that sticks out. Wiggle the whole cover off evenly and it should be just fine.
Mate if you don't want to risk damage get the proper tool. I'm poor so used ply wood between the the basket and the casing and clamped with vice grips. If you use this method you have to be very careful not to damage either the clutch basket or the casing.
+1995dresser I'm not sure of the brand. I purchased at the local "Super Cheap Auto" store. It was a bit to high for the DR and I had to lift the bike from the rear onto it. This became a bind the older I got so I purchased an ATV lift which was ideal. So I didn't like it for the DR but I'm sure It would be good for a higher dirt type bike. Thanks for watching.
Im guessing it took too much time. I found that holding the front brake to keep the bike from moving works. If it doesnt then put the brake lever back on to keep the back wheel from moving. Also u need a 27mm socket to remove the clutch basket nut.
