DR650 upper chain roller

[Manfred]

Greetings all

I removed the upper chain roller and closed it with this:



To the DR650 guru's out there, is this flat enough..?

[Ganjora]

take the screw out.
leave it open,  or if you have to seal it use pratley steel.

[Ganjora]

when you remove your side stand switch,  pull out the little holders forth cable
same story with the pratley in the holes.   
completely sealed,  completely flush.

[Manfred]

Sweet.
Have some of that pratley metal stuff.
Mix the two together, silver colour.
Sets rock hard.

What about filing down.  Wouldnt that be the best..?

[Ganjora]

filing it down?
smudge it in nicely,  then,  when semi dry-ish,  wipe with a rag for any excess.

[RobC]

I would give it a dab of silicone sealer... that is a welded nut on the frame, I do not think it has a hole into the tube?

[Ganjora]

correctomundo RobC

[Manfred]

Good observation RobC.

Will remove that fastener and seal with Silicone or that pratley stuff.

[RobC]

Another dumb question from the KLR crowd... why do you guys want to take it off? I would have thought it would be a good thing to have the roller? Most big MX bikes do?
(Beginning to see a DR parked next to the Green Ogre)

[Inprogress]

Another dumb question from the KLR crowd... why do you guys want to take it off? I would have thought it would be a good thing to have the roller? Most big MX bikes do?
(Beginning to see a DR parked next to the Green Ogre)

It has a tendency to break off and takes a chunk of your frame with it. 

[Manfred]

And if you weigh in the region of 100kg's, that will happen sooner than you think.

Id rather be safe than sorry   

[Martin-DR650]

Nie nodig om die gate te seel nie!

Los dit net oop. Punt.

[RobC]

And if you weigh in the region of 100kg's, that will happen sooner than you think.

Id rather be safe than sorry   

Eish! So that is the DR Doo? 
Minor issue if you know about it, with some proper welding and gusseting one could overcome that tendency but only on an oldish bike that needs a frame respray.
The more I read about them the more I am starting to like them. At least they have no radiator that springs leaks...

[lecap]

Blind allen set screw M8x12, no matter what tip. Fit with low strength threadlock.

It's not an issue to remove the upper roller as it's totally useless. Suspension travel is not enough to allow the chain anywhere near the airbox or to increase slack to unhealthy amounts. On hard landings the chain hits the roller hard and sooner or later breaks it out of the frame.
I considered a modification with a support for the rollers shaft from the engine mount. Never made it as it's easier to just remove the roller all together.

[Manfred]

LeCap, what is a "Blind allen set screw M8x12"

Is that something like I have put on my bike..?

[lecap]

A set screw is a fastener to fix something with the geometrical form of the tip rather than with its head. A blind set screw is one without a head but with only a slot or allen fit.
They are (for example) used to secure pulleys onto shafts.

Have a look here to see what it looks like
or just ask your friendly hardware & fastener merchant

[Manfred]

I see what you mean.

Will check it out today, thanks

[Inprogress]

Also known as a Grub-screw or as some in our workshop called them, Grab-screw