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Nearly died from the Doom man, instructions unclear.... Hahaha, sadly taken a job and things are on hold... eish... luckily this one is quite simple to put together again with a service manual.... I'll be like Arnold, back....

wheeler  - I believe the offset clutch plate is just to transfer/offset stresses in the outer clutch basket "teeth", the basket looks machined for that... but you will  have to a service/owners manual and just make it like the manual says so ensure that if you do break any teeth off the outer...

Sorry to report, a spider spun a web in my spokes... what do you use for depression? 125cc?

Thanks Slasher - my chain is already nearing end of life and the PBR 15T XR650R sprocket seems to keep things line up straight - I've already bought a replacement PBR but will likely go with the Dirt Bike Africa front and rear sprockets (reversible) when change out the chain - currently just...

Weedkiller - Adie  Edit: Interesting and makes sense, no play = no lube required. The Honda XR650L uses a retainer plate with a couple bolts that mount the plate to the sprocket but don't go into the case, nor does anything fix the sprocket to the shaft... it grips on the splines to turn, same...

Just buy it from the suppliers for R100 - SARS have nothing to do with the price of the goods. EDIT: Sorry only saw page two here... hope you find a solution!

BuRP - Shot for that crash course on silencers, feel like I'm getting somewhere again in the knowledge department but I still need to go back and fill in the gaps, Meteor - your manual should also state the API category that the bike requires, From what BuRP is saying I understand that it's...

I too believe Moly paste / grease is the right stuff to be using here, something with at least 60% molybdenum content - Bill the Bong  - where do you find this stuff?

Neutral switch will be in the same wire plug thingy as as alternator/stator (one of those wires, check your manual) - unlikely that you cut it out unless went out of your way to do so? Worth bypassing that / all switches check if it works before sending it anyway? Probably a 5 minute job? If...

Thanks again BuRP - Ah, I think I now understand the difference between free flow and uhmm.. stock silencers... will have a look inside soon enough... but will leave that for a(nother) rainy day... Have dropped off my cylinder, piston and head with Tim Bosson and placed hopefully my last (for...

Thanks for the input JMG Bike updates... Have removed the top end and pretty much the entire right side of the engine, The oil pump will come out for inspection and probably seal replacements next. I want to be sure that too much oil isn't passing the pump through bad seals too quickly when...

For anybody reading in future, in this case the basket would move about 1cm forward and stick there, if you don't have a deep socket that fits exactly on the "clutch outer guide", I used a short length of regular 20mm PVC pipe, had to cut it lengthways and widen with longnose pliers to get it...

raphaeltube - Ouch! Glad I didn't use those bolt posts. Investing in tools is important if you want to save money on repairs. Anytime I can buy a tool instead of hire one... ;-) Now left with just the clutch outer and clutch outer guide (manual names), basically, the outer clutch basket, from...

meteldog - Don't think you can get a 15 tooth XR650R sprocket from Honda, you have to find an aftermarket one, my XR650L had a PBR 15 tooth front for XR650R installed by the previous owner, only recently got a look at my countershaft and it seems to be in good condition so I bought another PBR...

meteldog - there are some reports that the R sprocket can stop/slow wear even on an already worn countershaft, maybe you can put the R sprocket on and tack weld it in place... that holds as long as the sprocket or until you want to change the countershaft... I believe.

Must agree! Can't take any credit that must go to the welder (he does things simple and they just work). I was thinking of something adjustable and what not but could hardly finish the thought and this was welded up... must just slap some NS4 on and get myself a white marker to write the part...

Spoke to a friend who does metal work and asked him if he could make me a tool, took a couple measurements and came up with this in about an hour, Works like a charm! Think I unstaked the nut (to some degree) with a screwdriver and hammer, just laid out all flats to get the perfect size and...

BuRP Thanks a mil. , so if one must use car oil use one that is not labeled "energy efficient" or mentions friction modifiers, seems simple enough to get comfortable with, Hehehehe, shhh! It does save fuel... saves it in the right side of the tank so when I run out on reserve I can tip the...

Howzit all, Sitting here thinking about the clutch basket center nut on the XR650L, For those that don't know, that nut is staked by knocking it out of shape into a grove on the shaft. Honda say it should be unstaked before you remove the nut. Trying to get a screwdriver in there to lift it up...

Excellent info BuRP - been reading more about it as well, PS. Castrol is part of the BP group Many people seem to swear by Motul 5100 or Motul 7100? I think I've already decided to switch at least to 5100 unless I convince myself that I need a full synthetic oil, in which case I might be...