DR650’s BUILD FOR RTW – PART 3

Putting it all back together, pretty simple, at the same time I add some case protection with a copyrighted RTV pattern, the places these bikes are headed they will be taking a few naps

and the oil filter is changed out for a reusable unit as we are heading to some remote areas so don’t want to carry a stock of them or have to go searching

To finish up the lower right-hand side, a good clean of the brake pedal and new grease added

around the other side, time to add the seal retainer which honestly I am surprised hadn’t be done or suggested earlier as both bikes had seals leaking!!!

Sprocket covers were swapped out, scored this one from a guy in OZ for real cheap inc. shipping

couldn’t find another so went with the Procycle version

Next thing I do on most every bike after loosing a shift lever once, is pull out the stock bolt and add a longer one with a Nylock on the back side for security. On the DR shifter the top and bottom faces are at different angles so don’t tighten the nylock all the way as it’ll bend the bolt. This helps you have a little warning that its loose before it could disappear, or ride the rest of the day using vise grips as a shifter peg.

Whilst you are down there add oversized washers to the footpeg mount to take the slop out of the rubber mount

I had a pair of Promoto Billet adventure pegs laying around so ordered a DR mount kit and put them on, still looking for pegs for the other bike

Stock cotter pin are good for maybe one or two removals so they were swapped out for hairpin spring retaining clips everywhere cotter pins were used

The one on the back of the brake is positioned correctly so if hit by a rock it can only be knocked on further, the one on the master cylinder is wrong as a rock from underneath could hit it and knock it off. After the photo it was oriented correctly.