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mayday!!!!upper chain roller broke off!!

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02 dr 650 stock chain

ok my upper chain roller broke of at the frame weld.:applause:

it fell in under the chain and i have it.:applause:

i can weld it back on correct?do i need to disconnect any electronics before welding??

help quick mr wizard......

i also want to upgrade to the bearing unit and replace the chain slider thing on the swingarm.

of course it breaks with the sheetiron next week and me pouring the patio tommorrrow :p :p :p :p

any suggestions would help greatly

MZR

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Most of us take it off before it does what yours did. I hope it didn't leave to big of a hole in your frame.

A design flaw by Suzuki. DON'T weld it back on. It serves no purpose unless you like a hole in your frame to lessen the weight a little. :applause:

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Congrats! You've just improved your DR!

Leave it off, it's a designing mistake from mr Suzuki. The fact that it broke off proves to me it shouldn't have been there in the first place.

When I bought my last DR it had already broken off, and there are many more here on this forum.

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thanks guys.yes there is a hole in the frame. less wieght like drilling the rotors???

i will just plug the hole with my base gasket leak fixing compund {rtv!}

good one less thing to take care of....

MZR

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thanks guys.yes there is a hole in the frame. less wieght like drilling the rotors???

i will just plug the hole with my base gasket leak fixing compund {rtv!}

good one less thing to take care of....

MZR

+1 Yes, be sure to plug the hole to keep water out of your frame tube.

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I took a look and putting a bolt into the hole would leave the head exposed enough to contact the chain. So what are you guys using to plug the hole? I was thinking of some caulking compound.

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I fit some steel wool into the hole to take up some space then covered it over with JB Weld.

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Allen set-screw with some Loctite? Flush and permanent. :)

Sounds like a good solution-probably should use some thread-lock to keep it there. I think it's a 6mm hole. I'll stop at Home Despot on the way home today and look for a set-screw.

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How bigs the hole? if it's over 1/4", i'd be getting a bit of thin sheet and stitching it there.

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The hole takes an 8mm set screw. I put threadlock on it and screwed it in so the head is just above the flat surface. $1.09 solutuion.

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