Reattaching the rotor using conrod holder

Questions regarding the DR800

Reattaching the rotor using conrod holder

Postby GrahamW » Thu Nov 23, 2017 10:39 pm

Hi I have kind of been held up rebuilding my engine as I have been trying to work out how I am going to re-torque the rotor bolt without a rotor holder tool. Is there any reason I cannot just use a bar through the con rod to hold the crank from turning while doing up the rotor bolt? I thought it might put too much stress on the balancer chain but thinking about it the chain won't be stressed at all.
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Re: Reattaching the rotor using conrod holder

Postby BigBob » Fri Nov 24, 2017 12:00 pm

If you check in the Holy Book section 3-14 you`ll see the tool you really need 09930-44913. Shame they are £160 from Suzuki :tdown:
The same tool is used on the DRZ400 and GN250 plus various ATV and Quad bikes so a local Suzuki dealer may have one he can lend you.
Also, it`s used on Suzuki marine engines so will probably be a lot cheaper from them. Check them out.
Cheaper one here http://cheapsuzukiparts.net/09930-44913
I`ve got a genuine one that I`ve used for years. Shame you are not local to me.
I wouldn`t bother nipping the bolt up tight just yet. Why not put the whole engine back together before attempting to torque the bolt? That way you`ll have a lot more resistance to fight against when the time comes, and less strain on any individual component.
Funnily enough, I was using that tool last week in stripping an engine down to remove and replace a crankshaft. Of course, it was all done and rebuilt in a few hours, but then I have done it countless times before.
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Re: Reattaching the rotor using conrod holder

Postby spendango » Fri Nov 24, 2017 6:56 pm

:tup: :tup: :tup:
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Re: Reattaching the rotor using conrod holder

Postby GrahamW » Sat Nov 25, 2017 8:57 am

Cheers I remember using your tool to take it apart. Would it be too much stress on the crank using the con rod method then instead? I have used that to undo other bolts. I have been thinking I might be able to rig up square out of 4x2 timber screwed together with a couple of bolts going through and a long length screwed to stop it turning to hold it instead of the proper tool.

I asked a local bike garage if they had a tool to do it and they said "no mate we just use an impact gun".
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Re: Reattaching the rotor using conrod holder

Postby BigBob » Sun Nov 26, 2017 11:49 am

I used the locked con rod method to whizz off the wrong handed big nut on the end of the crank with an air gun so it should be OK
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Re: Reattaching the rotor using conrod holder

Postby GrahamW » Sun Nov 26, 2017 6:52 pm

Yep I think I will use the con rod as I already used it to do up nuts on the clutch side. It takes less torque to do them up then undo them.
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Re: Reattaching the rotor using conrod holder

Postby GrahamW » Thu Nov 30, 2017 1:11 pm

Wow I managed it using a long spark plug wrench in the con rod wrapped in a bit of rag and then rags on the mating surfaces where the cylinder goes as well to stop it damaging them. I had to use my granddads old torque wrench on the maximum setting 110ft pounds but couldn't do it with my bad right arm. Had to put the bottom end on the floor of the garage and hold the motor with both arms and tread on the end of the torque wrench until it clicked. I degreased the mating surfaces with brake cleaner on a rag and used a bit of blue loctite on the rotor nut as well. That thing shouldn't be going anywhere now.
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Re: Reattaching the rotor using conrod holder

Postby BigBob » Thu Nov 30, 2017 5:04 pm

:tup:
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Re: Reattaching the rotor using conrod holder

Postby Agiora » Mon Dec 25, 2017 12:24 pm

Hey guys, here is my home made rotor holder, which costed me about 5 euros and it works perfectly.

26102279_10212580085351434_1147706165_o.jpg


26062805_10212580085631441_1684633144_o.jpg


Now it's a bit bent, but it still works and easy to repair.
Hope it will help save some money.
Cheers
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Re: Reattaching the rotor using conrod holder

Postby BigBob » Fri Feb 02, 2018 7:06 pm

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