Service manual errors and questionable statements

[greywolf]

The spec for the rear sprocket nuts is 60Nm. I disagree with it. People have stripped nuts and broken studs using it. The generic chart for 10mm hardened bolts says 50Nm. Rich Desmond of Sonic Springs uses 40Nm with no problems.

The spec on the front sprocket nut on the Vee is 115Nm. That seems fine. The spec on the exact same nut on the DL650 is 145Nm, which is way high.

In the same vein, the spec on the 8mm bolts that connect the engine mount hanger to the frame is 23Nm on the Vee which is a good value. The spec on the same bolts on the 650 is 35Nm, which has broken bolts and stripped frame threads.

Stainless steel nuts on SS engine mounts, the SS swingarm pivot and the SS rear axle have a tendency to gall. Use anti seize on the threads to prevent problems and reduce the torque to 80% of the spec to account for the lubrication effect. For example the 100Nm spec'd for the rear axle nut becomes 80Nm.

There is a misplaced connection dot in the fuse box of wiring diagrams I've seen for K4 and K5 DL1000s. The K3 was okay. I've put a green dot where the connection appears in the manual. That spot should be a crossover. The connection should be where I've added a red dot. (on the left for the colorblind). The common wire feed to those fuses should be the orange wire.


In the DL650 service manual the following error occurs.

"If the TP sensor output voltage is out of specification, turn the
fast idle adjusting screw and adjust the output voltage to
specification.
TP sensor output voltage: 1.21 V
(Red - B/Br)"

Actually, Red - B/Br is the input side. It will always read 4.5-5.5V. The output side is P/W - B/Br as shown on pages 4-30 and 9-50

In the service manual for the 650

Reserve Approx. 250 ml
tank side (0.53 US/0.44 lmp qt)
Engine Approx. 1650 ml
side (3.49 US/2.90 lmp qt)

You see the problem? The US measures are over twice the metric measures.
250ml is actually 0.264 US quarts 0.220 Imp quarts
1650ml is actually 1.74 US quarts 1.45 Imp quarts


For the 1000

2200ml(2.3/1.9 US/Imperial oz)

Which are good numbers for quarts instead of ounces.

Just a tad under 2 US quarts or 1.66 Imp quarts for both models will do it.

[Fatbelly]

For European riders it might be useful to point out that a "quart" was a measure of liquid used in the olden days when soldiers fought with swords.




.......Just joshin', Greywolf. This is the first mention I have seen of an imperial quart in almost 50 years!
I have always doubted torque figures for fasteners, they often seem way too high - it must put a huge strain on the threads.

[Gassoon]

I for another have lost confidence in the stated torque values for the bike: that is, many or most of them may well be OK, but once one or two are 'found out' you have to think proactively about everything the buggers say in the manual! And I hate thinking.

I think (ouch!) that we should include this info in the VStrom Compendium on here. Cheers Greywolf - what the hell did we do before you visited ?  

[greywolf]

I was just using the units in the manual. Life would be easier if the everybody went totally metric.

[Gassoon]

Pound for pound, metric is probably better



[edit: sorry ]

[MartinW]

Gassoon - You need a more sincere apology than that.

Technically, Mr Rat has banned Metric from this forum.

[StromGeeza]

Gassoon - You need a more sincere apology than that.

Technically, Mr Rat has banned Metric from this forum.

Does that mean my DL1000 now is a DL33.8 (fluid ounces)??

[Juvecu]

[Oop North John]

Gassoon - You need a more sincere apology than that.

Technically, Mr Rat has banned Metric from this forum.

Does that mean my DL1000 now is a DL33.8 (fluid ounces)??

But you've used American fluid ounces, so why hasn't the Americanism filter done its job?  

[greywolf]

Totally wrong. The DL996 displaces 35.0542849 Imp fluid oz.

[Gassoon]

Does that mean my DL1000 now is a DL33.8 (fluid ounces)??  

 

And DL996 sounds very Ducati-ish, might increase sales of the new one...

[Brockett]

Thread Hijack alert !!!!!!
years ago when the UK Government was forcing metrication down our throats the pro propagandists invented metrication rhymes to get us used to the idea.

Daily Mirror journalist Keith Waterhouse came up with the best reply
" A litre is a metre only wetter".

The usual Brit compromise was reached and the general public took no bloody notice and so our kids were all taught metric so we couldn't help them with their homework.
Go to a timber yard and buy wood " got any 25 by 50 (mm) mate"  
"nah got some 1 by 2" (inches) -  and it comes in 1.8 or 2.4 metre lengths.
We still do miles per gallon rather than kilometres per litre
and watch a 42 inch TV
Strangely Tyres are sold in inch diameter but are the other specification measures metric?

[Jacko]

I do miles per litre.. I ride in miles and buy fuel in litres, makes sense to me..

[Fatbelly]

If you go to a timber yard and ask for 1"x2" the man serving you will say yes and give you 25x50 with a smile while thinking, "Poor sad old gentleman".

[Andy M]

Measure it. The tooling was all made to bs standards, so the Europeans may kid themselves it's metric but it ain't. EU standard medical tube is 1.6, 2.4 ,3.2mm and so on. Silly numbers until you convert to inches and see where the big manufacturers are. Look at all those half litres served in pint glasses. You might as well go the Japanese route, call it a no.3 beer glass and not worry what the actual size is.

As a manual writer it is pointless putting torques. Few of you have the means to control them and the fact you question the number but not the lack of a tolerance proves it. I would take them all out and add a one pager about professional competence and which tools to use. You wouldn't like that either as you have all been trained to believe the extension bar with the numbers on the handle makes you competant and professional. The 'mistakes' may even be of the cartographers variety, built in copyright. I would never do this with a torque setting, but I know a writer who changes the closest number to line 666 to a multiple of 13 to do this.

Andy

[greywolf]

Sure there's a tolerance, a big one in fact. But publishing figures that cause fasteners to break when a properly calibrated torque wrench is used is a cause to bring them into notice.

[Strommer]

This one always makes me giggle (K5 handbook page 5-3).....knew I must be doing something wrong...I should be in 5th at 31mph!

[greywolf]

You can be in 5th at 31mph for maximum economy if the bike is properly set up. I wouldn't go as far as to "should" on you.

[Strommer]

Tried it once...utterly lethal, no escape power at all.  Might work on an empty desert highway...but not around traffic.

[greywolf]

True. Accelerating from 2500rpm is problematical. I like a 3000rpm minimum and higher is better in tricky situations.