Rear Set Removal Question 05 620

[The ModFather]

2005 M620. Took off the left rear set no problem. The right rear set there's a lot going on there in terms of connections to the rear set. (e.g. behind the footpeg springs for the lever etc.) Anything I should know before taking off the right rear set outside of make sure I know where and how everything goes back?

[seanster]

Just only one spring for the brake pedal.  The rest included the rear brake reservoir, brake micro switch.  That's it.  Easy to reassemble.

[Latinbalar]

the only thing different it the break light switch and the brake master.  unscrew the two bolts on the break master and pull it out of the way the linkage from the pedal and it just  separates. The brake light unscrews you can either unclip it further up the bike (follow the wire up) or just unscrew it and twist the wire.  after that it un-bolts just like the other side.

[Slide Panda]

Don't break your brakes... ahem

As noted it's easy.

[The ModFather]

The brake light switch cable (I think thats what it is ) which bolts on to the right rearset via a rubber bolt thats part of the cable is not unscrewing easily. I dont want to damage it. It seems to be somewhere between a 10mm and 11mm wrench size. 10mm wrench is too small and 11mm wrench seems to big and since its rubber it keeps slipping. Any tips on getting this thing off. Pic of cable below:


IMG_5078 by ricknieto, on Flickr


Also I noticed while taking off my right rearset that there's a crack in it. Do I need to replace this right away? Is there a danger if I dont? I'm taking off these rearsets to get them powder coated. Can I get just a right rearset for a reasonable price? Cracked rearset pic below:


IMG_5080 by ricknieto, on Flickr

[seanster]

I think u can unscrew it fairly easy, i was able to do mine with just my fingers.  Try a little harder and see, and i dont think you can damage it that easily.  Lots of easy stuff haha...

I have a pair of rearsets but dont know if i want to sell it though.  How much are you willing to take them for?

[The ModFather]

How does that crack look? I didnt notice it until I took the rear set off. What options do I have here? If its still structurally sound is there a way to treat the crack before powder coating that will make it less visible? I like some of the after market rearsets but the cheaper ones (DucaBike) dont seem to come with passenger foot rest options. Does anyone sell just a passenger foot rest that can be mounted independent of the main rearsets?

[Slide Panda]

You can have it welded, or buy a replacement. Depending on the costs for welding it might be cheaper to get a used replacement. As you're about to PC them you can probably get some 'cosmetically challenged' rearsets or just the side you need on the cheap.

And yes, you really need to do something structural about it. A cosmetic treatment might be fine for a not load bearing part. But the crack will continue if you just cover it

The brake switch is just threaded in. Don't turn the rubber, there's the wrench flats for a reason. PB Blaster, Seafoam Deep creep or other penetrating oil can be your best buddy. Get a can, spray some one and let it sit for a while - then put a wrench to it.

[Nottsbiker]

I'm no welder but I'd guess that youre going to need someone who is half-decent to weld cast aluminium, especially as I bet its cast from monkey metal.

[seanster]

AFAIK cast alum is hard to weld...

Duckoff...if someone can confirm my 2000 M750 original rearset fits your 05 M620, then I will work out the price for ya.  Got your PM by the way.

[Slide Panda]

All DSS monsters can cross fit rear sets. Only differences were colors.