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Sur-Ron Modifications, adjustments, tips & tricks

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  • paxtana
    Placing the dust cap on DNM fork

    Click image for larger version

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    This black piece on the left is the dust cap. This goes into the other piece on the right. Use something plastic to push seal into place , and hold it firmly in place for about 30 seconds to allow the ribs to settle in place.

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  • Sebz
    How to convert the primary belt drive to a chain drive

    Remove plastic motor pulley cover, 2 screws

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    Remove motor Pulley nut, jam the driveshaft pulley to stop motion (screwdriver through the bigger pulley while turning the nut). Or use an impact gun makes everything so easier

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    Loosen both upper and lower motor mounts, lift motor, remove belt from front pulley.

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    Remove front motor pulley. This may be difficult, do not pry against your $650 motor case. Use a chain vice grip on the pulley and place the pulley puller arms behind the chain. Or use the right tool and get your self a cheap gear pulley from amazon.. But what ever you do DO NOT PRY IT OUT USING LEVERAGE ON THE MOTOR!

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    Remove rear tire, chain, and ziptie brake caliper bracket unit safely away.
    Remove drive shaft black plastic cover, 3 bolts in swing arm, rotate cover down and out
    Remove swing arm shaft, use needle nose vice grips on 4 slotted nut, screwdriver between vice grip noses to turn nut. Allen wrench on left side, pull shaft out. Or if you have an impact gun with impact rated allen tip it works too. Or use this mac guyver technique, electric driver on the left while you do your best to hold the 4 slot nut

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    Remove bolt through painted connection of swing arm and shock linkage, note the two white nylon washers on each side of the linkage bearings.

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    Pull swing arm slightly up and backwards.
    Pull drive shaft from swing arm; remove belt, small bushing from left side, large bushing from right side

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    Remove large belt pulley from drive shaft, clean the surface replace with large chain sprocket, use lock tight on bolts

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    Install Motor Sprocket and key; tighten this when everything else is in place.

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    Install driveshaft; remember bushings, long on final drive, short on primary drive
    Install bolt and nylon washers through swing arm /Linkage junction.
    Install Primary chain, motor to driveshaft

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    Tension Motor to Primary Chain, Balance both sides equally, tighten upper and lower motor mounts, make sure snail adjuster is tight.
    Jam wrench into chain drive and tighten Motor sprocket nut (or use an impact!!!)
    Replace motor sprocket cover, replace, driveshaft plastic cover, bitch, whine, moan…
    Replace rear wheel, brake,



    Leave a comment:

  • paxtana
    Aftermarket sprockets
    This goes over what length chain you would need with a given sprocket size.
    • 420 CHAIN WITH 1/2" PITCH (NO "O" RING) on the standard LightBee (LB)
    • 420 GOLD CHAIN WITH 1/2" PITCH "O" RING on the LightBee "X" (LBX)
    All the next measurements are for a 14T front ring
    • 102 links 42T
    • 106 links 48T
    • 108 links 48T + pedal kit
    • 108 links 52T
    • 108 links 54T
    • 112 links 58T
    • 114 links for 60T
    • 118 links for 64T
    Chain are ALWAYS an even number, and this is the best way to count a chain:

    Leave a comment:

  • Sebz
    Replacing the Ignition and battery lock

    You will need a new ignition and lock kit, a philips head and flat head screwdriver a 4 and 6mm allen key and a 10mm socket wrench


    Remove the 2x 4mm allen heads and lift the ignition and USB assembly from the top.

    Use a small flat head screwdriver and press on the 2 tabs to release the ignition barrel, unplug the connector and swap the ignition barrel with the new one. The rest is pretty simple , no need to explain!

    Battery lock

    Remove the 2x 4mm Allen head on each sides

    Remove the 2x 6mm allen head under the lock

    Remove the philips head screw holding the 2 plastic part covering the lock assembly

    Remove the 2X bolts with your 10mm socket wrench and swap the lock assembly and reinstall the cover back on (follow the steps in reverse)

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  • Sebz
    Removing the kickstand sensor

    You will have to remove the bash guard and access the triangular 3 pin connector and unplug it.

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    If you are unsure how to remove the bash guard then watch the controller swap video here:

    Leave a comment:

  • Sebz
    Adding a voltage meter to your Sur-Ron,

    Please click this link

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  • Jindyeric
    commented on 's reply
    Hello, How did you get the cable "nib" past the press fit bearing?

  • Sebz
    Adjusting / setting the headset and stem.

    From the factory the headset should be tight but it's possible that it was not done perfectly so you should check before your first ride.

    Checking the headset for any play before each ride is highly recommended. Riding with a loose headset will result in a damaged headset, cracked frame or fork.

    In this following video it shows you how to set it with a direct mounted stem but on your Sur-Ron you have a regular stem so just make sure to loosen the stem bolts too!

    Leave a comment:

  • ElectricMud
    commented on 's reply
    Can I just disconnect the two terminals and leave the cables attached to the brake levers? Is it necessary to take the wires completely off? Does it matter if the wire is removed from the brake lever since it would already be disconnected to the power source?

  • Sebz
    Sur-Ron Black Edition with the RockShox Boxxer 2019 RC fork with Debonair air spring technology.

    Click image for larger version

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    Rest assured you have one of the best downhill fork that hit the market. Reviewers, blogs, magazines praise that new 2019 RockShox Boxxer series fork ....But it will need proper tuning to work fine on your Su-Ron...

    So since your bike is not a 30lbs downhill bike but a 110lbs monster bike you will likely have to tune it like if you weighted 80lbs more.

    Your Boxxer comes with the following adjustments:
    • Charger 2 RC damper featuring low speed compression adjust
    • DebonAir air spring offers a coil-like consistent feel throughout the travel (you will need a shock pump that goes over 150PSI)
    • Optional Bottomless air tokens to prevent bottoming out for agressive riders.
    So now what?

    Open this manual, we edited the manual to reflect the options found on your fork model, please follow the guide step by step to tune your fork.

    Tip: You have the right sag and the fork works perfect for most of your riding but bottoms out on drops and jumps? Adding more air pressure will change the sag and also affect the plushness of your fork... So maybe try to add some bottomless tokens to change the air spring rate when the fork compresses further than 50% travel.

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  • paxtana
    commented on 's reply
    Thanks for the heads up Mark, I have edited this to point to your page instead :)

  • paxtana
    Preliminary docs for installation of the belt kit

    Backup link

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  • Markk
    Originally posted by paxtana View Post
    Aftermarket cranks for the Sur-Ron pedal system

    These cranks are lightweight aluminum with a good offset.
    Confirmed these will fit but they are about half an inch longer than stock.

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    Unconfirmed but also possibly suitable from the specs:

    These cranks are also aluminum, little less expensive.
    These have not been confirmed yet, but are likely to work (no promises though)
    The Jitsies did not work for me. I've written a post about what did work for my cranks:

    Leave a comment:

  • paxtana
    commented on 's reply
    Typically on these types of connectors there is a tab that latches it into position, you may need to move the tab to unplug it.

  • deserthi
    commented on 's reply
    I unbolted the ignition but could not get it off. It simply would not come out. I feel like such a klutz!