No announcement yet.

Sur-Ron Modifications, adjustments, tips & tricks

This topic is closed.
This is a sticky topic.
  • Filter
  • Time
  • Show
Clear All
new posts

  • paxtana
    Aftermarket upgrade parts

    Aftermarket pedal system - This is not connected to the drivetrain so it is far less likely to break, and if it does it will not affect the operation of the bike unlike the normal pedal system. A nice upgrade.

    Tail Tidy - This updates the area behind the rear seat so you have more options for mounting stuff

    Seat extender - This raises the seat

    Foot peg bracket - This replaces the original cast foot peg brackets with something that is nicely machined for enhanced durability
    Last edited by paxtana; 1 week ago.

    Leave a comment:

  • Sebz
    Removing the jackshaft castle nut and replacing it with a standard Nyloc nut

    You will need a Nyloc M10 x1.0 nut
    You will need a washer 20mm OD with a M10 hole :

    Tools, you can buy the Sur-ron official 4 prongs nut remover (if you can find one) or you can just use a long nose plier (vise-grip preferably) and a allen key on the other end and remove it. IF you don't plan on reusing that nut you can also use a flat head screwdriver (or a punch) with a hammer on one of the 4 notches and hammer/spin it counter clockwise.

    Click image for larger version

Name:	fetch?id=108744&d=1593478387.jpg
Views:	882
Size:	752.8 KB
ID:	114839Click image for larger version

Name:	fetch?id=108743&d=1593478362.jpg
Views:	878
Size:	834.2 KB
ID:	114840

    Leave a comment:

  • paxtana
    Aftermarket Sur-Ron forks

    Stock forks are fine for normal riding but for the hard core motocross rider you may find the stock fork a bit soft and hard to tune to you pro riding style ;)

    The Stock Sur-ron uses a standard downhill (DH) mountain bike forks (called double crown or triple tree forks) 200mm of travel, for 26 inch MTB wheel and a straight tapered steerer 1 1/8". The Sur-Ron front hub is a non-boost 20mmX110mm. . If you find a newer model fork with the new boost 20x110mm axle system you can still add a 5mm brake disk spacer and the Sur-ron wheel will fit. If you find a fork with a tapered steerer (called 11/8" to 1.5") then you will just need to replace the lower headset with a cane creek headset like this : . Click here for more info on headsets

    So what model you should buy? That is up to you all the different model out there have different adjustments and properties, but
    • Fox 40 (do not put a Fox36 on your bike, stanchions are not strong enough) this one is likely the best fork available but it's not cheap and often is over 1600$ It's plush, rigid and almost any rider will find the perfect setting for their style of riding.
    • Manitou Dorado pro or expert, 26" or 27.5". Probably the best bang to the buck if you can get one at 700-950$. it is one of the "plushest" fork out there when tuned properly! Killer inverted motocross looks too.
    • DVO Emerald, another amazing fork, probably one of the top 3 best forks out there, and if you can get your hands on one they are often in the 1100-1300$ range
    • DVO Onyx, a new fork built just for Sur-Ron
    • Marzocchi boomber or any 40mm stanchion model, this fork can be found used for cheap and it's pretty easy to get it serviced.
    • Öhlins DH38 m.1... OHlins makes the best suspension period but this one is only 38mm... might not be as rigid as the Fox 40.
    Last edited by paxtana; 5 days ago.

    Leave a comment:

  • paxtana
    Programming Sur-Ron Controller,

    Support notes this only works if you have the X controller pre-installed. IF you bike came with the base controller and added the x controller later this will not work.

    Note the factory bike comes programmed at level 3 (which is max regen)

    Level 1 regenerative coasting = 2 short brake pull, 1 long
    Level 2 regenerative coasting = 3 short brake pull, 1 long
    Level 3 regenerative coasting = 4 short brake pull, 1 long
    Turning off the regenerative coasting = 7 short brake lever pull
    Turning off the e-brake sensors = 8 short brake lever pull
    Turning ON the e-brake sensors = 9 short brake lever pull and 1 long
    Last edited by Sebz; 09-01-2020, 04:11 PM.

    Leave a comment:

  • paxtana
    Equipment to change from belt drive back to chain

    Leave a comment:

  • paxtana
    Placing the dust cap on DNM fork

    Click image for larger version

Name:	IMG_1106.jpg
Views:	3370
Size:	101.4 KB
ID:	109847

    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.

    Leave a comment:

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

    Remove plastic motor pulley cover, 2 screws

    Click image for larger version  Name:	IMG_2236.jpeg Views:	0 Size:	858.5 KB ID:	108739

    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

    Click image for larger version  Name:	IMG_2286.jpeg Views:	0 Size:	750.1 KB ID:	108740
    Loosen both upper and lower motor mounts, lift motor, remove belt from front pulley.

    Click image for larger version  Name:	IMG_2238.jpeg Views:	0 Size:	931.4 KB ID:	108742

    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!

    Click image for larger version  Name:	IMG_2287.jpeg Views:	0 Size:	815.2 KB ID:	108741

    Jackshaft removal

    Remove the chain of the rear sprocket , remove the rear wheel, and ziptie brake caliper bracket unit safely away (so you don't break the brake fluid line)
    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

    Click image for larger version  Name:	IMG_2229.jpeg Views:	0 Size:	834.3 KB ID:	108743Click image for larger version  Name:	IMG_2230.jpeg Views:	0 Size:	752.8 KB ID:	108744

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

    Click image for larger version  Name:	IMG_2231.jpeg Views:	0 Size:	857.0 KB ID:	108745Click image for larger version  Name:	IMG_2232.jpeg Views:	0 Size:	780.1 KB ID:	108746

    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

    Click image for larger version  Name:	IMG_2239.jpeg Views:	0 Size:	1.52 MB ID:	108747

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

    Click image for larger version  Name:	IMG_2242.jpeg Views:	0 Size:	864.1 KB ID:	108748Click image for larger version  Name:	IMG_2243.jpeg Views:	0 Size:	845.4 KB ID:	108749
    Click image for larger version  Name:	IMG_2244.jpeg Views:	0 Size:	930.8 KB ID:	108750Click image for larger version  Name:	IMG_2245.jpeg Views:	0 Size:	806.4 KB ID:	108751

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

    Click image for larger version  Name:	IMG_2288.jpeg Views:	0 Size:	825.9 KB ID:	108752

    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

    Click image for larger version  Name:	IMG_2246.jpeg Views:	0 Size:	987.3 KB ID:	108753Click image for larger version  Name:	IMG_2248.jpeg Views:	0 Size:	1.04 MB ID:	108754

    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,


    Last edited by Sebz; 09-08-2020, 07:56 AM.

    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)

    Leave a comment:

  • Sebz
    Removing the kickstand sensor

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

    Click image for larger version

Name:	image_17655.png
Views:	10453
Size:	987.7 KB
ID:	101558

    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

    Click image for larger version

Name:	Screen Shot 2020-01-07 at 12.53.49 PM.png
Views:	11370
Size:	756.9 KB
ID:	99497

    Leave a comment:

  • 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

Name:	Screen Shot 2019-08-28 at 11.07.26 AM.png
Views:	13998
Size:	256.2 KB
ID:	92473

    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.

    Leave a comment:

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