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Sur-Ron Modifications, mechanical repairs, adjustments, tips & tricks

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    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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    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

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    There is also the flat head screwdriver and hammer technique that works wonderfully, but be careful not to scratch the frame!

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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,


    Last edited by Sebz; 5 days ago.


      Placing the dust cap on DNM fork

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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.


        Equipment to change from belt drive back to chain


          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. Please note it is not promised or guaranteed that all X controllers have this capability, but if you want to give it a try, go for it!

          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 paxtana; 11-30-2020, 09:54 AM.


            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; 10-15-2020, 05:24 PM.


              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.

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              There is also the flat head screwdriver and hammer technique that works wonderfully, but be careful not to scratch the frame!

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              Last edited by Sebz; 5 days ago.


                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; 10-13-2020, 05:26 PM.


                  Changing the brake lever blade

                  1) loosen the set screw on the lever, the one holding the main pin, not the reach adjuster

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                  2) Push the main pin out from the bottom of the lever. You can use a nail, a punch, screwdriver...

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                  3) Turn the adjuster with an 2mm Allen wrench until it comes out of the lever

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                  To reassemble, slip in your Allen wrench in the new blade threaded hole and reach the adjuster 2mm hex head and turn till you get the threaded adjuster all the way in. Push the main pin in and don't forget the set screw or the pin will fall out eventually.

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                    How to replace the RST fork spring with a firmer spring to make it not bottom out.

                    1. Get this spring here. Click me. Make sure to get the blue firm one.
                    2. Cut 3" inches off the new spring because it comes too long.
                    3. Just unscrew the top cap of the left leg on your fork and replace with new spring.
                    4. You do not need to add grease you can just take the grease from the
                    stock spring and transfer to the new one. It's an easy 5-10 minute job.

                    Last edited by paxtana; 5 days ago.


                      How to fix the battery latch or remove it.

                      First step it to remove the seat off the bike, please click here for instructions.

                      Once you have the seat out of the way you will have to remove the latch plastic cover

                      1 Allen head bolts on each sides and one philips head on top.

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                      Under the latch you have 2 Allen head bolts to remove to be able to remove the 2 plastic covers.

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                      Then it's time to remove the latch assembly, just remove the 2 main bolts and you can remove the latch

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                      The next step is to fix the latch if your key does not catch the latch, so follow the procedure below:

                      (with thanks to Robert from Facebook)

                      This is a fringe case that has only been seen a few times so in most instances you want to check the latch is not caught on something and that the cylinder does not need lubricating.

                      What is happening here is the mechanism the cylinder fits into is not working. This is the mechanism that sits between the latch and the lock cylinder. If you can turn the key in the lock but it does not turn the latch then this may be the issue.

                      You have to dismount the lock mechanism and then open it up. Inside of the lock-mechanism there is an axle going through the entire mechanism. In the end of this axle there is a nut and this nut has become unscrewed. This then causes the hook that locks the lid to slide off the spline of the axle. Hmmm... difficult to explain but start with opening up the mechanism and then you'll see. I was lucky because my battery was not in the bike when this happened to me. This made it easier to dismount the lock mechanism.
                      Red straw points to small Phillips head screw that backs off shaft letting latch disengage from turning shaft

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                      Solution: Drill hole in end of casting just large enough to get a Phillips screwdriver in but small enough that screw can not fit through hole in case. Unscrew screw to expose threads, apply lock tight to threads, screw back in tight.

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                      If you can wiggle that gold colored metal latch that hooks your battery cover down, if it is not centered in the mechanism, the screw is backing out. It is a very tiny Phillips head screw with no lock washer or lock tight on the end of the lock shaft furthest from the key. I drilled a hole in the end of the case so I could get at it with a screwdriver, backed the screw out until it hit the case (twice) and dosed it with blue lock tight (twice), running the screw in and out a few times. The screw can not fall out because it hits the case first, but the gold latch can get out of its purchase on the lock shaft notch and not unlock anymore. If that gold metal latch is loose it's only a matter of time before you won't be able to open the lid.