REAR-SETS OFF, REAR-SETS ON, REAR-SETS OFF, REAR-SETS ON...............Etc.....
The images below show the difference in quality and machining between the Dan-Moto units and the COGNITO.
COGNITO wins hands down both in material value and workmanship.
You can see the DM lever plus pegs in front of the COGNITO unit.
After considering the options that flooded in (Thanks 5T & 1/2 Mile); I bit the bullet.
Sod it, lets just grind off the welded plates of the Dan-Moto pegs and see whats what.
Same both sides so I now have an exposed steel frame with holes in!
A quick flash over with some primer to keep the rust at bay would suffice for now.
Time to look at mounting options.
The COGNITO sets are machined to fit the original XS650 threaded mounting stubs that are welded in place.
Mine are long gone so I need another solution. First I offered up the gear link side to find a suitable location.
I decided to fit the pegs a little lower than the Dan-Moto ones to offer more leg room as I'm well over 6' tall with long legs.
I drilled out a hole , top right, to accept a 10mm stainless steel button head hex bolt.
Same at the bottom for the lower fixing. The bottom holes I also tapped to accept the 10mm thread.
Top holes were bolted straight through with a security 'Nylock' nut on the back.
A test fit was next to confirm the peg positions, and lever actuation.
The frame was then tidied up with some bondo to remove nasty grinder marks.
Sanded down to an acceptable finish; primed & re-sanded then primed again.
The nearest paint match I could find in Halfords auto shop was Peugeot Graphite Grey metallic.
A couple of coats of the paint and topped off with some clear lacquer did an acceptable to me job.
This would do for now as I plan to completely refinish the whole frame next winter when funds permit.
In the test fit I ran the gear linkage under the lever and mount. This meant the link was a little too acutely angled.
It did work but I didn't like the look of it and felt it would stress the fittings over time.
Another strip down and I ran the link bar above the mount to the gearbox actuator.
This was far more satisfactory both visually and mechanically. Stainless button hex bolts used, with tread-lock to mount.
The link tube shown is just a temporary item to get the length right. I have a new one supplied with the rear-sets.
A test of the levers in the shop show them to be far more robust and solid feeling compared to the Dan-Moto units.
The Cognito sealed bearings are really smooth. The shift is 'snicekrty-snick' slick and very positive up and down the box.
Yes they were quite expensive to buy at $470.00 plus shipping; but for the material and quality of workmanship they are totally worth it to me. The feel of the machine has improved beyond my expectation. I now feel I can trust the machine to ride efficiently and safely. A feeling that the old DM units did not inspire.
Also I now longer need a triple joint ankle to work the things!
Next job is to build up a new rear disc wheel using the COGNITO XS650 wire wheel hub with disc conversion.
This will allow me to use a sensible 33 tooth rear sprocket, and ditch the 40 tooth
brown pants wheelie maker currently installed.