Wild Dog Adventure Riding

Technical Section => Make / Model Specific Discussions => Suzuki DR & DRZ => Topic started by: Hankeeb on November 29, 2016, 08:17:18 pm

Title: My DRZ400E thread
Post by: Hankeeb on November 29, 2016, 08:17:18 pm
So for a while now I have been surfing forums online for DRZ400 threads on mods and updates.  Found a few with some good info and some with nothing really of much help.

I decided I will add to the pool of info by starting a thread on some of the mods that I have done and still planning to do.

My thinking with the DRZ was to have an all rounder bike that I could 1-use for commuting to work and back(5km per day), 2-use as an Adventure bike to still go ride Cederberg, Die Hel, Tankwa and all those beautiful places and 3-use it as a plastic bike to do some local Funduro's.

So about 5 months ago I bought a 2013 model DRZ400E from a Wild Dog, gave it a new air filter, oil filter, oil, sparkplug, clutch cable and rear brake pads.  With the NB maintenance stuff out of the way I set my sights on some mods.

First on the list was the fugly rear light assembly.  I replaced it with a LED brake/running light unit under the rear fender. With this I can just pop off the number plate for Funduro's.

Secondly I replaced the rear indicators with small LED flush mount  units next to the brake light.  I used an inline resistor to fix the hyper flash.  This works great for Funduro's as the are flush and can't break off when you crash.

Third inline was to get remove the stock chain guard on the swing arm.  Makes it easier to clean the chain.

Next up was to replace the stock 7/8th bars with 1 1/8th fat bars from Airtime and also some Airtime standard to fatbar risers.

I also replaced the stock grips with some half waffle grips. (Sorry for the left side skew grip...this thing is a beast to hold on to! lol)

I replaced the clutch and brake levers with some folding shorty levers.  Good for when you crash and also much better for 2 finger use.

While I was busy with the controls I removed the huge mirrors that rattle so much you can about see jack nothing in them with some 2" convex blind spot mirrors.  I made some custom aluminium brackets from 3mm flatbar for them with some 3M VHB to keep them glued on.  The are mounted to the Zeta hand guards with a rubber washer and a set of M3x16 allen cap, M3 oversize flat washer and nyloc nut.  Easy to to fold in behind the hand guard when you go OTBT.

I moved the key assembly to the side of top shock mount.  Gives you more space for the other bits and pieces to come.

I removed the stock front indicators and used some smaller ones I had on the rear.  I placed the front left indicator in one of the open holes of the ignition key assembly.  For the right front indicator I manufactured a matching bracket from 3mm aluminium flatbar.

I mounted a set of LED spots on the stock front indicator brackets that I left on after moving the indicators to a higher up location.  I hooked the LED spots directly on the battery with an inline fuse and switch on the handle bar to switch on and off.

The front headlight assembly comes off a KTM 690 Enduro and fits with some tweaking here and there.

The front fender comes off a newer model RMZ450 and is much stiffer than the stock floppy one.

I got a set of case savers to protect the magnesium covers from breaking when you fall over.  I also rounded the back side of the gear lever to prevent a sharp edge from doing more damage.

At the bottom it has a Hyde bash plate to keep the belly safe.

I derusted the exhaust and sent it to Powerkote in Montagu Gardens to ceramic coat the header pipe and rear pipe assembly.  The Cowley slip on was still in good nic.

I have a charge point on the front for those long trips when you need to charge a phone or GPS.  I also use the same charge point to charge the battery.  I bought a float charger from a local supplier and changed the clamps to a cigarette lighter style point.  Now I can but the battery on the float charger without taking covers off to get to the battery or having more plugs and cables on the bike.

Tyres for road and DS use is a set of Michelin T63 90/90R21 in the front and 120/80R18 in the rear with heavy duty tubes + sealant.  For Funduro's I will swop them out with a set of full intermediate knobby's.

I have a slightly lowered seat since I am 1.69m.

Not in the photos are a billet rear rack that I can put on when packing the bike for a longer trip.

**Future Mods**
1.  Larger tank, maybe a 17l or so.  Not to keen on those 27l tanks.
2.  Longer shift lever, struggling to get those boots under the shifter.
3.  Brake rotors with a bit more bite.
4.  Busy designing and manufacturing some DIY Stegspegs.

(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165254-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165254-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165430-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165430-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165319-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165319-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165409-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165409-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165512-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165512-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165409-02.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165409-02.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165415-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165415-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165328-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165328-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165442-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165442-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165530-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165530-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165503-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165503-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165454-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165454-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165544-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165544-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_165553-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_165553-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_170935-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_170935-01.jpeg.html)
(http://i258.photobucket.com/albums/hh267/HancoB/IMG_20161129_170925-01.jpeg) (http://s258.photobucket.com/user/HancoB/media/IMG_20161129_170925-01.jpeg.html)
Title: Re: My DRZ400E thread
Post by: katana on November 29, 2016, 08:35:53 pm
While I was busy with the controls I removed the huge mirrors that rattle so much you can about see jack nothing in them with some 2" convex blind spot mirrors.  I made some custom aluminium brackets from 3mm flatbar for them with some 3M VHB to keep them glued on.  The are mounted to the Zeta hand guards with a rubber washer and a set of M3x16 allen cap, M3 oversize flat washer and nyloc nut.  Easy to to fold in behind the hand guard when you go OTBT.

This is awesome.  Where did you get the mirrors?
Title: Re: My DRZ400E thread
Post by: Hankeeb on November 29, 2016, 08:41:41 pm
While I was busy with the controls I removed the huge mirrors that rattle so much you can about see jack nothing in them with some 2" convex blind spot mirrors.  I made some custom aluminium brackets from 3mm flatbar for them with some 3M VHB to keep them glued on.  The are mounted to the Zeta hand guards with a rubber washer and a set of M3x16 allen cap, M3 oversize flat washer and nyloc nut.  Easy to to fold in behind the hand guard when you go OTBT.

This is awesome.  Where did you get the mirrors?

You should be able to get them from any auto store or so.  I took a trip to my local China Town's car department and found them there at R15 a set.
Title: Re: My DRZ400E thread
Post by: katana on November 29, 2016, 08:48:35 pm
While I was busy with the controls I removed the huge mirrors that rattle so much you can about see jack nothing in them with some 2" convex blind spot mirrors.  I made some custom aluminium brackets from 3mm flatbar for them with some 3M VHB to keep them glued on.  The are mounted to the Zeta hand guards with a rubber washer and a set of M3x16 allen cap, M3 oversize flat washer and nyloc nut.  Easy to to fold in behind the hand guard when you go OTBT.

This is awesome.  Where did you get the mirrors?

You should be able to get them from any auto store or so.  I took a trip to my local China Town's car department and found them there at R15 a set.

Thanks.  High-jack off  :thumleft:
Title: Re: My DRZ400E thread
Post by: Hankeeb on November 29, 2016, 08:50:37 pm
 :thumleft:
Title: Re: My DRZ400E thread
Post by: Ri on November 29, 2016, 11:06:21 pm

Looks really great! Is that the standard back brake? It looks substantial and has a very nice shape.

And that powercoated exhaust pipe really looks great! I'm thinking of doing same because mine looks dire, but then apparently I can also just wrap it. Sure it'll look like the English Patient, but it's better than the current rusty look.

Also, where did you get the shorty levers? I would love a set.
Title: Re: My DRZ400E thread
Post by: Hankeeb on November 29, 2016, 11:12:34 pm

Looks really great! Is that the standard back brake? It looks substantial and has a very nice shape.

And that powercoated exhaust pipe really looks great! I'm thinking of doing same because mine looks dire, but then apparently I can also just wrap it. Sure it'll look like the English Patient, but it's better than the current rusty look.

Also, where did you get the shorty levers? I would love a set.

Thanks! Yes the rear brake lever is standard.

I also looked at wrapping my pipe but when I saw that a roll of exhaust wrap tape is close to R500 a roll I decided to ceramic coat it rather at R420. 

I ordered myself a set from over the waters, you might be able to get something locally but I have not really shopped around.
Title: Re: My DRZ400E thread
Post by: madmax on November 30, 2016, 10:35:15 am
unfortunately here in corporate friggern world the pics don't display..but looking forward to seeing the mods ..want to taillight and indicator mine...like sound of headlight
Title: Re: My DRZ400E thread
Post by: Black_Hawk on November 30, 2016, 10:48:21 am
Well done... looking good  :thumleft:
Title: Re: My DRZ400E thread
Post by: Hankeeb on November 30, 2016, 10:51:08 am
Thanks guys.  :biggrin:
Title: Re: My DRZ400E thread
Post by: sidetrack on November 30, 2016, 11:44:28 am
Headlight look good too  :thumleft:
Title: Re: My DRZ400E thread
Post by: Ri on December 01, 2016, 02:43:39 am

Looks really great! Is that the standard back brake? It looks substantial and has a very nice shape.

And that powercoated exhaust pipe really looks great! I'm thinking of doing same because mine looks dire, but then apparently I can also just wrap it. Sure it'll look like the English Patient, but it's better than the current rusty look.

Also, where did you get the shorty levers? I would love a set.

Thanks! Yes the rear brake lever is standard.

I also looked at wrapping my pipe but when I saw that a roll of exhaust wrap tape is close to R500 a roll I decided to ceramic coat it rather at R420. 

I ordered myself a set from over the waters, you might be able to get something locally but I have not really shopped around.

I didn't realise powercoating was so relatively affordable. Thanks for the info!  :thumleft:

The indicators look really neat, that is a great idea especially for someone like me who drops their bike at least once per trip  ::)
Title: Re: My DRZ400E thread
Post by: Hankeeb on December 01, 2016, 06:52:25 am

Looks really great! Is that the standard back brake? It looks substantial and has a very nice shape.

And that powercoated exhaust pipe really looks great! I'm thinking of doing same because mine looks dire, but then apparently I can also just wrap it. Sure it'll look like the English Patient, but it's better than the current rusty look.

Also, where did you get the shorty levers? I would love a set.

Thanks! Yes the rear brake lever is standard.

I also looked at wrapping my pipe but when I saw that a roll of exhaust wrap tape is close to R500 a roll I decided to ceramic coat it rather at R420. 

I ordered myself a set from over the waters, you might be able to get something locally but I have not really shopped around.

I didn't realise powercoating was so relatively affordable. Thanks for the info!  :thumleft:

The indicators look really neat, that is a great idea especially for someone like me who drops their bike at least once per trip  ::)

It is a pleasure,  glad the thread can be of help.

Just to clarify, it is not powder coating , the companies name is "Powerkote" and it is a heat treatment coating much like powder coating, however its temperature ranges are much much much higher.  You can even coat your valves and piston.  The advantages of coating your exhaust is that you now channel more heat to the exit of the exhaust(helps a bit with performance) instead of radiating large amounts of heat through the bare metal to the riders legs and other critical engine parts.

 ;D
Title: Re: My DRZ400E thread
Post by: sidetrack on December 01, 2016, 07:28:43 am
How did you manage to source the headlight and is it from a R or supermoto ?
Title: Re: My DRZ400E thread
Post by: Hankeeb on December 01, 2016, 07:59:34 am
How did you manage to source the headlight and is it from a R or supermoto ?

It comes off a KTM 690 Enduro and the extra screen is just a bolt on. 
Title: Re: My DRZ400E thread
Post by: super ten on December 05, 2016, 10:04:18 pm
I'm looking for a 17-20 L tank for my DRZ. Anyone got one to offer?
Title: Re: My DRZ400E thread
Post by: Hankeeb on December 06, 2016, 09:45:55 am
I'm looking for a 17-20 L tank for my DRZ. Anyone got one to offer?

Hens teeth.  :-\
Title: Re: My DRZ400E thread
Post by: sidetrack on December 06, 2016, 02:26:01 pm
Hankeeb if you ever find another 690 headlight please let me know, will work nicely on my Husaberg as well. Did you spray it ? Cant see any stock ones that came in black. Either white or black is what I need.
Title: Re: My DRZ400E thread
Post by: Hankeeb on December 06, 2016, 02:39:17 pm
Hankeeb if you ever find another 690 headlight please let me know, will work nicely on my Husaberg as well. Did you spray it ? Cant see any stock ones that came in black. Either white or black is what I need.

Nope not painted.  Stock.  They come in White, Black and Orange and some even come with a sticker kit.

https://ktmtwins.com/products/ktm-76508001000-2-4-5
Title: Re: My DRZ400E thread
Post by: sidetrack on December 06, 2016, 02:43:08 pm
Hankeeb if you ever find another 690 headlight please let me know, will work nicely on my Husaberg as well. Did you spray it ? Cant see any stock ones that came in black. Either white or black is what I need.

Nope not painted.  Stock.  They come in White, Black and Orange and some even come with a sticker kit.

https://ktmtwins.com/products/ktm-76508001000-2-4-5
Ok great, is that the updated light that came out around 2013 or the first gen one ?

*Edit see it's the later "better" one
Title: Re: My DRZ400E thread
Post by: Hankeeb on December 06, 2016, 02:44:31 pm
Hankeeb if you ever find another 690 headlight please let me know, will work nicely on my Husaberg as well. Did you spray it ? Cant see any stock ones that came in black. Either white or black is what I need.

Nope not painted.  Stock.  They come in White, Black and Orange and some even come with a sticker kit.

https://ktmtwins.com/products/ktm-76508001000-2-4-5
Ok great, is that the updated light that came out around 2013 or the first gen one ?

*Edit see it's the later "better" one

Indeed yes, it is the later "better" one! :)
Title: Re: My DRZ400E thread
Post by: Hankeeb on December 07, 2016, 08:28:53 am
Getting married on Saturday means I do not have lots of time on my hands but still enough time to work on my DIY Steg pegs.

Manufacturing the mounting plates from 3mm 1050-H14 Aluminium means it will be strong enough yet easy enough to work it by hand.

Design looks good in Solidworks but the prototyping is a whole other story.

Will keep the updates coming in a few weeks.
Title: Re: My DRZ400E thread
Post by: Ri on December 07, 2016, 04:30:11 pm

Firstly - Congratulations on getting married!! Wishing many joyful and prosperous years to you and your beautiful lady!

Secondly - What are Steg pegs for?
Title: Re: My DRZ400E thread
Post by: Hankeeb on December 07, 2016, 04:41:56 pm

Firstly - Congratulations on getting married!! Wishing many joyful and prosperous years to you and your beautiful lady!

Secondly - What are Steg pegs for?

Stegs pegs is a peg for behind your calves that allows your legs/boots to "grip" the bike better when standing on the bike. Google steg pegs and you will see. It works great!

Thanks for thw wishes!  :)
Title: Re: My DRZ400E thread
Post by: mtbbiker on January 12, 2017, 09:42:12 am
Out of curiosity is that KTM light better than the stock head light?
Title: Re: My DRZ400E thread
Post by: Hankeeb on January 12, 2017, 10:52:39 am
Out of curiosity is that KTM light better than the stock head light?

For sure!
Title: Re: My DRZ400E thread
Post by: XTZFegen on January 29, 2017, 07:32:46 pm
Just made up my mind this is my next bike. I love the Ten but I need something smaller for solo runs. These look perfect for my needs.
Title: Re: My DRZ400E thread
Post by: sgt on February 18, 2017, 05:35:51 pm
Had the pleasure of riding in Stellenbosch area today with Hankeeb and another rider. I really like his DRZ, and I'd love to find one as well!
Title: Re: My DRZ400E thread
Post by: Hankeeb on February 20, 2017, 11:24:02 am
Had the pleasure of riding in Stellenbosch area today with Hankeeb and another rider. I really like his DRZ, and I'd love to find one as well!

Thanks SGT.  Was real nice to ride with you!  You handle a R1200GS very well!  Looking forward to our next outride...maybe on a DRZ!
Title: Re: My DRZ400E thread
Post by: Hankeeb on May 27, 2017, 06:24:26 pm
So I finally had some time to work on the bike again.

Having done a very long technical Enduro'ish ride on the bike I decided to do some mods.

One of my concerns on the ride was ripping off a brake pedal or shifter.  I decided to do a DIY brake saver that honestly cost me R20 at Builders.

Drilled a small hole in the pedal and made a loop through it and also looped it around the frame.

Another thing I realised on this ride was how unprepared I was for break downs on this type of ride.  A physical breakdown can lead to a mental breakdown and of course the other way round too.  So I made a recovery/tow strap for the front and rear of the bike. 

Now for the next ride!
(https://uploads.tapatalk-cdn.com/20170527/0a031f17e6ed8c211763e5fccc3836d4.jpg)(https://uploads.tapatalk-cdn.com/20170527/191ad7d37cdf8f7e06a316649ad84bde.jpg)(https://uploads.tapatalk-cdn.com/20170527/9a61c6af10719558c9382dde4bfa018d.jpg)(https://uploads.tapatalk-cdn.com/20170527/ff36b2f5e9af35fa21ee098547d2ee8f.jpg)
Title: Re: My DRZ400E thread
Post by: Ri on May 28, 2017, 04:48:18 pm
Those recovery straps would've been handy on my trip through Anysberg a while ago - I broke off my number plate trying to manhandle the bike in the sand. How do you fix them to the bike? Or do they simply loop around and hook to each other?

And that brake saver... never knew such a thing existed. I don't know what the original shape of my brake lever is even meant to be anymore and the front triangle sheared clean off when I ploughed up Gydo Pass.
Title: Re: My DRZ400E thread
Post by: Hankeeb on May 28, 2017, 04:59:04 pm
Those recovery straps would've been handy on my trip through Anysberg a while ago - I broke off my number plate trying to manhandle the bike in the sand. How do you fix them to the bike? Or do they simply loop around and hook to each other?

And that brake saver... never new such a thing existed. I don't know what the original shape of my brake lever is even meant to be anymore and the front triangle sheared clean off when I ploughed up Gydo Pass.
The straps are bolter to the sub-frame on the rear and the front ones to the tripple clamps.  Large washers and M6 bolts and nuts keeps the straps on tightly.  In the front it is M8 bolts and large washers.

You can do things like this fairly cheap.

Sent from my HUAWEI GRA-L09 using Tapatalk

Title: Re: My DRZ400E thread
Post by: Ri on May 28, 2017, 05:25:21 pm
Those recovery straps would've been handy on my trip through Anysberg a while ago - I broke off my number plate trying to manhandle the bike in the sand. How do you fix them to the bike? Or do they simply loop around and hook to each other?

And that brake saver... never knew such a thing existed. I don't know what the original shape of my brake lever is even meant to be anymore and the front triangle sheared clean off when I ploughed up Gydo Pass.
The straps are bolter to the sub-frame on the rear and the front ones to the tripple clamps.  Large washers and M6 bolts and nuts keeps the straps on tightly.  In the front it is M8 bolts and large washers.

You can do things like this fairly cheap.

Sent from my HUAWEI GRA-L09 using Tapatalk

Great thanks!  :thumleft:
Title: Re: My DRZ400E thread
Post by: blauth on May 29, 2017, 07:05:49 pm
What gearing are you running on your DRZ. My current setup is 15/44 but I'm sure it would be better at 15/40. Sure, will suck big time on the technical stuff in first but cruising will be at much lower RPM. Currently it pulls this gearing in top gear with lots of power to spare.
Title: Re: My DRZ400E thread
Post by: Hankeeb on May 29, 2017, 09:36:31 pm
What gearing are you running on your DRZ. My current setup is 15/44 but I'm sure it would be better at 15/40. Sure, will suck big time on the technical stuff in first but cruising will be at much lower RPM. Currently it pulls this gearing in top gear with lots of power to spare.
I am running stock gearing on my bike.  It is a pretty happy medium between going off-road technical riding and on-road commuting.

When I washed the bike the other day I found a stiff link.  Guess I will have to swop out my chain and sprockets soon.  Maybe I will change the gearing then and give something else a try.
Title: Re: My DRZ400E thread
Post by: blauth on May 30, 2017, 07:55:35 am
What gearing are you running on your DRZ. My current setup is 15/44 but I'm sure it would be better at 15/40. Sure, will suck big time on the technical stuff in first but cruising will be at much lower RPM. Currently it pulls this gearing in top gear with lots of power to spare.
I am running stock gearing on my bike.  It is a pretty happy medium between going off-road technical riding and on-road commuting.

When I washed the bike the other day I found a stiff link.  Guess I will have to swop out my chain and sprockets soon.  Maybe I will change the gearing then and give something else a try.

Maybe lube your chain. I've stopped using chain wax on my road bikes. I found it was causing my chain to get really stiff. I now just clean my chain regularly and use gear oil to lube it. It's a much happier chain since Although in seriously dusty condition this may not work so well, the oil may just make a grinding paste with all the dust.

Stock gearing on the E is 14/47 so your bike must be screaming at 110km/h.
Title: Re: My DRZ400E thread
Post by: Hankeeb on May 30, 2017, 08:01:55 am
What gearing are you running on your DRZ. My current setup is 15/44 but I'm sure it would be better at 15/40. Sure, will suck big time on the technical stuff in first but cruising will be at much lower RPM. Currently it pulls this gearing in top gear with lots of power to spare.
I am running stock gearing on my bike.  It is a pretty happy medium between going off-road technical riding and on-road commuting.

When I washed the bike the other day I found a stiff link.  Guess I will have to swop out my chain and sprockets soon.  Maybe I will change the gearing then and give something else a try.

Maybe lube your chain. I've stopped using chain wax on my road bikes. I found it was causing my chain to get really stiff. I now just clean my chain regularly and use gear oil to lube it. It's a much happier chain since Although in seriously dusty condition this may not work so well, the oil may just make a grinding paste with all the dust.

Stock gearing on the E is 14/47 so your bike must be screaming at 110km/h.
Yeah I was and lube the chain with wax lube about every 3 to 4 weeks and or after every heavy offroad ride.

At 110km/h the bike is pretty high in the revs but can still give some more.

Will see if I can get that link fixed this week.
Title: Re: My DRZ400E thread
Post by: Hankeeb on May 31, 2017, 05:38:24 pm
So while I had some free time I though about doing some graphics for the DRZ.  Played around with some ideas and ended up with this.

Still have to think what I want to do with the number board panels on the side and headlight shroud.(https://uploads.tapatalk-cdn.com/20170531/e9c58ce8fd5ccede2bbf2d7e8207c82c.jpg)
Title: Re: My DRZ400E thread
Post by: blauth on June 01, 2017, 08:44:00 am
Does anyone stock these case savers in the Joburg area?
Title: Re: My DRZ400E thread
Post by: blauth on June 05, 2017, 12:09:50 pm
Took my bike out for a test ride yesterday.

http://www.wilddog.za.net/forum/index.php?topic=210796.0

Jeez, my bike is heavy on fuel though. I get about 15-16km/l if I'm lucky.

Carb settings:
Standard Pilot jet
152 main jet
Needle, third from the top.

The bike runs well on these settings.
Title: Re: My DRZ400E thread
Post by: BSAfrica on June 05, 2017, 12:17:31 pm
Hankeeb, I would be interrested in similar graphics, let me know.
Title: Re: My DRZ400E thread
Post by: Hankeeb on June 05, 2017, 12:27:29 pm
Hankeeb, I would be interrested in similar graphics, let me know.
I will apply them this afternoon and see how it looks.
Title: Re: My DRZ400E thread
Post by: Hankeeb on June 05, 2017, 12:28:46 pm
Took my bike out for a test ride yesterday.

http://www.wilddog.za.net/forum/index.php?topic=210796.0

Jeez, my bike is heavy on fuel though. I get about 15-16km/l if I'm lucky.

Carb settings:
Standard Pilot jet
152 main jet
Needle, third from the top.

The bike runs well on these settings.
That sounds pretty good.  On my last ride out like that I got about12km/l.
Title: Re: My DRZ400E thread
Post by: sidetrack on June 06, 2017, 02:41:06 pm
No jis guys a DRZ even with FCR must get 20km/l at least normal riding. Got around 22 - 24km/l on my Z with FCR and about the same with a FCR equipped 525.
Title: Re: My DRZ400E thread
Post by: Hankeeb on June 06, 2017, 02:45:48 pm
No jis guys a DRZ even with FCR must get 20km/l at least normal riding. Got around 22 - 24km/l on my Z with FCR and about the same with a FCR equipped 525.
Well I have never gotten better than about 15km/l (120km before the reserve came into play) on T63 front and rear.
Title: Re: My DRZ400E thread
Post by: blauth on June 09, 2017, 08:59:52 pm
I fitted a new set of rear wheel bearing to my DRZ during the week. What a pleasure. Literally took me half an hour. Super impressed with the double bearing on the drive side. From what I've tinkered with so far, this is a quality bike.
Title: Re: My DRZ400E thread
Post by: Hankeeb on June 10, 2017, 10:40:51 am
I fitted a new set of rear wheel bearing to my DRZ during the week. What a pleasure. Literally took me half an hour. Super impressed with the double bearing on the drive side. From what I've tinkered with so far, this is a quality bike.
That is one thing I still need to do.  What bearing puller do you have?  And where did you get the bearings? And how much did they cost?

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Title: Re: My DRZ400E thread
Post by: Hankeeb on June 10, 2017, 10:42:40 am
Meanwhile I got down to sticking my decals on.  Not an easy job!  Just one decal left to do.(https://uploads.tapatalk-cdn.com/20170610/3d131f3526c873ca5b7275c4c29b40b1.jpg)

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Title: Re: My DRZ400E thread
Post by: blauth on June 11, 2017, 09:19:28 pm
I fitted a new set of rear wheel bearing to my DRZ during the week. What a pleasure. Literally took me half an hour. Super impressed with the double bearing on the drive side. From what I've tinkered with so far, this is a quality bike.
That is one thing I still need to do.  What bearing puller do you have?  And where did you get the bearings? And how much did they cost?

Sent from my HUAWEI GRA-L09 using Tapatalk

I got the bearings from Bearing Man Group. There are branches everywhere. They sell NTN and NSK. Same same, I got the NSK's. The sizes are:
2 x 6004 2rs
1 x 6204 2rs

You don't need a bearing puller. Just hit them out from the opposite side. It'll take you an hour max if it's your first time. Just make sure when you put the new ones in, you tap gently evenly around the outer race of the bearing. Don't smack it in skew else you'll damage your hub. Gentle gentle ...evenly and straight.

Also clean everything and put a health bit of grease between the bearing and the seal. It helps stop kak from getting past the seal. My seals are toast but the little bushes are worn too so will machine them down a bit and get some seals with a smaller ID.
Grease also stops the shaft from rusting and going mankie.
Title: Re: My DRZ400E thread
Post by: blauth on June 11, 2017, 09:20:33 pm
Can't wait to see your sticker kit on. Post pics when it's done.
Title: Re: My DRZ400E thread
Post by: blauth on June 11, 2017, 09:22:27 pm
I've decided to call my bike Captain Custard. I've never named a bike before....weird.....

The proverbial 'we' did a ride today to the Mareisburg mine dumps. Check out my report.

http://www.wilddog.za.net/forum/index.php?topic=210796.0

Title: Re: My DRZ400E thread
Post by: chopperpilot on June 12, 2017, 04:00:27 am
I fitted a new set of rear wheel bearing to my DRZ during the week. What a pleasure. Literally took me half an hour. Super impressed with the double bearing on the drive side. From what I've tinkered with so far, this is a quality bike.
It's a Suzuki! They are quality bikes!


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Title: Re: My DRZ400E thread
Post by: Hankeeb on June 16, 2017, 05:03:04 pm
Finally got around to putting the last stickers on.  Sadly the tank shroud stickers was for the wrong model so I need to do those over.

All in all it looks ok from far since my sticker sticking skills suck.

(https://uploads.tapatalk-cdn.com/20170616/5031afe44c584726835e962471f7a381.jpg)

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Title: Re: My DRZ400E thread
Post by: Ri on June 16, 2017, 06:28:52 pm
Lyk bed˘nnerd  :thumleft: :thumleft: :thumleft:
Title: Re: My DRZ400E thread
Post by: Hankeeb on June 16, 2017, 06:33:55 pm
@Ri thanks! 😀

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Title: Re: My DRZ400E thread
Post by: mtbbiker on June 16, 2017, 07:25:28 pm
Finally got around to putting the last stickers on.  Sadly the tank shroud stickers was for the wrong model so I need to do those over.

All in all it looks ok from far since my sticker sticking skills suck.

(https://uploads.tapatalk-cdn.com/20170616/5031afe44c584726835e962471f7a381.jpg)

Sent from my HUAWEI GRA-L09 using Tapatalk



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Title: Re: My DRZ400E thread
Post by: Hankeeb on June 17, 2017, 07:58:43 pm
Took the bike out for a spin before we head out to Namibia.  Bike felt sooo good!(https://uploads.tapatalk-cdn.com/20170617/02f0e2f034767cff1aad26daf92d82f1.jpg)
Title: Re: My DRZ400E thread
Post by: blauth on June 19, 2017, 08:38:57 am
Finally got around to putting the last stickers on.  Sadly the tank shroud stickers was for the wrong model so I need to do those over.

All in all it looks ok from far since my sticker sticking skills suck.

(https://uploads.tapatalk-cdn.com/20170616/5031afe44c584726835e962471f7a381.jpg)

Sent from my HUAWEI GRA-L09 using Tapatalk

I think it looks great. Well done....apparently, your stickering skills don't suck that bad....   hehe
Title: Re: My DRZ400E thread
Post by: Hankeeb on June 19, 2017, 08:47:40 am
Finally got around to putting the last stickers on.  Sadly the tank shroud stickers was for the wrong model so I need to do those over.

All in all it looks ok from far since my sticker sticking skills suck.

(https://uploads.tapatalk-cdn.com/20170616/5031afe44c584726835e962471f7a381.jpg)

Sent from my HUAWEI GRA-L09 using Tapatalk

I think it looks great. Well done....apparently, your stickering skills don't suck that bad....   hehe
Thanks man.  From close up you will see a few wrinkles but hey, I am no pro!

Title: Re: My DRZ400E thread
Post by: blauth on June 19, 2017, 10:52:47 am
I remember when I did enduro's, we'd get stickers where we had to apply the sticker wet which allowed you to move the sticker around whilst working with it. I almost always had to cut a little incision here and there to get it to work well with compound curves though.

I'll be honest, applying stickeris not my favorite pass time, you need uber patience.....something I inherently lack.

Title: Re: My DRZ400E thread
Post by: blauth on July 05, 2017, 09:25:56 pm
No jis guys a DRZ even with FCR must get 20km/l at least normal riding. Got around 22 - 24km/l on my Z with FCR and about the same with a FCR equipped 525.
Well I have never gotten better than about 15km/l (120km before the reserve came into play) on T63 front and rear.

Coming back to this topic. I used to get about 21km/l on my 525 and the bike had a lot more power. It was great on juice but this bike is just solo heavy. Even with nice riding I only got 15km/l. What the hell is making this bike so heavy on juice. Could the throttle position sensor be messing with the timing or something that's causing it to be heavy on juice?

One thing that must be a factor is this close ratio gearbox....surely, you're revving the balls off this bike even at slowish speeds.
Title: Re: My DRZ400E thread
Post by: super ten on July 06, 2017, 07:06:15 am
Guys

My 2002 model DRZ with fcr flatslide carb gets ave 14k/L. I also thought it should give more, but googled USA sites a bit and thats spot-on. My carb is perfectly tuned and engine in tip top condition. What we must remember is that its a performance carb. It will use more fuel. You can go back to a more standard carb, gives much more mileage, but then its not the same bike.
Title: Re: My DRZ400E thread
Post by: sidetrack on July 06, 2017, 09:12:30 pm
I know of a XR650R with FCR that got 23km/l, my TE610 with FCR gave 27km/l once, 525 gave me 22km/l, CRF 450 X gave me 24km/l (cruising obviously)-  no way a FCR should give 14km/l on a DRZ. Something is wrong.
Title: Re: My DRZ400E thread
Post by: blauth on July 12, 2017, 09:18:00 am
I know of a XR650R with FCR that got 23km/l, my TE610 with FCR gave 27km/l once, 525 gave me 22km/l, CRF 450 X gave me 24km/l (cruising obviously)-  no way a FCR should give 14km/l on a DRZ. Something is wrong.

Jacques, do you know what jetting and needle clip settings you had? Also was it the standard carb kit i.e. not an aftermarket kit like DynoJet?

A friend of mine had a DRZ400E as well and he also said he used to get about 21km/l on his.
Title: Re: My DRZ400E thread
Post by: katana on July 12, 2017, 02:20:07 pm
It is all in the wrist...  How you get to 120km/h makes a big difference if that is your chosen speed.
Title: Re: My DRZ400E thread
Post by: blauth on July 12, 2017, 03:30:24 pm
It is all in the wrist...  How you get to 120km/h makes a big difference if that is your chosen speed.

My wrist action is pretty constant (open fast and keep it open    :laughing4:)....on a more serious not, there is consistency between my DRZ and my previous 525 and my 525 was light on juice.
Title: Re: My DRZ400E thread
Post by: sidetrack on July 13, 2017, 11:10:28 pm
I know of a XR650R with FCR that got 23km/l, my TE610 with FCR gave 27km/l once, 525 gave me 22km/l, CRF 450 X gave me 24km/l (cruising obviously)-  no way a FCR should give 14km/l on a DRZ. Something is wrong.

Jacques, do you know what jetting and needle clip settings you had? Also was it the standard carb kit i.e. not an aftermarket kit like DynoJet?

A friend of mine had a DRZ400E as well and he also said he used to get about 21km/l on his.
No idea, came of a crf 450x. Offroad cycles jetted it for my 440kit


Title: Re: My DRZ400E thread
Post by: blauth on July 14, 2017, 08:48:58 am
I know of a XR650R with FCR that got 23km/l, my TE610 with FCR gave 27km/l once, 525 gave me 22km/l, CRF 450 X gave me 24km/l (cruising obviously)-  no way a FCR should give 14km/l on a DRZ. Something is wrong.

Jacques, do you know what jetting and needle clip settings you had? Also was it the standard carb kit i.e. not an aftermarket kit like DynoJet?

A friend of mine had a DRZ400E as well and he also said he used to get about 21km/l on his.
No idea, came of a crf 450x. Offroad cycles jetted it for my 440kit

Ahh, maybe that's where the difference is. If I am not mistaken, the CRF450X has a FCR39MX carb and the DRZ has the FCR39 Single carb. They are quite different from what I understand.


My bikes performance characteristics are as follows:
- It's top end is ok. I can get about 155km/h. This would improve a little with a larger main jet I think.
- Mid range and quick throttle opening is spot on. Smooth and fairly responsive without being brutally snappy.
- Idle (crappy)
- Throttle just cracked open with near no load on the engine, the bike hunts. It's frustrating but not noticeable on an adventure ride, only irritating in traffic where this throttle position is used a lot.  I haven't really noticed if this is better when the bike is cold or hot.
- The bike starts quite easily but does need choke sometimes.
- Fuel consumption: about 14km/L.  Riding offroad vs on the road at about 110km/h doesn't really change this much.

I'm confused about the cause of the hunting at low throttle/load condition and the crazy heavy fuel consumption.

The jets I run are:
Location: Johannesburg so altitude is roughly 1750 meters.
Pilot: #45
Main: #152 (I think 160 is stock but I've read conflicting report here. Some locations come with a 145 stock but maybe that's in the DRZ400S, not sure.)
Leak Jet: I can't see what mine is. Standard is a #60.
Fuel Mixture screw: 2.5 turns. I think I should return mine to 2 turns out.
Needle position: 3rd from the top.
Float level: My little tab on the needle is exactly horizontal. Not sure exactly where the fuel level is sitting.

I've removed the coast enrichener circuit on mine. This little device enrichens the bottom end circuit on overrun and coasting to eliminate the popping (backfiring). Mine doesn't pop at all, even after removing this circuit indicating that it certainly isn't lean on the bottom end. I chose to block off the little nipples as opposed to connecting them when I removed this circuit. This actually calls for a different size air jet which I didn't do. I'm going to connect these two nipples together instead which is not supposed to need any change in air jet size (will try it this weekend).

My fuel mixture screw is a little far out at 2.5 turns but it's such a ball ache to adjust it (carb needs to come out).

I tried running my bike with the throttle position sensor unplugged. The ECU then falls back to a default closed circuit setting for the ignition timing which is only variable at lower RPM's. The bike ran well but I did find that it would run on a little when tapping off the throttle. With the TPS plugged in, the overrun behaved more normal and the bike runs a little better but there is no difference in fuel consumption.

I've read a lot of complaining about the DRZ bog when you crack the throttle. Mine doesn't have this problem at all. Now this can be improved with having the needle position in the correct position (which is the correct starting point) but the correct way to fine tune it on the pumper carb is the fuel accelerator circuit. This injects a spray of fuel into the carb when you crack the throttle, thus enriching the mixture for the acceleration.
1) There are two factors here, the timing of the fuel accelerator spray i.e. exactly when it sprays. Too early and it sprays onto the back of the slide becoming ineffective. Too late and the slide is already too far open and the lean condition has already been caused hence the bog. Timing of this should be so the spray just misses the slide as it's pulled up.
2) The duration of the spray. The pump diaphragm creates the pressure required to pump fuel into the accelerator jet. Different diaphragms are available to tune this but these make huge difference and the place to start tuning this is on the leak jet. A shorter shirt will result in less enrichening on acceleration and possibly still a lean condition. A longer squirt will result in more enrichening and possibly a rich condition. By adjusting the size of the 'Leak' jet, you can manipulate the duration of the spray. The leak jet actually allows excess fuel to return to the bowl when the accelerator pump is actuated. This is kinda counter intuitive. To create a leaner mixture on the accelerator pump, you actually need to go up in size on this leak jet   :P   because it allows more fuel to return to the float bowl as opposed to the jet stream. I haven't messed with this.

Anyway, food for thought if anyone has anything particularly intuitive to add, I'm all ears.