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Author Topic: The tale of the Suzuki DRZ400 Super Motard  (Read 2815 times)

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Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #20 on: December 22, 2019, 04:48:32 pm »
Got to love a spotless gold chain  :ricky: :ricky:
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #21 on: December 22, 2019, 04:50:10 pm »
 :ricky: :ricky: :ricky:
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #22 on: December 22, 2019, 04:51:21 pm »
 :ricky: :ricky: :ricky: :ricky:
 

Offline GravelFox

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Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #23 on: December 22, 2019, 06:29:38 pm »
Looks super neat. A 21” front wheel even be more neater and people will drool over it!


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Offline Kobus Myburgh

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Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #24 on: December 22, 2019, 06:35:00 pm »
This is sweet Brinkman!  Hang on to this.  :thumleft:
"If you have men who will only come if they know there is a good road, I don't want them.  I want men who will come if there is no road at all."

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Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #25 on: December 25, 2019, 11:13:30 am »
I have been doing research on the DRZ night and day and there seems to be a few problems that the factory neglected at assembly. This was probably not necessary, but for complete peace of mind I decided to double check the stator and starter clutch bolts. As there has been tons of cases on Thumpertalk where these bolts backed out and caused a lot of problems.

I was pleasantly surprised that everything was in spotless condition. I just felt all the bolts for tightness and the ones that moved and broke the locktite I took out, cleaned, reapplied locktite and snugged down good and proper. The only ones that tightened more  with moderate torque was the ones holding the stator coil.
 
« Last Edit: December 27, 2019, 03:10:00 pm by Brinkman »
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #26 on: December 25, 2019, 11:14:08 am »
 :thumleft: :thumleft:
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #27 on: December 25, 2019, 11:32:40 am »
I decided to replace the JIS phillips bolts on the starter Bendix cover as they were prone to rounding off.

I borrowed an impact screw driver from a mechanic at work, to loosen the bolts. My dad was burning to test it out as it is a Snap-on one. I walked into the garage while braai-ing and as I came around the corning I just heard "Dit is 'n groot fokk@p!"

While he was loosening the 3rd bolt the Snap-on bit snapped and rounded the head of the bolt.

The next day I asked the mechanics at work if  they have a matching one and in all their buckets of bolts there were just one that was a little bit too long. Got home and my dad pulled out the dremmel to shorten it. Bolted into the vice and there the 10000rpm dremmel disc grabs in to the bolt and catapults it into Neverland!
I doubt he has ever had such bad luck in the garage before!!

3rd try was the charm as I went to source some allen head bolts from the bolt buckets again.

Found these 3 perfect condition manly looking bolts. They just need to be shortened.

Drank some beer last night and decided to shorten them and make some progress with the bike. Got out the steel HAND SAW this time and assembled.

The left hand side bolt in the picture is the standard bolts. The second picture is the really nice looking allen head bolts and then installed.

« Last Edit: December 27, 2019, 03:12:38 pm by Brinkman »
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #28 on: December 25, 2019, 11:33:25 am »
This is sweet Brinkman!  Hang on to this.  :thumleft:

 :thumleft: :thumleft: :ricky: :ricky: :ricky: Thanks!
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #29 on: December 25, 2019, 11:34:35 am »
Looks super neat. A 21” front wheel even be more neater and people will drool over it!


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Thanks! What would look even sexier is a good quality sticky new 17" front tyre  :drif: :drif: :drif: :drif:
 

Offline sidetrack

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Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #30 on: December 25, 2019, 11:51:10 am »
Nice bike, best mod by far is fitting a FCR carb ! My DRZ -S really flew after I fitted one.
Little by little, one travels far
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Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #31 on: December 25, 2019, 12:26:31 pm »
Nice bike, best mod by far is fitting a FCR carb ! My DRZ -S really flew after I fitted one.

Decided to not go the FCR route just yet. I know that was probably a mistake, but I could only get a second hand one for R2500 and then I still don't know in what condition it is in.

The 3x3 mod and jetting kit really livened it up. But I have to pull the carb again as the solenoid on the carb is not a fuel shut off valve as I thought. This stupid bit of electronics limits the slide from lifting fully open in the first three gears.

That will be happening today as well as installing the new diaphragm slide today. As I broke the old one when installing the needle holder!!!!! I was so pissed off with myself.
« Last Edit: December 26, 2019, 10:09:43 am by Brinkman »
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #32 on: December 26, 2019, 08:21:57 am »
Morning and merry belated Christmas!!

I've been making some progress to get the bike where I want it.

I did an oil change with some Motul 7100 10w40 as I want to keep this bike in tip top shape. I did not do the frame oil strainer this time around but I will do it in the next 3000km when I do a service again. I did not have the copper washers for the bottom oil line banjo bolt and neither the strainer's. Also lacking the deep 24mm socket.

I used some Yamaha drain washers, one 12mm sump crush washer and a 10mm copper washer for the frame

« Last Edit: December 27, 2019, 03:14:04 pm by Brinkman »
 

Offline LoopSoosStroop

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Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #33 on: December 26, 2019, 08:35:40 am »
Sies maar hierdie bike is lekker!
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #34 on: December 26, 2019, 08:44:58 am »
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #35 on: December 26, 2019, 08:50:32 am »
This morning I woke at at 5AM and got the urge to pull the carb again and do the necessary mods/repairs.

First up was swapping the Diaphragm to the new slide and installing the needle and holder into the damn fragile slide. This was the part I was dreading most and did it first thing just to get it over with.

Bike stripped and photo of the two broken needle holder tabs on the old slide.
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #36 on: December 26, 2019, 08:52:37 am »
Diaphragm coming off. The ring that holds it into place is quite flexible to my surprise. All went 100% in the romaval
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #37 on: December 26, 2019, 08:57:32 am »
Needle and bits swapped over. The needle holder installation went according to plan. I applied some grease on the oring of the white needle holder and pushed it in with a twisting motion keeping an eye on the amount pressure applied.
The first two attempts it seated a bit skew, but the third time around it slipped in and the tabs grabbed hold of it. 
 

Offline Operator

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Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #38 on: December 26, 2019, 09:02:37 am »
Ruan........... Dalk is dit ek, maar daardie ronde ball-shape flicker lights en die Std taillight op die DRZ het nog altyd gelyk of dit nie óp die bike hoort nie.

Miskien vervang met aftermarket taillight en tail tidy lig.
Dit gaan die bike baie cooler laat lyk.

Hier is my ou DRZ met Edge taillight en Oxford led indicators




Lyk my jy het 'n mooi speciman gekoop  :thumleft:
 

Offline Brinkman

Re: The tale of the Suzuki DRZ400 Super Motard
« Reply #39 on: December 26, 2019, 09:06:54 am »
Ruan........... Dalk is dit ek, maar daardie ronde ball-shape flicker lights en die Std taillight op die DRZ het nog altyd gelyk of dit nie óp die bike hoort nie.

Miskien vervang met aftermarket taillight en tail tidy lig.
Dit gaan die bike baie cooler laat lyk.

Hier is my ou DRZ met Edge taillight en Oxford led indicators




Lyk my jy het 'n mooi speciman gekoop  :thumleft:

More more. Jy get my gedagtes gelees. Klaar pryse gekry op die smoked Edge 2 unit. Sodra ek by kosmeties kom gaan dit op saam met n stel DRC LED flikkers vir voor en agter :thumleft:
« Last Edit: December 26, 2019, 09:12:52 am by Brinkman »