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Offline N[]vA

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Re: The DRZ Thread
« Reply #1760 on: December 23, 2011, 05:16:07 am »
So my drz is (was) a 2004 DRZ400SM that was like this:



Shortly after I bought the bike, as a DRZ450SM, the engine seized. During the rebuild it turned out that the bike was in fact a 420 and not a 450  :dousing:. Jurgen aka LeCap did the rebuild, I instructed him to replace the head with an Athena 400cc head and piston kit (Athena heads have bigger water channels and this stay cooler)

During the rebuild LeCap decided it was ok to weld a damaged crank and reuse it without telling me which resulted eventually in the crank coming apart and causing the engine to seize  :dousing: So I decided to take my time and rebuild the bike into a full blown dirt version, I was planning to race the bike in the Botswana 1000 next year June.

Pic of the welded crank failure  :-\





Had a long back and forth with him and eventually decided it wasn't worth the effort to peruse any legal action as most of our correspondence was via phone and not email  :patch:

Any how so I decided I would replace every single part in the engine that was even remotely out of spec or had any damage, I had Mario from DirtRider do the rebuild and I have nothing but praise for his work. He is a meticulous master in his craft.

I bought new oil seal kits, gasket kits, Wiseco timing chain, Hot Rods +4mm stroker crank & main bearings. The head was skimmed & barrel honed by Angus from RedLine engineering. Andy660 put me onto him and he does a hell of a good job.

During the rebuild Mario noticed that my water pump needed to be replaced as well as the starter clutch bearing, though its no wonder he picks up issues when you consider this is how he inspects an engine pre-rebuild  :deal: :thumleft:



The engine is all done and ready to go, with the exception that it is currently dry and and will remain so (under plastic wrap) until the bike goes for its run-in and dyno tune ( In cape town only ever use Julian from SuperBike Solutions aka wrench on the forum)

Some details on the engine as it is currently:
Athena 400cc cylinder head kit, including piston
The head has been ported and gas flowed by TBR (Tim Bosson racing)
HotRods +4mm stoker crank
HotRods main bearings
Wiseco timing chain
HotCams intake cam
All bearings, oil seals, pumps & gaskets have been replaced
Every component is withing its ideal running specification
The auto cam chain tensioner has been changed out for a manual one
cam chain sliders have been replaced
shims changed over to hotcams shims.

In terms of every thing else changed on the bike: 

motard wheels have been changed to standard DRZ400E wheels

Both front and back have new AllBalls wheel bearings
Both have the original motard brake disks
Both calipers have been stripped, repainted and serviced. new seals
Brake lines changed to braided hoses


The radiators have been reconditioned and straightened by radiator king

The hoses are to be replaced with silicon radiator hoses (still has to be fitted)



The frame has been stripped to bare metal and checked for stress indicators or rust, then repainted in 5 layers





Swing arm bearings have been replaced (oem), neck bearings have been replaced (AllBalls)


the front forks and rear shock has been serviced and checked by SuperFoxi (best place to go for any suspension work in cape town) Also got the front fork boot dust guards from him.

The electrics have been rewired by Krogs (again only guys to use for electrical work in Cape Town) They also fitted the brand new trail tech Vapor with (dont have any pics of it fitted but this is what it looks like)


I sanded and sprayed all of the plastics (with Krylon fusion) in a matte white and sealed with a gloss finish
Added a IMS 17L Fuel tank, also sprayed but the paint doesn't bond well.
Added Zeta hand guard to the Zeta Hand guard bars
The bike has Zeta fatbars, Zeta two finger unbreakable front brake and clutch lever
I added bar end mirrors, which are clamped on the inside/under of the handle bar. they are convex so they work well
I have a full set of flush mount bright LED indicators
The bike has a new battery, small LED brake light, custom aluminum luggage rack
Seat has been recovered
Foot pegs replaced with wide off-road pegs (it needs a spring fitted)
Air Filter if a TwinAir
The Exhaust is a Yoshimaro-RS2 with full header
The header and heat shield has been ceramic coated in mate satin black (Franky from PoweKote)
The headlight has been changed to a H4 HID
Grips are brand new foam grips, great for longer distance
The CDI is a Yoshimaro racing CDI as such the rev limit has been raised to 11000 rpm

some pics:














I was planning to mount a fairing to the bike for the Botswana 1000, SuperFoxi sells them and would have done all the work mounting it. I would have done the cutting and molding. to get the fairing to fit the tank. this is NOT included with the bike




The bike still needs a chain slider and an oil line spacer, I am having MildDog (Adam) get prices on that for me.
The engine run-in and Dyno tuning still needs to be done by Wrench (Julian @ Superbike Solutions) which will cost around R2000 together.

The reason I am considering selling it that I have moved to Vietnam for an amazing job back mid October. I figured I would ship the bike out here once I had worked out the red tape...... turns out the red tape of fucking insane. Both from a risk of having the bike taken away by the cops here and the cost of bringing it in I figure I am going to be better off selling her  :-[

Have a few toys I am working on out this side but this zook was my baby.

Before I left SA i signed over full power of attorney to a good mate whom can facilitate the sale if needs be.
So much of win it hurts! ^.^


http://www.adventuregeek.co.za/
 

Offline DJ

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Re: The DRZ Thread
« Reply #1761 on: December 23, 2011, 07:20:41 am »
She looks very good N[]va!! You have done a great job!!  :thumleft:

Like the fairing, will PM Superfoxi for a price.

Previously owned: Vuka RM200, Aprilia Pegaso Cube 650, Suzuki DRZ400E, Kawasaki KLE500, Suzuki DR350



 

Offline Frannarossi

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Re: The DRZ Thread
« Reply #1762 on: December 23, 2011, 07:34:48 am »
+1 On that fairing.Let us know what the price is DJ :thumleft:
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Offline madmax

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Re: The DRZ Thread
« Reply #1763 on: December 23, 2011, 07:39:28 am »
agree on fairing..once details gotten plse advise
fornicate the proletariat
 

Offline DJ

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Re: The DRZ Thread
« Reply #1764 on: December 23, 2011, 07:40:50 am »
+1 On that fairing.Let us know what the price is DJ :thumleft:
agree on fairing..once details gotten plse advise

Cool guys, will do!!  :thumleft:
Previously owned: Vuka RM200, Aprilia Pegaso Cube 650, Suzuki DRZ400E, Kawasaki KLE500, Suzuki DR350



 

Offline letsgofishing

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Re: The DRZ Thread
« Reply #1765 on: December 23, 2011, 07:44:08 am »
Jan, you did a great job on her  :thumleft:
Looks awesome.
There is nothing you can do about the past and you can't predict the future...all you have is the now...live it to the fullest.

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Offline mtbbiker

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Re: The DRZ Thread
« Reply #1766 on: December 23, 2011, 07:45:15 am »
So where is the pictures of the completed bike ?
Without goals and plans to reach them, you are like a ship that has set sail with no destination - Fitzhugh Dodson
Project Meerkat:DRZ rally build http://www.wilddog.za.net/forum/index.php?topic=86025.0
 

Offline N[]vA

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Re: The DRZ Thread
« Reply #1767 on: December 23, 2011, 07:59:56 am »
So where is the pictures of the completed bike ?
So where is the pictures of the completed bike ?
I moved to Vietnam before I could finish everything so MildDog is sourcing the last few items and will take it to superbike solutions for the dyno/run in.

Then I guess it will be time to sell :(
« Last Edit: December 23, 2011, 08:02:43 am by N[]vA »
So much of win it hurts! ^.^


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Offline N[]vA

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Re: The DRZ Thread
« Reply #1768 on: December 23, 2011, 08:04:08 am »
What ya reckon is a fair price to ask?
So much of win it hurts! ^.^


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Offline lecap

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Re: The DRZ Thread
« Reply #1769 on: December 23, 2011, 10:11:56 am »
...I instructed him to replace the head with an Athena 400cc head and piston kit (Athena heads have bigger water channels and this stay cooler)...

During the rebuild LeCap decided it was ok to weld a damaged crank and reuse it without telling me which resulted eventually in the crank coming apart and causing the engine to seize  :dousing: So I decided to take my time and rebuild the bike into a full blown dirt version, I was planning to race the bike in the Botswana 1000 next year June.

...
Had a long back and forth with him and eventually decided it wasn't worth the effort to peruse any legal action as most of our correspondence was via phone and not email...

Corrections:
Tha cylinder and piston fitted by me were Athena parts. They were fitted because I could get them on short notice (at a time when engineering shops doing SCEM platings were closed), because I know that they are good quality (just as good or even better than OEM) and the price was right too. I also know that the other performance parts used on the bike (hotcams & Yoshi exhaust) were the ones responsible for good performance, not a mere 5% displacement increase.

The head is a stock standard Suzuki part which at some time and to some extent was worked on by TBR as can be seen from the engraving.

I do not repair crankshafts but outsource this job to third parties read specialised engineering shops.
I recommended to replace your crank since it was seriously damaged during the first previous rebuild.
This was communicated to you and some of your friends can confirm this.

You wanted to make a warranty claim over a year after the rebuild, with no maintenance record and no proof of mileage covered by the bike which in the meantime had been raced too. Each and every single one of these three facts would void any warranty. Simple & no long back and forth at all.

I anyway wish you good luck with the sale & the buyer a lot of fun with the bike.
"If you think it's expensive to hire a professional to do the job, wait until you hire an amateur." (Red Adair)
 

Offline sidetrack

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Re: The DRZ Thread
« Reply #1770 on: December 23, 2011, 10:57:29 am »
Going to be a great bike, some quality parts on there !
Little by little, one travels far
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Offline sidetrack

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Re: The DRZ Thread
« Reply #1771 on: December 23, 2011, 07:15:50 pm »
Saw this on ADVrider, small screen with built in lights. Nice light adv bike setup.

« Last Edit: December 23, 2011, 07:17:48 pm by sidetrack »
Little by little, one travels far
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http://www.wilddog.za.net/forum/index.php?topic=241580.msg4325284#msg4325284
 

Offline Rolf

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Re: The DRZ Thread
« Reply #1772 on: December 23, 2011, 07:42:13 pm »
Saw this on ADVrider, small screen with built in lights. Nice light adv bike setup.



Those are great and made of carbon fibre - it is the Lynx fairing by Britannia Composites. When I still had a DRZ the cost for it shipped, before tax was around R4 500.
Now:  Royal Enfield Classic Chrome

Previously:  Zongshen 200GY - Aprilia Pegaso 650 iE - Aprilia Caponord 1000
                  Suzuki DRZ 400 SM - Yamaha Virago 535 Bobber - Aprilia Caponord Adventure
 

Online LoopSoosStroop

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Re: The DRZ Thread
« Reply #1773 on: December 25, 2011, 08:43:12 pm »
For sale yet? Very nice!
 

Offline N[]vA

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Re: The DRZ Thread
« Reply #1774 on: December 25, 2011, 11:03:43 pm »
For sale yet? Very nice!
well yea but it isn't finished
So much of win it hurts! ^.^


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Offline Frannarossi

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Re: The DRZ Thread
« Reply #1775 on: December 29, 2011, 01:51:04 pm »
I bought Operator's DRZ about a month ago.Didn't get a manual with the bike and I want to fiddle with the rear suspension a bit.Where do I adjust what?I saw a screw on the bottom of the rear shock and one at the top.Is one for rebound and the other for height?
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Offline DJ

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Re: The DRZ Thread
« Reply #1776 on: December 29, 2011, 03:01:18 pm »
I bought Operator's DRZ about a month ago.Didn't get a manual with the bike and I want to fiddle with the rear suspension a bit.Where do I adjust what?I saw a screw on the bottom of the rear shock and one at the top.Is one for rebound and the other for height?

Compression of the rear shock is a 2 part adjustment:  sml screw in the middle of a 14mm nut on top of the shock reservoir. These are referred to as the low speed (screw) and high speed (nut) compression adjusters, set the screw about 11 clicks out and the nut 2 full turns out. Start by tuning adjusting the screw first.

Rebound for the shock is a screw at the bottom of the shock body, below the swing arm. Set at about 4 clicks out.

Rear spring length:
Std - 258mm
Soft - 259.5mm
Hard - 247.5mm
 
Previously owned: Vuka RM200, Aprilia Pegaso Cube 650, Suzuki DRZ400E, Kawasaki KLE500, Suzuki DR350



 

Offline Frannarossi

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Re: The DRZ Thread
« Reply #1777 on: December 29, 2011, 04:01:43 pm »
Thanks DJ :thumleft:
If you don't live on the edge,you take up too much space!!!
 

Offline DJ

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Re: The DRZ Thread
« Reply #1778 on: January 05, 2012, 08:23:38 am »
+1 On that fairing.Let us know what the price is DJ :thumleft:
agree on fairing..once details gotten plse advise

Cool guys, will do!!  :thumleft:

Guys, sorry for the delay...got an answer from Superfoxi, the fairings go for 2.5k, but will NOT fit straight onto the DRZ as it is made to fit the Honda Africa Twin.  But Superfoxi is sure that it would be possible to modify the fairing and mounting points on the DRZ frame to make it fit.
Previously owned: Vuka RM200, Aprilia Pegaso Cube 650, Suzuki DRZ400E, Kawasaki KLE500, Suzuki DR350



 

Offline N[]vA

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Re: The DRZ Thread
« Reply #1779 on: January 05, 2012, 10:01:31 pm »
+1 On that fairing.Let us know what the price is DJ :thumleft:
agree on fairing..once details gotten plse advise

Cool guys, will do!!  :thumleft:

Guys, sorry for the delay...got an answer from Superfoxi, the fairings go for 2.5k, but will NOT fit straight onto the DRZ as it is made to fit the Honda Africa Twin.  But Superfoxi is sure that it would be possible to modify the fairing and mounting points on the DRZ frame to make it fit.
with a lil cutting/molding/fabricating ti will fit damn well enough on the IMS 17.5L tank

all considered it's really not that much work to get it fitted i think
« Last Edit: January 05, 2012, 10:02:43 pm by N[]vA »
So much of win it hurts! ^.^


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