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Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #160 on: March 17, 2011, 11:46:03 am »
Those aluminium spacers? naw borrow mine and have a set made

Front wheel
2 x 6904 2RS

Rear wheel
2 x 6004 2RS (R 25.04)
http://za.rs-online.com/web/6190345.html
1 x 6204 2RS (R 32.16)
http://za.rs-online.com/web/search/searchBrowseAction.html?method=searchProducts&searchTerm=6204-2RS&x=0&y=0

Where can I get those bearings? Preferably Today :)

Thanks, the SM spacers are different. So I am gonna have to get some E-model spacers. The punks at Suzuki wanna charge R226 per spacer.
I crash test all of my safety gear. Do you?
 

Offline Rolf

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Re: Milddog's DRZ pimp thread
« Reply #161 on: March 17, 2011, 11:51:24 am »
Those aluminium spacers? naw borrow mine and have a set made

Front wheel
2 x 6904 2RS

Rear wheel
2 x 6004 2RS (R 25.04)
http://za.rs-online.com/web/6190345.html
1 x 6204 2RS (R 32.16)
http://za.rs-online.com/web/search/searchBrowseAction.html?method=searchProducts&searchTerm=6204-2RS&x=0&y=0

Where can I get those bearings? Preferably Today :)

Thanks, the SM spacers are different. So I am gonna have to get some E-model spacers. The punks at Suzuki wanna charge R226 per spacer.

Any industrial area will have a couple of bearing places. Take them the bearing numbers and they'll supply them to you.
I've bought "motorcycle bearings" at Centurion bearing Supplies and even at Acorn Fasteners.
Get some good quality bearings though: SKF, FAG, Nachi, etc.
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
 

Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #162 on: March 17, 2011, 02:31:33 pm »
Any industrial area will have a couple of bearing places. Take them the bearing numbers and they'll supply them to you.
I've bought "motorcycle bearings" at Centurion bearing Supplies and even at Acorn Fasteners.
Get some good quality bearings though: SKF, FAG, Nachi, etc.
I got sealed NSK bearings from BMG for R150 for all three. However I think I've got a set of new All Balls racing bearings and partially used spacers from a WD  :thumleft:

Suzuki wanted R230 a spacer so I was going to take the stock ones to les stainex in wynberg for machining. Seems I won't need to do that either :)
I crash test all of my safety gear. Do you?
 

Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #163 on: March 18, 2011, 04:23:41 pm »
Oil check method:
1) Ride bike (till warm/hot)
2) turn off bike
3) take out dipstick
4) wipe dipstick
5) insert dipstick back into bike, as far at it will go without using the thread
6) pull out dipstick, check level

Is this right?

I put in 2liters of oil when I did the service (changed oil filter and drained oil), it says do 1.9 liters when changing oil filter, so I figured the extra 100ml wouldn't make a difference. That was Around 1800kms ago. When I checked the oil today there was nothing on the dipstick at all. I put in 600ml then rode the bike and then put in another 400ml.

Thinking about it now I have most likely over-filled it.
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Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #164 on: March 24, 2011, 09:54:26 am »
Turns out I have oil on the spark plug. From the workshop manual it seems I am missing the cushion on one bolt of the tappet cover. May also need a new tappet cover gasket. Will phone the suzuki boys and find out the damage. I am really hoping its the cushion and gasket causing the oil leak, if it's not it'll be rings or something expensive sounding.
I crash test all of my safety gear. Do you?
 

Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #165 on: March 24, 2011, 11:35:32 am »
Can anyone provide me with the parts fiche pic of the tappet cover, bolts and washers?

I am not sure if I have all the bits yet. The 'cushion' that I bought today looks very different to the 2 washers that are already on the bike.
I crash test all of my safety gear. Do you?
 

Offline N[]vA

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Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #167 on: March 29, 2011, 11:31:44 am »
ALL of the gaskets and rubber pieces on my tappet cover have stopped working. Seems they stop sealing after a while. I think that also explains the water in the oil, I found an oily emulsion on the underside of the tappet cover that started at the two bolt holes.

Well, I have replaced the tappet cover gasket, without gasket sealant, so it pissed oil everywhere this weekend- will do a service and rectify all of that tomorrow or Thursday.

Also had to replace the two washers that go under the nuts on the breather side, R26 per washer!
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Offline sidetrack

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Re: Milddog's DRZ pimp thread
« Reply #168 on: March 29, 2011, 04:46:47 pm »
ALL of the gaskets and rubber pieces on my tappet cover have stopped working. Seems they stop sealing after a while. I think that also explains the water in the oil, I found an oily emulsion on the underside of the tappet cover that started at the two bolt holes.

Well, I have replaced the tappet cover gasket, without gasket sealant, so it pissed oil everywhere this weekend- will do a service and rectify all of that tomorrow or Thursday.

Also had to replace the two washers that go under the nuts on the breather side, R26 per washer!
Fork MD something is wrong, I had mine off about 5 times with cams and valve inspections and never used sealant on the tappet cover gasket. As it's rubber it's reusable  ???
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #169 on: March 29, 2011, 05:25:56 pm »
Fork MD something is wrong, I had mine off about 5 times with cams and valve inspections and never used sealant on the tappet cover gasket. As it's rubber it's reusable  ???

This all started (I think) after I over-heated the bike at the Nelson's Creek training day. Could the magnesium tappet cover have warped? I will replace all the rubber bits, do the gasket sealant and then check what happens with the oil. It was leaking so much the spark plug got fouled and wouldn't spark. My bike is also 27 000kms old, so maybe the rubber has just lost its flexibility and is brittle and not sealing anymore.
I crash test all of my safety gear. Do you?
 

Offline N[]vA

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Re: Milddog's DRZ pimp thread
« Reply #170 on: March 29, 2011, 05:31:45 pm »
ALL of the gaskets and rubber pieces on my tappet cover have stopped working. Seems they stop sealing after a while. I think that also explains the water in the oil, I found an oily emulsion on the underside of the tappet cover that started at the two bolt holes.

Well, I have replaced the tappet cover gasket, without gasket sealant, so it pissed oil everywhere this weekend- will do a service and rectify all of that tomorrow or Thursday.

Also had to replace the two washers that go under the nuts on the breather side, R26 per washer!
Did it look anything like this?

If so , given that the bike overheated I'd be inclined to think it might be the head gasket

If the bike runs do you get any bubbles or oily residue int he top of the radiator?

chemical test is also a good way to test
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Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #171 on: March 29, 2011, 08:01:37 pm »
Did it look anything like this?

If so , given that the bike overheated I'd be inclined to think it might be the head gasket

If the bike runs do you get any bubbles or oily residue int he top of the radiator?

chemical test is also a good way to test

That is exactly how it looks! I wanted to take a pic but couldn't find the camera.

No, there are no bubbles in the radiator fluid. Also no loss of water at all, so the water pump is fine.

Yeah, other option is that the head gasket has gone :(

I am hoping after the service, and replacing all these rubber tappet cover bits the oil will stop leaking, but its unlikely.

There was oil on top of the spark plug (on the outside) as well as actually on the electrode.
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Offline grego

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Re: Milddog's DRZ pimp thread
« Reply #172 on: March 30, 2011, 08:24:08 am »
Fork MD something is wrong, I had mine off about 5 times with cams and valve inspections and never used sealant on the tappet cover gasket. As it's rubber it's reusable  ???

This all started (I think) after I over-heated the bike at the Nelson's Creek training day. Could the magnesium tappet cover have warped? I will replace all the rubber bits, do the gasket sealant and then check what happens with the oil. It was leaking so much the spark plug got fouled and wouldn't spark. My bike is also 27 000kms old, so maybe the rubber has just lost its flexibility and is brittle and not sealing anymore.
use a steel rule (or similar straight edge) across the gasket face of the tappet cover to check for warpage.
maybe with the high mileage and overheating the gasket failed  :-\
 

Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #173 on: April 19, 2011, 02:33:47 pm »
My bike is leaking oil from the gear lever/clutch cover area.

Initially I thought it was the hairline crack that I sealed with Pratley Steel.

On second inspection I can see that there is oil on the chain.

I think I am leaking oil from the front sprocket seal.

Is this common? Is it likely? Is it easily fixable?
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Offline N[]vA

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Re: Milddog's DRZ pimp thread
« Reply #174 on: April 19, 2011, 03:37:43 pm »
My bike is leaking oil from the gear lever/clutch cover area.

Initially I thought it was the hairline crack that I sealed with Pratley Steel.

On second inspection I can see that there is oil on the chain.

I think I am leaking oil from the front sprocket seal.

Is this common? Is it likely? Is it easily fixable?
Counter shaft seal.

I have 3 xrays that say DO NO RIDE THAT BIKE until you fix it.

http://www.thumpertalk.com/forum/archive/index.php/t-625998.html
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Offline sidetrack

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Re: Milddog's DRZ pimp thread
« Reply #175 on: April 19, 2011, 03:47:24 pm »
My bike is leaking oil from the gear lever/clutch cover area.

Initially I thought it was the hairline crack that I sealed with Pratley Steel.

On second inspection I can see that there is oil on the chain.

I think I am leaking oil from the front sprocket seal.

Is this common? Is it likely? Is it easily fixable?
Some last forever, yes it's easily fixable. Remember the blue loctite on the CS nut and splines when you reinstall the sprocket. Read all about it on TT.
Little by little, one travels far

J.R.R Tolkien
Ride reports :
http://www.wilddog.za.net/forum/index.php?topic=134175.0 Penge's pass and the Old Forest http://www.wilddog.za.net/forum/index.php?topic=9421.0 - Orange Atlantic adventure http://www.wilddog.za.net/forum/index.php?topic=7514.0 - 805 km day trip http://www.wilddog.za.net/forum/index.php?topic=20260.0 - East Cape Bash http://www.wilddog.za.net/forum/index.php?topic=70199.0 - Two KTM thumpers head north
 

Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #176 on: April 19, 2011, 05:02:56 pm »
Seal : R54
Washer : R7

Taking it all through to TMC tomorrow morning for sorting :)

When changing chain and sprockets; don't re-use that crush washer thing that holds the sprocket on. I did. It's only R7. Rather replace.
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Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #177 on: April 21, 2011, 10:14:44 am »
Yes, I realise that big bore kits are a terrible idea. but still. they're fun  >:D

I am looking at getting this kit:

http://cgi.ebay.com/ebaymotors/SUZUKI-DRZ400-JE-PISTON-440-BIG-BORE-KIT-DRZ-400-12-1-/360337342156?pt=Motorcycles_Parts_Accessories&hash=item53e5c77ecc

I am worried that the sleeve is steel. How do I figure that out? my google-fu is weak. Apparently the steel sleeves have a problem with heat dispensation and they warp.

I am ALSO getting a 19 liter clarke tank. win.

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Offline Poffmuis

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Re: Milddog's DRZ pimp thread
« Reply #178 on: April 21, 2011, 10:23:27 am »
The best kit for that bike is the full Athena kit, piston and barrel. The Athena barrel has bigger water channel = better cooling.
The best (only) way to go IMHO
 

Offline MildDog

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Re: Milddog's DRZ pimp thread
« Reply #179 on: April 23, 2011, 10:04:57 pm »
yes, turns out buying from the states is a silly plan. NSC up in jo'burg stock the athena kits, waiting for a price from them, and renz.co.za have some very reasonably priced stuff kits. turns out the kit I bought has a steel sleeve, and the common opinion on the interweb is that putting a steel sleeve into an aluminum cylinder is a kak plan, the steel doesn't dissipate heat nicely and it can warp. either way it's considered a much better option to either buy a new cylinder like the athena kit or have your old barrel bored out and nikasil coated. apparently the only people who do that in this fine country are NSC up in jo'burg and they charge R1580 for it. so yes... we will see whether i keep this kit or not. may sell it on to mitigate costs of my clarke tank. may keep it and be awesome  >:D

and all this started because i found oil on spark plug and was worried about my rings  :imaposer:
I crash test all of my safety gear. Do you?