DRZ400 Adv build [Archive] - Kiwi Biker forums

k14

13th June 2011, 19:20

Well I bought my 08 DRZ with 2400km on the clock 2 months ago. It is a road reg'd model and I plan on turning it into a solid and reliable hardcore adv machine. I have some lofty ambitions of where I want this bike to take me so all mods are with those goals in mind. Basically I need it to be capable of taking on multi day/week rides and hopefully a 300-350km range!

At the moment the list of mods are:
Bashplate
Case guards
Rad guards
Manual cam chain tensioner
GPS mount and hardwire
16L tank (probably Clark at this stage)
Better seat
HID headlight
Tail tidy
Pack rack

I'll try and keep a log of all the mods I do and how they go in this thread.

thepom

13th June 2011, 19:25

can I recommend heated grips.........best money I ever spent.......

k14

13th June 2011, 19:34

So the first mod is fitting an alloy bashplate. I bought one off thumpertalk and it showed up about 4 weeks later after I opted to wait for the manual cam chain tensioner to come into stock so I could save on shipping. I would have to say they guys at thumpertalk are awesome. They even refunded me $7 because they overcharged me for shipping!

So it arrived and 2 hours before a ride I decided to chuck it on for a bit of extra protection. Standard there is a small alloy plate in the middle with some plastic bits on the side. The thumpertalk plate replaces all of this.

After 5 minutes I had removed the standard plate and tried to fit up the new one. It lined up easy enough and the only extra work was getting the clamp around the frame to sit right. I did up the 4mm head allen bolts for the 4 holes that use the original thread and then went to do up the frame clamp. This is where I realised the designer of the kit is a complete muppet and decided to use a Torx 40 bolt. WTF??? I think only 4 people in the world would have the right tool to do that bolt up so I had a rummage around in the toolbox and found a 6mm hex head bolt that will do for the mean time. All fitted up and looking pretty sweet. Took maybe 30 mins from start to finish.

The hex head bolts to hold it on are a real brain fart. Not only are they very easy to round (like I did to one) but you'd have to carry an extra tool if you needed to take it off on the trail. The torx 40 is just plain ridiculous. Also the heads fill up with mud really easily and make it even easier to round off when you work on them. I will replace them with some standard 10mm and 12mm head galv bolts and then it will be good to go. The actual bashplate is very well made using 6mm (i think) alloy plate with clean welds and a great finish. Would quite happily recommend them to anyone if they were after one!

Pics: 1.) Suzuki's attempt at protecting the engine... 2.) Thumpertalk bashplate kit 3.) All fitted and ready for some thrashing

Night Falcon

13th June 2011, 20:16

Cool...a new build thread :corn:

Padmei

13th June 2011, 22:04

Where have you found the best value for tanks? Ican'tseem to get thru to the safari tanks site to see what their prices are.

k14

14th June 2011, 08:17

Where have you found the best value for tanks? Ican'tseem to get thru to the safari tanks site to see what their prices are.
I am just going to get one from here http://www.justgastanks.com/

I haven't really considered the safari tanks option because imo they are too big. Yes I did say I want good distance but I believe that 16L is sufficient. The safari tanks to me would sacrifice too much in handling. If I knew I wasn't going to have enough fuel to make it to the next stop I would just carry a 5L fuel can and that would stretch the range to around 370km. So far in my few rides (one over thompsons track) I managed 5.7L per 100km. So the 16L tank would get about 270-290.

dino3310

14th June 2011, 08:42

http://www.coreracing.co.uk/aqualine_detail.php?make=5
safaris expensive from engaland

k14

14th June 2011, 08:49

http://www.coreracing.co.uk/aqualine_detail.php?make=5
safaris expensive from engaland
Holy crap they are expensive. I think the ones from just gas tanks will be under $400 landed. I will probably buy it this week, take advantage of the USD at such a good rate.

NordieBoy

14th June 2011, 08:54

Safari Trail tank is 17L

k14

14th June 2011, 09:03

Safari Trail tank is 17L
Oh yeah, that is probably the perfect size but is over twice the price of the 16L clarke so I am just going to get the clarke.

NordieBoy

14th June 2011, 09:39

Oh yeah, that is probably the perfect size but is over twice the price of the 16L clarke so I am just going to get the clarke.

I'd look at the IMS over the Clarke just for the extra rad protection.

Padmei

14th June 2011, 17:48

Oh yeah, that is probably the perfect size but is over twice the price of the 16L clarke so I am just going to get the clarke.

Which clark tank are you speaking of?
Nevermind I was looking at the KLX models. If I was replacing tanks 16L would havetobe the bare minimum I'd go with... Even then Ithink the extra money for the 17L Safari would be worth it.
Are the KLX the same as the E or S model?

k14

14th June 2011, 18:18

I'd look at the IMS over the Clarke just for the extra rad protection.
I've searched on every forum I can find and there is no consensus over which is better. I came to the conclusion that the Clarke was better because it didn't have the tank where the shrouds would be. I thought that would risk the tank getting damaged if you dropped the bike? Or is the plastic strong enough to hit a rock/tree branch and not have a worry about being punctured?

Which clark tank are you speaking of?
Nevermind I was looking at the KLX models. If I was replacing tanks 16L would havetobe the bare minimum I'd go with... Even then Ithink the extra money for the 17L Safari would be worth it.
Are the KLX the same as the E or S model?
This one here http://www.justgastanks.com/store/index.php?main_page=product_info&cPath=1_69_171&products_id=449
I agree that the 17L safari is a big plus but I struggle to see the advantage when price is taken into account.

Shipping from Just Gas Tanks is $65 for all 3 tanks so that gives a price incl shipping to NZ of:
Clarke - $340 NZD
IMS - $380 NZD
Safari - $680 NZD

So for $300 more plus a likely ~$100 with gst it is just not worth it. You'd be better to get one of their aux tanks like this (http://www.justgastanks.com/store/index.php?main_page=product_info&cPath=1_71&products_id=574) which I don't think would be too difficult to mod. Then the other option is to get a slimline tank like this (http://cgi.ebay.com/ebaymotors/Kolpin-Fuel-Pack-Jr-1-1-2-Gallon-89185-_W0QQcmdZViewItemQQhashZitem4158ed2f06QQitemZ28066 4813318QQptZMotorsQ5fATVQ5fPartsQ5fAccessories) and mount it on your pack rack. That way you don't have to take it with you unless you know you need to go over 300km without a petrol station and you don't suffer the disadvantage of having a massive tank getting in your way.

Buddha#81

14th June 2011, 19:00

DRZ400 = gurls bike, should be perfect for you Kirk.......seriously dude neat wee bikes and look forward to catching up with ya soon!

buggsubique

14th June 2011, 19:31

I plan on turning it into a solid and reliable hardcore adv
HID headlight

Awesome bikes bro. Nothing you need to do to turn it into a solid reliable bike - it already is! WRT your HID light, I rode my 400 in the DB1K with a 55/100W (however it reads - it was 100W on full beam) replacement bulb and that was awesome but I also fitted a HID spotlight which was killer bright. From memory I had to run the HID with the main light on dip due to the alternator output.

I miss my DRZ.

k14

14th June 2011, 19:39

Awesome bikes bro. Nothing you need to do to turn it into a solid reliable bike - it already is! WRT your HID light, I rode my 400 in the DB1K with a 55/100W (however it reads - it was 100W on full beam) replacement bulb and that was awesome but I also fitted a HID spotlight which was killer bright. From memory I had to run the HID with the main light on dip due to the alternator output.

I miss my DRZ.
I've already bought a cheap kit off ebay ($55 iirc) which fits in the std headlight housing. Not 100% wof legit but I am not too worried about that. Getting more than the std light output is something I am keen to improve. To say it is crap is an understatement. I will see how it goes and look at other options if it isn't up to the task.

Woodman

14th June 2011, 21:32

[QUOTE=k14;1130086615]I've searched on every forum I can find and there is no consensus over which is better. I came to the conclusion that the Clarke was better because it didn't have the tank where the shrouds would be. I thought that would risk the tank getting damaged if you dropped the bike? Or is the plastic strong enough to hit a rock/tree branch and not have a worry about being punctured? /QUOTE]

Not a DRZ but my KLR has a IMS tank that eliminates the radiator shrouds. I have dropped the bike countless times and the tank does a wonderful job of protecting the radiator etc. It has never punctured but there are some garks.

One thing to look out for when you are considering the capacity is how much of the gas in the tank is useable.

andy mac

14th June 2011, 21:54

Likewise the Safari on my WRR (has many garks) and protects the radiator so well that (next time) I wouldn't use an alloy radiator guard.

Your DRZ needs case savers installed NOW. During the weekend enduro a DRZ cracked its case & was run without oil until it started making terminal noises!

zeRax

14th June 2011, 22:29

i had some good garks on my 28 litre safari tank,, tough as nails :D good stuff.

timmehpwr

15th June 2011, 08:13

http://www.bboffroad.com.au/drz_400.htm

had all BB products on my klx400; case guards, radiator guards, bash plate... made it one mean machine :)

Tony W

15th June 2011, 18:55

Where have you found the best value for tanks? Ican'tseem to get thru to the safari tanks site to see what their prices are.

Safari are ridiculously expensive

Tony W

15th June 2011, 18:58

Oh yeah, that is probably the perfect size but is over twice the price of the 16L clarke so I am just going to get the clarke.

I have a Clarke, and it is choice. 435km to empty !
Get one.

Tony W

15th June 2011, 19:07

Genuine BARKBUSTERS are the most important thing you can buy.
Trust me :weep:

k14

15th June 2011, 19:08

Safari are ridiculously expensive
And that is a shame cause it looks like they are the best for the job.

I have done a lot more research in regards to tanks and I am still just as confused. It seems that the listed capacities and the actual amount of fuel they fit are two different things. Then there are some tanks that only fit the DRZ400S or vice versa, the whole thing is clear as mud.

The clarke is still top of the list but I have been looking at the acerbis too. Although the IMS that nordieboy suggested still has merit, although with some reservations. Firstly there are a lot of reports on ADV rider and thumpertalk about poor fitting and not being able to fit around the radiator properly. So with that in mind the clarke is top of the list, surely? Well no, it is listed on the justgastanks website as only 3.6 gallons for the DRZ400E and 3.9 for the S. So that means I would sacrifice around 1L over the IMS. Then the acerbis is listed as 4.2 gallons but on the justgastanks site it says it only fits 3.7 gallons. I was really wanting 15L minimum and if the clarke is indeed 3.6 gallons I am back where I started. I did find a few guys saying the safari that is listed as 17L actually fits closer to 20L although I think there is some dead space where the petrol sits lower than carb and thus can't be used.

It's a real pity that the safari tank isn't closer to the $500 mark. I'd be quite happy to pay that but $700 is just not good value for money. If the acerbis is in fact 15-16L I will probably go for that but if not then I am still on the fence.

k14

15th June 2011, 19:14

I have a Clarke, and it is choice. 435km to empty !
Get one.
Is that on an E model or the SM? What model tank did you get? Was it the one for the S or E? How many liters does it fit??

Tony W

15th June 2011, 19:27

Is that on an E model or the SM? What model tank did you get? Was it the one for the S or E? How many liters does it fit??

For the S model. 14.75L when brand new, but 16L on the next fill.
Evidently it's normal for them to expand naturally.
Zoom onto my site for pics.

topo

15th June 2011, 19:35

I have a Clarke, and it is choice. 435km to empty !
Get one.

thats over 27km/l (assuming it's a 16ltr tank), i struggle to get over 11km/l in xc's and anything over 17.5km/l while "adv" riding i consider a bonus. whats your secret?

Tony W

15th June 2011, 19:46

thats over 27km/l (assuming it's a 16ltr tank), i struggle to get over 11km/l in xc's and anything over 17.5km/l while "adv" riding i consider a bonus. whats your secret?

My best is 30km/l on SH1.
My bike is frugal and more powerful ever since I opened up the muffler and airbox.
Also I ride really slowly and carefully, as some who may remember me, will attest to.

buggsubique

15th June 2011, 19:47

During the weekend enduro a DRZ cracked its case & was run without oil until it started making terminal noises!

THat's why I've installed the warning buzzer on my AT, paralleled off the oil light.

k14

15th June 2011, 19:53

thats over 27km/l (assuming it's a 16ltr tank), i struggle to get over 11km/l in xc's and anything over 17.5km/l while "adv" riding i consider a bonus. whats your secret?
He has an SM which I believe has the CV carb whereas the E models that are most common in NZ have the FCR carb which produces iirc 5-7hp more but at the expense of fuel economy. If I could get 300km out of my one I'd be happy. It has an FMF pipe which I am guessing won't do anything for fuel economy.

ADVGD

17th June 2011, 17:57

I talked to the local Suzuki shop, the manager said there was such a major price increase on the DRZ400E that Suzuki NZ cannot justify importing so there will be no more DRZ400E's brought into NZ on the next shipment or any future shipments until the price drops :blink:

They had none on the floor so I got him to check stock levels in Auckland, only 1 yellow and 1 black left in stock... I ordered the black one :)

Have you seen these Lynx (http://www.britanniacomposites.com/lynx.html) fairings with adjustable screen k14? Aside from the immediate increase in light output there is also an HID upgrade option

http://www.britanniacomposites.com/gallery/lynx/Black-DRZ-2lg.jpg

http://www.britanniacomposites.com/gallery/lynx/nite-lg.jpg

Eddieb

17th June 2011, 18:21

They had none on the floor so I got him to check stock levels in Auckland, only 1 yellow and 1 black left in stock... I ordered the black one :)

Woohoo! 

Crim

17th June 2011, 19:01

I ordered the black one :)

Great stuff Josh - I am waiting with baited breath to see what you do to her - I am sure she'll be an absolute beaut in no time! - racks and cases swap over?

NordieBoy

17th June 2011, 19:06

Squiggles

17th June 2011, 20:12

DRZ400s

Whats the diff between the s and the e?

bart

17th June 2011, 20:44

Whats the diff between the s and the e?

'E' is the full hp enduro version. Plastic tank, big (ish) suspension etc.

'S' = mellow carb, soft suspension, steel tank. A little more roady.

'SM' = S model with motard rims.

All great bikes. Only issue I had was the close ratio 5 spd gearbox. Brilliant for trial riding, but a bit limited for the varied riding I'm currently doing.

ADVGD

17th June 2011, 21:14

'E' is the full hp enduro version. Plastic tank, big (ish) suspension etc.

'S' = mellow carb, soft suspension, steel tank. A little more roady.

'SM' = S model with motard rims.

:yes:

Whats the diff between the s and the e?

The DRZ400E:
Has cams with a more high performance profile
Has a higher compression ratio, E=12.2:1, S=11.3:1
Has the KEIHIN FCR39 carb, S has Mikuni™ BSR36 carb
Is lighter than the S by approximately 6kg, S is road oriented, steel tank, pillion pegs etc

Padmei

18th June 2011, 08:39

What'sthe KLX then- it hasa steel subframe

NordieBoy

18th June 2011, 10:20

What's the KLX then- it has a steel subframe

Effectively the DRZ400S.
36mm CV carb and 11.3:1 compression.

The frame is steel. The subframe should be rectangular section alloy?

ADVGD

18th June 2011, 10:49

What'sthe KLX then- it hasa steel subframe

DRZ400 - KLX400 subframe info (http://www.adventureguide.co.nz/articles/12/99/drz400e-klx400r-subframe.php)

The subframe should be rectangular section alloy?
:yes:

dino3310

18th June 2011, 12:12

Have you seen these Lynx (http://www.britanniacomposites.com/lynx.html) fairings with adjustable screen k14? Aside from the immediate increase in light output there is also an HID upgrade option

http://www.britanniacomposites.com/gallery/lynx/Black-DRZ-2lg.jpg

i reckon these are the bees knees, the practability of the adjustabilty is bang on for what we do. was gonna look at one for my pig but would need to upgrade stator for lighting:weep:

k14

18th June 2011, 15:12

I talked to the local Suzuki shop, the manager said there was such a major price increase on the DRZ400E that Suzuki NZ cannot justify importing so there will be no more DRZ400E's brought into NZ on the next shipment or any future shipments until the price drops :blink:

They had none on the floor so I got him to check stock levels in Auckland, only 1 yellow and 1 black left in stock... I ordered the black one :)

Have you seen these Lynx (http://www.britanniacomposites.com/lynx.html) fairings with adjustable screen k14? Aside from the immediate increase in light output there is also an HID upgrade option
No I hadn't seen them, nice piece of kit! But for the best part of $1k I think I'll give it a miss. I am thinking of getting a screen that fits onto standard front cowl from here http://www.screensforbikes.com

NordieBoy

18th June 2011, 18:05

No I hadn't seen them, nice piece of kit! But for the best part of $1k I think I'll give it a miss. I am thinking of getting a screen that fits onto standard front cowl from here http://www.screensforbikes.com

Get a good one instead...
http://sports.nelson.geek.nz/motorsport/mybikes/TT350/20110507%20Screening/slides/20110509-105556-0003.jpg

Goose_DRZ400E

13th July 2011, 22:02

Goose_DRZ400E

13th July 2011, 22:05

I also see you mentioned the Lynz Fairing from Britannia Composites.

I like the look of them myself but I'm still up in the air on that one.

I also like the look of the "Universal Rally Fairing" supplied by Off The Road in Germany. http://www.off-the-road.de/Other-bikes/Fairing-Light/Universal-Rally-front-fairing-otr.html

k14

14th July 2011, 06:57

I just bought a 2005 DRZ400E about 5 weeks ago. I'm planning quite a few mod's but due to work have had bugger all time.

I was looking at the Clarke Tanks and it looks like you get about 14L for around $400.

Safari you get 17L (apparently they often swell to 20L after a few uses) for around $700.

Personally I have decided to go with Safari. They offer the translucent option to and have alot of use in Desert racing by the top teams etc. I have yet to see a bad review about Safari tanks.
Yeah I am still debating gas tank. I am actually tending towards IMS, although I am going to Oz in September so am wondering if maybe I can get the safari tank sent to my mate and pick it up when I am over there. Save on shipping at least.

I have all the parts bar tank sitting in garage, I'm just too lazy to install. Bike reg on hold till september so might start doing a few bits and pieces in next couple of weeks.

NordieBoy

14th July 2011, 07:41

Padmei

14th July 2011, 08:12

I have ordered my safari - it will be waiting for me at my Gold coast hotel when I go there in a coule of weeks.

Cost.tank $408 Aus
freight $25
Total $433AU

Shipping would have been $98AU to here.
Thisis straightfrom safari tanks

Re the screens - I got my DRZ as a bit of a hack after buying a brand new KLR for adv riding then breaking orscratching the plastics. Although the DRZ plastics are cheap enough to replace, that screen looks a bloody expensive thing to replace after the first off. I would seriously look at somethinglike Nordies for hard core adv riding protection.
Be alright for highway use etc

k14

14th July 2011, 11:18

Safari stuff is/was usually quite a bit cheaper straight from the States than Oz. So much so that justgastanks won't ship to Oz, stating "freight prices" as the issue. But they're happy freighting to everywhere else in the world...
I thought safari tanks are made in auzzie and the reson just gas tanks doesn't ship there is because of this??

I have ordered my safari - it will be waiting for me at my Gold coast hotel when I go there in a coule of weeks.

Cost.tank $408 Aus
freight $25
Total $433AU

Shipping would have been $98AU to here.
Thisis straightfrom safari tanks

Re the screens - I got my DRZ as a bit of a hack after buying a brand new KLR for adv riding then breaking orscratching the plastics. Although the DRZ plastics are cheap enough to replace, that screen looks a bloody expensive thing to replace after the first off. I would seriously look at somethinglike Nordies for hard core adv riding protection.
Be alright for highway use etc
That is exactly what I was thinking. Going over for mates wedding on gold coast so hesistant on ordering it to him seeing as he will have more important things to think about when I am there. I was wondering if shipping to a hotel is possible. We're staying at the holiday inn so I wonder if that is possible. Also remember you can claim the gst back when you leave oz.

Eddieb

14th July 2011, 11:35

Also remember you can claim the gst back when you leave oz.

Only if you carry the item onto the plane as hand luggage, the GST refund claim centre is between security and customs when you are going to your gate and you need to have the item and it's receipts with you.

Last time I did it the rules were there had to be a minimum of $400aus on each receipt you were claiming back on.

k14

14th July 2011, 13:43

Only if you carry the item onto the plane as hand luggage, the GST refund claim centre is between security and customs when you are going to your gate and you need to have the item and it's receipts with you.

Last time I did it the rules were there had to be a minimum of $400aus on each receipt you were claiming back on.
I did it 2 years ago and brisbane airport for some golf clubs which were checked in. The claim room was on the bottom floor (under check in counters) and they gave you a reciept which you took to the booth at the terminal and gave you your $$.

Padmei

14th July 2011, 17:10

I paid online so GST wasn't included. I emailed the hotel& asked them-they were fine about it.

NordieBoy

14th July 2011, 17:13

I thought safari tanks are made in auzzie and the reson just gas tanks doesn't ship there is because of this??

They used to send to Oz no problems. It was cheaper for the Ozzites to get them from the States than from RV Aqualine themselves.

Goose_DRZ400E

14th July 2011, 19:11

I think Safari is the way to go. As I said I'm looking at a 17L tank for my DRZ.

So far my bike has:
B&B Bashplate
B&B Radiator Guards
Zeta Hand Guards
Zeta Fat Bars
Leo Vince X3 Muffler
Edge Tail Tidy (haven't got the small indicators yet)
Custom Top Clamp with Ralle Moto Steering Damper
Wolfman Racks and Soft Luggage (not fitted - only fit it when when Adventure riding).

On the stock rims I am running a set of Mefo Explorer Dual Purpose Tyres. I am awaiting delivery of a set of Excel rims which I will fit with some knobblies.

I'm also off to New Plymouth in a few weeks time to have the suspension tuned for my weight, riding style etc. I'm getting Racetech internals for the front end and an Ohlins shoch on the rear.

I can't wait!!!

Goose_DRZ400E

14th July 2011, 19:22

On my wishlist are:

17L Safari Tank
New Fairing/headlight. (Considering LYNX, Polisport HMX or Univeral Rally Fairing from Off The Road)
Roadbook
GPS
Trail Tech Speedo

oh....and an aftermarket seat!!!

XF650

14th July 2011, 20:32

Go the 440 kit:
http://www.kiwibiker.co.nz/forums/showthread.php/133267-Talk-to-me-about-DRZ-KLX-400s?p=1130101283#post1130101283

NordieBoy

14th July 2011, 21:39

On my wishlist are:

GPS
Trail Tech Speedo
Go for this one then...
http://trailtech.net/voyager.html

Tony W

14th July 2011, 21:42

buggsubique

15th July 2011, 07:35

Padmei

15th July 2011, 08:02

SHit bro, wont be much DR-Z 400 left by the time you're done!

It'll be the most blinged out Drz in NZ.

Don't forget the TT case covers. got mine the other day-for those unfortunate moments

Goose_DRZ400E

15th July 2011, 20:51

Have you considered just buying a 1200 GS ! :scooter:

I think I'd struggle to Trail ride a 1200GS!!!

This way I can change my wheels, strip off the Soft luggage and racks and go trail riding......and when I get home refit the bells and whistles and go for an Adventure ride. SWEET!!!

Goose_DRZ400E

15th July 2011, 20:55

Go the 440 kit:
http://www.kiwibiker.co.nz/forums/showthread.php/133267-Talk-to-me-about-DRZ-KLX-400s?p=1130101283#post1130101283

Yeah. Quite keen on this to....especially with the exchange rate!!! $750 USD + shipping.....vs. $1595 NZD..!!!!!

Padmei

16th July 2011, 09:47

Have you read Pachows (I think that's his name) site. It is quite good.

http://www.paochow.com/DRZguide/DRZguide.php

Iwould read his caution on the front page.Basically he's saying if you're spending shitloads of money on what is basically a very basic bike you may be better off buying something different.

Just saying from one drz owner to another

Toxic

17th July 2011, 14:37

Where have you found the best value for tanks? Ican'tseem to get thru to the safari tanks site to see what their prices are.

In this months edition of Kiwirider there is a company in New Zealand who sell the IMS tank's. www.rageracingltd.weebly.com

Padmei

17th July 2011, 19:54

In this months edition of Kiwirider there is a company in New Zealand who sell the IMS tank's. www.rageracingltd.weebly.com

Cheeers but getting/got a safari. Apparently I have to checkout the jetting on mine as it may be not quite stock.

Goose_DRZ400E

27th July 2011, 17:11

Finally got my suspension done by Rob Taylor at CKT. What an amazing difference. Bike handles fantastic! :gob:

Made the new Ohlins shock 3mm longer than stock to make the handling even better, raising the rear by 8-9mm.

However..... after 320+ km's my seat is offically about as popular with my arse as a fart in a elevator. :shit:

I think my next purchase will be a more comfortable seat! :woohoo: