Making a road legal XR400 or DRZ400

[Paulus]

I would like to get a road legal trailbike. It would be something to ride to work on nice days during the week and take out occasionally trail riding at the weekend. I don't really want a high maintenance machine like a WR450 and have zeroed in on the XR400 and the DRZ400. There are lots of these for sale but only about 20% or so seem to be the road legal version and they usually are either way overpriced or sell very quickly. For some strange reason the road legal ones never seem to be within a couple of hours drive of Chch either.

Does anyone have any experience converting an offroad version to road legal? Looks like all the bits required can be got pretty easily from a number of sources (xrsonly.com have a dualsport kit). I'm guessing that the alternator is the same on both variants. You would need mirrors, indicators, horn, flasher, switch block, hi/lo headlight, two brake light banjo bolts, a number plate bracket (with LED light) and a wiring loom. What would the LTSA have to say about it? Since there is already a variant of that same bike on the road would it give trouble?

EDIT: and a speedo obviously.

Don't really want to take on a whole lot of hassles so if it is difficult I'll just wait out a road legal one.

[timmehpwr]

heya, im actually in the process of doing the same thing to a 1993 dr350.

Its the offroad model and has never been registered before. Rang VINZ and Land transport, and they couldnt find any records by the frame number I gave them. So I called Suzuki NZ and got a letter confirming it was legally imported, then took that letter into VINZ in chch, who then gave me two forms, one to take to the Police to get stamped saying the bike is of no interest to them, and the other form is for brake certification. Then they said to come back with those forms and bring the bike in and pay $130 odd + reg/wof fee's and its all doneburger

So got the Police form signed all fine, and have taken the bike in to a local shop who failed it on the front disc (its worn down to 2.5mm but OEM spec is 3.8-4mm or something) so ordered a replacement from them, went to put it on today and its the wrong size haha, so will have take it back this weekend.

I'm waiting on quotes for dualsport kits at the moment, and have been sanding down any rusty bits and spraypainting them to make it look nice in the mean time :)

The whole process seems pretty do-able, keen as to get it on the road :D

Be interested to see how you get on :)

[cave weta]

If you really want one I have a honey here- its a 2003 done 8500km I think (will have to go outside and look)
it has the std muffler (unused) and a pro circuit t4 fitted. brand new tyres and has reg on hold. it does about one days gentle trail riding each month over the summer. All the road legal bits are in a box and have never been used, I want to get a 250 enduro as it seldom gets used in my business.
Most customers want to ride more serious machines. Yours for $4500.

EDIT: I have a mate who works for air New Zealand and he says that waihi is within two hours of christchurch.:rolleyes:

[Paulus]

Be interested to see how you get on :)

Thanks for the info. When we were growing up everyone rode street legal dirtbikes. I had a quite a few XRs, TTs, ITs and KDXs in the early 80s through to about the late 80s when I discovered MX and moved on to a CR. Now I just miss going trail riding out at the Waimak - they were fun times.

For some strange reason I also have a desire to buy an XR350 for pre 86 Vintage MX. There are several for sale at the moment but I'm hoping I'll see sense and not buy one.

All starting to sound a bit like a midlife crisis.

[Paulus]

If you really want one I have a honey here- its a 2003 done 8500km I think (will have to go outside and look)
it has the std muffler (unused) and a pro circuit t4 fitted. brand new tyres and has reg on hold. it does about one days gentle trail riding each month over the summer. All the road legal bits are in a box and have never been used, I want to get a 250 enduro as it seldom gets used in my business.
Most customers want to ride more serious machines. Yours for $4500.

EDIT: I have a mate who works for air New Zealand and he says that waihi is within two hours of christchurch.:rolleyes:

Possibly interested but every alarm bell in the world starts sounding when I think about buying a dirt bike sight unseen (hence the 2 hours from Chch comment). You only have to read this forum to see some of the disasters that have befallen people.

[cave weta]

Possibly interested but every alarm bell in the world starts sounding when I think about buying a dirt bike sight unseen (hence the 2 hours from Chch comment). You only have to read this forum to see some of the disasters that have befallen people.

Yes- But this is ME!!!! lol!
honestly, if I tell you 1 slight scuff on front guard and one on RHS sidecover.that is the only marks you will find aside from some paintchips on the front of the downtube. it is just about to get a new set of Goldfren sintered brake pads. still on first chain. fastidiously maintained. tyres have been on for two weeks- done 4 hours on clay. this bike just doesnt get used! I will replace it with a klr 250 or 300. I registered it and used it on motard wheels for a year then sold the wheels and it sat for a year unridden. its just not suitable for the kind of customers I get and the riding we do. all shock linkages swingarm and wheel bearings are sweet. only thing that lets it down is that the graphics stickers fell off cos the I let my nephew water blast it!

[cave weta]

Not a brilliant photo- but if you look at my profile pic thats it in the background, Ill pull it out and photo it all over on monday when I get back from my big tour over the weekend.

[CRM]

Hi there. Selling my Gas Gas 250 road legal. It's also in the treading section and on Trade Me at http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Dual-purpose/auction-178095709.htm. Already road registered. Very sweet bike but may be a bit small for you if you are looking for a DRZ but check it out - she's a great bike but I'm going to a 650 adventure bike most likely. Pics of ride today - had a ball...:woohoo:

[Dent]

If you were converting a DR-Z 400E, I have all the removable lights, switches, speedo etc from a 2003 DR-Z 400S.
I purchased them to convert my DR-Z400E, but in the end decided against it as I had purchased a trailer.

The E model seems to have a very minimal wiring harness, so you really do have to add quite a lot.

[nallac]

a mate wanted to go thru with road legaling his drz400,
he gave up in the end, too much hassel with LTNZ.
them saying he needs to change the disks and calipers to the "road spec ones" and a hell of alot more,( i can't remember,twas a couple of years ago)
he worked out the costs and it would have been heaps cheaper to sell his and buy a road legal version.

If i was you I'd catch a flight to Wahi and get Cave wetas one..

[Paulus]

a mate wanted to go thru with road legaling his drz400,
he gave up in the end, too much hassel with LTNZ.
them saying he needs to change the disks and calipers to the "road spec ones" and a hell of alot more,( i can't remember,twas a couple of years ago)
he worked out the costs and it would have been heaps cheaper to sell his and buy a road legal version.

If i was you I'd catch a flight to Wahi and get Cave wetas one..

I was almost certain that the road spec and off road only E model had exactly the same discs and calipers. Is that not the case?

[MXNUT]

I was almost certain that the road spec and off road only E model had exactly the same discs and calipers. Is that not the case?

Yes you are right, both E spec models are identical except for the Extra road going bits.Slightly different wiring loom also.I have owned them both.

I have just gone through the same process to get my wifes DR200 road registered.
If i were you i would buy the registered version( cave weta`s bike sounds like a good deal ) but if you want to do it the other way start with the letter of compliance for the lighting and brakes from SUZUKI NZ. This will be your biggest hurdle.

[bart]

Buy the road kitted version. I priced it out when I bought mine. Far too much hassle to convert off road model. Even the headlight is different (same as DR650 for road model)

Look out for ex-demos. Quite often these are the road legal version, as they get better resale.

[Paulus]

Thanks for all the advice guys. I've actually had a change of heart and am now on the lookout for a WR450. There seem to be a heck of a lot more road legal ones about and they don't command such a price premium. Much time spent scoping thumpertalk has convinced me that the WR is a pretty bulletproof machine provided it gets clean air and oil. Just got to find a nice one. Should be a blast.

[Rob Bark]

Hey there...

I'm looking for the necessary parts to get my XR400 road legal and was wondering if anyone has them floating around in their garage?
Speedo gearbox and cable (will buy a speedo as they only came with a odo i believe?)
indicators
brake light switch
switch block
horn
mirrors
and anything else the road legal version might have had..

Ive looked into the Tusk enduro kits but they look like thet wont provide enough for a wof here in NZ

cheers
Rob

[pete376403]

Easist speedo would be a CatEye bicycle unit. Bike wrecker for the rest of the bits (switch doesn't have to be a genuine Honda unit) indicator lenses will have to have the correct marking if the testing station wants to get picky.

[Rob Bark]

Thanks Pete.. definitely head down that path If i can’t find original XR parts.. just hoping someone stripped their road version for dirt riding and has them stored ready to dust off and sell to me..

[george formby]

Thanks Pete.. definitely head down that path If i can’t find original XR parts.. just hoping someone stripped their road version for dirt riding and has them stored ready to dust off and sell to me..


Have you been in touch with EconoHonda (I think that's the name)?

[Rob Bark]

Yeah I have.. something about hens teeth/tits on a bull!

[george formby]

Yeah I have.. something about hens teeth/tits on a bull!

T'was a thought. I got the same response looking for CRM / XR wheels..

[george formby]

Fill THIS (http://www.jp-parts.com/contact/contact.html) in and see what they turn up.

I've found them excellent to deal with getting parts for my DT and CRM.

[Rob Bark]

Awesome.. have sent a request for the parts I’m after. See what comes back?

[george formby]

Awesome.. have sent a request for the parts I’m after. See what comes back?

It's worth a punt. If any parts are available they send back the info and quote the cost including P & P.

Dunno if they are good value or not but I got all the parts to rebuild my DT 230 motor from them, top and bottom end, piston kit, all bearings, seals, con rod etc. Was a helluva list! Less than $800, delivered in 2 days.. Oh, that included chain and sprockets, too.

Fingers crossed.