DRZ400 Adv build

[k14]

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]

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

[k14]

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]

Cool...a new build thread

[Padmei]

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]

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]

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

[k14]

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]

Safari Trail tank is 17L

[k14]

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]

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]

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]

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/in...roducts_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 which I don't think would be too difficult to mod. Then the other option is to get a slimline tank like this 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:Me]

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

[buggsubique]

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.