Drz400e help. Crisis in my mind.

Drz project.

hi old bull.

I’ve been toying with a little project for about a year now. I’m close to making a start but thought I might just get some external input however it turns out.

Basically I want a bike that is an great allrounder, light, still reliable, bomb prof and able to be rebuilt on the side of the road. Did I mention it needs to be light. About a 120kg max dry. I’ve found it. It’s the drz400. But what I’ve found is that when its loaded up or just on the road it’s a bit sluggish and feels under powered and it’s got to reved out to make gains.

So my project involves the ACT wide gear set and stroker/BB (465cc). I’m hoping it will give the bike the gear range and power to tackle all types of terrain including highway and tight stuff with 25+ lts of fuel, 6lts water + about 15kg of supplies. At the moment I belive I’m running a 14/47?? Or 45 Gear set. Can’t be sure as I’m away from the bike. But it’s great on the dirt and on the road around town but for the long slogs inbetween that I’m doing its a bit much. I know could just change gear sets to get the proformace I want. But I don’t want to be changing gear sets all the time. From road to dirt and back.

How far do I want to take it??
I am starting with an E model. I’ve read that the intake and exhaust cams in the E are similar to the hot cams stage one so they are going to stay the same.

Need to find a supplier for valves and what type of valves needed or want??

Stroker kit and BB from these guys. The 465cc plus all the trimmings listed on this page.
http://lukesracing.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=LR&Product_Code=BBSDRZ465

Will probably upgrade to the 41mm FCR if the stock 39mm FCR won’t Handel the upgrade. I’ll try and trade or defiantly sell the 39.

Already have a barett exhaust but am looking to change the bend of the head pipe. As seen in this thread from advrider bellow I’m also planing a front faring and nav tower (different light though) with a mini iPad or android running hema and oz topo 1:25000 maps encased in a life proof case and mount. (I would add photos but I’m on the iPhone.)

http://www.advrider.com/forums/showthread.php?t=709292&page=8

Also add in a SUB mounted Scott steering dampener from these guys
http://www.scottsonline.com/Stabilizer_Purchase2.php?Make=Suzuki&Model=DRZ&Bike_ID=4677&Year=2009&Size=400&Fred=

ACTwide ratio set
http://www.wheelingcyclesupply.com/shop/product/act-wide-ratio-gear-set/582

Kick starter with a manual decomp
http://www.drzparts.com/2010/03/dr-z400-kick-starter-install/

Sounds like a wepon hay. I hope so.

Some mods already done include;
JD jet kit for altitude in katoomba.
Pivot pegs
Seat and reupholster done by me
17lt safari tank
Cockpit rearrangement
Wind screen
Stiffer fork springs and shock done by tekniks penrith
Triple foam air filter
New nano lithium battery over a kg lighter than stock. It’s tiny. Had to pack the crap out it. But they supplied the packing with the battery.
I believe I am running a 14/47 gearing it’s great. Comfortably sits at 90/95 and can hit 120km no worries. Just about loud and it’s really working the engin.
I’ve not done the free power mod yet as in not running extra electronics but once the engine is out and all parts striped all electronics will be checked over and may even make a new wiring harness for it. (Got an auto leki in the family). Or just buy one.
http://www.thumpertalk.com/topic/541623-charging-system-diagnoses-plus-the-free-power-mod/

All in all I’m really stoked with the bike. It is burning a bit of oil though. Over about 500km I could use up to 250mil of oil during a hard ride(no pun intended). My guess is piston rings as there is no obvious oil leak. But not to worried about it for now. I just keep it toped up every week. And as it not a pressurised oil system I keep a few hundred mill extra in the frame.

So am I crazy or just plain crazy. It seams like it would be a great project. I’m planing to do the work myself with a mechanic over seeing the work and offering pointers along the way.

But The other side of my brain is thinking sell the Drz and get a 450 motocrossa like the crf450x or shall I say it. A ktm, as I think it’s one of the only 450s with six gears but expensive and more expensive parts. I would still detune flywheel, valves ect to gain a 5000k service intervals.

Who knows?? Probably stick to the Drz.
All the threads I’ve been following for the last year of Drz race’s who have done these mods and have floged em hard. There has been very little reliablity issues and a lage portion of riders are happy and would recommend the mods.

Any thoughts?
Queries??
Inqueries???
Statements????
Beliefs??????

Or anyone been down this road before and could offer some input on things I’ve missed or will need to consider.

All is welcome good or bad.