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I have had a hankering for another motard since I sold my Duke2. I have been looking around for a bargain as $$$ are tight. I spoke to the Good Wife and we agreed that If I sold some excess components out of the shed I could do what I like as long as it was out of the sale of quality stuff aka Junk. The penny dropped shortly afterwards when she asked me if she just okayed me to buy another bike. Yep!!! I said happily .
I found a stunning KTM 2003 Supermoto with 7.700k’s and was busy ebaying and came up about $1000 short. While still looking, I was chatting to an Inmate on Advrider and he had a DRZ400e with a blown bottom end he was parting out. I was a week late as the front end, forks & tripples, were gone, but I was welcome to take the rest. this included a new Crankshaft, high quality valves, spring kit, cam chain and engine bearings.
I went over one Saturday morning and placed the items in the back of the Disco and happily trundled off home with the booty.
The Piston Barrel is Kaput so a bigbore kit will be on its way too.
I recently won a front end off ebay which came to the Skunkworks from Townsville. The Previous Owner had installed RM forks on his 2008 DRZ.
After much effort and assistance from me mate from Cobar, OldDog the swingarm pivot was removed, which had seized in there pretty tightly, and the engine was removed from the frame.
I was originally aiming at a Motard, but now will get it ready for off road. I am looking at a lot of optioons to get it sorted and back together.
I have a leg issue and dont use the rear brake and have been cosidering a Rekluse Z-start and Left Hand rear Brake.
With some of the parts already supplied, I went looking for a 434cc piston kit, viola JE Piston, new Barrel and gaskets from eBay usa for $426 delivered. I will have a bit of work carried out on the head while I am fitting the new valves.
Time to survey what I have, so out with the Camera.
As it sits on the Stand, pretty grubby. I will get the Karcher onto it shortly.
Well I have 2 Banana’s for Radiators. I will try to source some bigger capacity Rads from the USofA. Probably work out cheaper than buying genuine stockers.
Here is the 39mm Flat Slide
Looks like the Crank may have got a little Hot!!! Good thing it came with a new one
Also appears to have been some movemnet in the crank, how else can one explain this??
Camshafts look to be okay, so will keep them stock. The ‘E’ cams are pretty good out of the box I hear.
Probably the biggest challenge is going to be puting something back together that I didnt pull apart. I have the manuals and they will be getting a thorough reading!!
I’m looking forward to see how this all goes Pezz, you obviously have a sound mechanical knowledge as I have a Drz too and didnt know a lot of that stuff existed !!
Good luck !
Trailboss wrote:Pezz I maybe able to help you with any or most questions or things you do with that if you get stuck as I know my way around a DR pretty well, don’t own one but have fiddled with a few. I have one apart now that has been dusted and I have the head off.Steve from adventure Moto reckons you are an alright bloke so that’s good enough for me, can do house calls but you need to have you fridge setup right :laugh:
Check the DIY section there is some DR stuff there with more to come in the next couple of weeks as I finish off the two I have here in pieces :huh:
TB
Thanks TB
Whats your flavour . . . . dont do CUB beers :sick:
I will have the head looked at by a good friend Wayne Smith of Smiths Engine Research in North Parramatta.
What he doesnt know about engines . . . .
Dropping the head down tomorrow, might have some fun with it
Let you know the feedback
I have had a little chat with Wayne, maybe looking for 1mm bigger inlet valves??
I am also looking at Fluidyne Powerflow Radiators
High Performance Radiators ensure modified motors maintain peak horsepower by increasing the efficiency of the cooling system.
Water passages are 33% wider than stock for improved fluid flow.
Radiator cores are thicker than stock, providing increased surface area, cooling and durability.
Rugged construction features aircraft quality aluminum for strength.
TIG welded tanks, furnace brazed aluminum cores.
Billet filler necks assure leak-proof sealing.
Beaded inlet/outlet hose connections for positive sealing.
Direct fit design – no installation modifications required.
Race proven by Baja 1000 and GNCC winners.Whilst waiting for some parts to come in, my mind has been wandering to other matters, mainly suspension.
I am aware the DRZ400’s have limited rear suspension travel and being as I dont stand on bikes, my leg issue, I have been chatting to a couple of friends who know more than me
I remember seeing one modify the swingarm and dogbone linkages on Kevin Schwantz’s Safari DRZ400 to give the 300mm rear travel. So the swingarm will come out and head to his workshop in the next few weeks.
The other, Paul Rooney will rebuild the shock and forks to be suitable and give me plush suspension!
Should have a sweet handler then too!
Well got a free 30 minutes and decided to start the deconstruct.
They come apart easy, the other way will take a bit more time
It went from this
To this
To this
I have the frame stripped and the swingarm heading to be modified, now to tidy up the frame paint.
Anyone know of a place I can get a can of ’24K – Light Charcoal Metalic’ frame paint from?
I called the big shops in Sydney with no luck
I know of VG Auto Paints, who will mix up a special scanned colour match.
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