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DT125R Forum -> Projects -> 2002 DRZ400E Project!
Post Info TOPIC: 2002 DRZ400E Project!
threadsta


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2002 DRZ400E Project!
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Hi guys,

Been a while since posting on here but alot has happened and I thought I should make a project thread for the DRZ :)
Got it back in October and literally rode it for two days before it went bang. Was riding it normally and all of a sudden it died with a lot of loud noises :@ Turns out two of the bolts holding the stator in had vibrated loose and destroyed it. The stator was then replaced and new high tensile bolts were loctited in. Once it was all put back together I was amazed to find out it wasn't starting. Since then a ridiculous amount of money was spent trying to find the problem and do other things while the bike was appart.

Work carried out included

-Checking valve timing/clearances
-Replacing valve stem seals
-Checking piston/bore condition
-Replacing cam chain
-Replacing cam chain tensioner with the recommended one
-Cleaning the carb
-Trying to start it with ez start and oil in the cylinder head
-Cleaning air filter
-New sparkplug
-New battery
-Checking the pet****
-New CDI Unit
-New battery

and much more :(

Pictures when it was off the road

The incredibly complicated 39mm fcr carb


The first little bastard that caused the problems







The problem was finally found just before christmas when we were trying to start it after adjusting valve clearances with different size shims and acidentally left the cable connecting the stator unplugged, it started straight away! and then not at all when the cable was connected haha. So that was another stator to be replaced, turns out the actual heads of two bolts had sheared off this time! Anyway the new stator was fitted this time with genuine suzuki bolts and the bike was back on the road christmas eve.
Oh and also crashed into a volkswagen polo head on at 30mph, just my luck :L surprisingly only damage to my bike was a bent key hahaha. However the polo had been left with a very large drz shape in the front :D

Also slowly been fitting new things here and there


Trailtech vapour was the first thing as I had no speedo at all before


New rear light and number plate which quickly began melting


Exhaust header heatshield as waterproofs were melting:L



Oxford heated grips



Wheels cleaned and new chain/sprocket kit fitted with different sizes because it wouldn't even cruise at 60mph

Other various pictures



Bike is now on the road daily but burning a stupid amount of oil -.- which im guessing is new piston/oil rings?

Also got quite a few things planned for it
-Make up a deflector for the end can
-Replace bolts with hex ones
-Bendy levers
-Hand gaurds
-Case savers
-Fork spotlights (ktm sort of style)
-More sliders e.g. footpeg/barends
-Possibly spoke skins
-Hel lines
-Bar mirrors



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GoProKid95


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Nice one man! Seems like you've done a lot of work. You're not the only one who has a bike that causes them jip. Mine does too! ;) haha see you around!

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Calum122


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Nah you've just given yourself a two stroke if it's burning oil...

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The Leviathan Project
threadsta


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A few parts have been ordered to go on the bike.

Acerbis handguards

www.ebay.co.uk/itm/300933375750

Couple of stickers

www.ebay.co.uk/itm/171237228698
www.ebay.co.uk/itm/200887048293

LED Spotlights for the forks

www.ebay.co.uk/itm/400583486542

Jack up kit

www.ebay.co.uk/itm/251424181847

TNT MX headlight but in white

www.easyparts.nl/showarticles_info/0118448136/0-4019-516-295-1073/Headlight_Unit_TNT_Cross_Black_Universal_Motos.html

Bendy levers

http://www.ebay.co.uk/itm/Racing-CNC-Pivot-Brake-Clutch-Levers-for-SUZUKI-DRZ400S-SM-2000-2013-/321234583975?pt=UK_Motorcycle_Parts_13&hash=item4acb12c1a7


Post will be updated again when the parts have arrived and been fitted :)

Also still trying to fix the oil problem. Thought it could have been the crankcase breather but that was cleaned out and still nothing :/. So I ordered a piston/oil ring set to see if that is the problem.



-- Edited by threadsta on Sunday 2nd of March 2014 11:25:11 PM



-- Edited by threadsta on Sunday 2nd of March 2014 11:26:50 PM



-- Edited by threadsta on Sunday 2nd of March 2014 11:27:47 PM

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Victor


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beast! and probably head gasket if it's burning oil?

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Luke


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Who is riding your DT when you're on the DRZ?

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threadsta


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Yeah I thought it might have been but i'm not losing cooling or overheating.

I sold the DT to one of my friends who was riding it.

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threadsta


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Made up a slider for the exhaust



And also the headlight arrived






Not 100% sure on it :/ but it's still not mounted properly though



-- Edited by threadsta on Wednesday 5th of March 2014 11:11:46 PM

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oli_125


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Lookin good mate! The headlights aint very bright though! Ive got the other twin style apico one, there just bathroom lightbulbs haha

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threadsta


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Haha yeah they're terrible.Thinking about buying some acerbis replacement bulbs

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threadsta


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All the parts have arrived and been fitted now apart from the levers as they're from coming from hong kong.







The spotlights are so much brighter than my headlight haha



A friend of mine got an r125. They're actually quite nice :L

Went for a ride with him and stopped off by the suspension bridge.



Liking how every thing looks just need to make a bracket for that headlight and fit the new piston rings now.

Also got the bike dyno'd a couple of weeks back. 43 hp :D



-- Edited by threadsta on Monday 10th of March 2014 10:50:02 PM

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GoProKid95


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Very nice, looks like she is coming along nicely! :) Glad to see it on the road clocking some miles! ahah we should meet up for a ride some time! :)

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