Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Bodger Fix
DRZ400 fixes DRZ400 fixes
Register FAQ Calendar Search Today's Posts Mark Forums Read
Bodger Fix What they don't show you in the repair manual - tales of duct tape, bailing wire and WD 40. Bodge, Bush Mechanics, farmers fix, patch, temporary repair, or whatever your definition, tell us YOUR best story of a bodge that got you home!
Photo by Ellen Delis, Lagunas Ojos del Campo, Antofalla, Catamarca

I haven't been everywhere...
but it's on my list!


Photo by Ellen Delis,
Lagunas Ojos del Campo,
Antofalla, Catamarca



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 4 Dec 2013
Registered Users
Veteran HUBBer
  
Join Date: Jan 2013
Posts: 289
DRZ400 fixes
Lost a screw out the side of the bash plate whilst in the Caucasus's, it was banging about so I thought it would fall down on one side and cause me to come off.

Stopped and asked a local and he let me look around in his shed and i found some wire which i cut with his axe to make a quick fix and it was fine



My rear fuel tank emptied faster than usually, i found a hole in the fuel line, this was in Kazakhstan on a route where i was not sure how far it was to the next petrol station as people mentioned on this forum that this stretch of road can be remote for getting fuel so i needed a repair to fix it




I drained the fuel out and poured it in the main tank and then fixed the fuel line with my water hydration bag pipe







After it worked fine and i fueled up both tanks as had no worries with fuel on this stretch of road
Reply With Quote
  #2  
Old 5 Dec 2013
Big Yellow Tractor's Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jan 2008
Location: England
Posts: 649
I have various bits of wire in my "fix kit"

Plastic-coated soft garden tie wire; easy to cut and bend and also somewhat re-useable.

Thin stainless lock wire

Fence straining wire (maybe 2.0mm) easy enough to bend and cut whilst still being stiff enought to use as a hook or bracket.

Push-bike spokes are a handy source of useful wire. Next time you're in the tip, take some snips and have a rummage.

I also have some stainless-steel cable ties. They are the mutt's nuts for holding exhausts on and very strong.
Reply With Quote
  #3  
Old 5 Dec 2013
Registered Users
Veteran HUBBer
  
Join Date: Jan 2013
Posts: 289
Yes wire is great, plastic tie wraps are a waste of time.

Next time i will just wrap wire around the rear soft pannier frame for when i need it.
Reply With Quote
  #4  
Old 5 Dec 2013
mollydog's Avatar
R.I.P.
Veteran HUBBer
  
Join Date: Aug 2003
Location: california
Posts: 3,822
I'm not sure if the DRZ400S model uses magnesium side engine cases like the DRZ400E does. :confused1: These Mag cases are super soft. My shift lever punched into mine ... minor crack ... but leaking vital fluid out. Temporary solution? Chewing gum!! Worked perfectly, was on there for a week!

Finally got round to pulling the cover off and using JB weld on the inside.
Job done. Permanent fix.

So little ever breaks on the DRZ's (unless you crash hard) I'm amazed any repairs ever needs doing. Over loaded luggage racks will crack on any over land bike used off road. No surprise.

I carry two types of wire in my "misc." kit. 10 gauge plastic covered and thin safety wire. Used it only once ... saved the day.
Reply With Quote
  #5  
Old 8 Dec 2013
Registered Users
Veteran HUBBer
  
Join Date: Jan 2013
Posts: 289
Quote:
Originally Posted by mollydog View Post
I'm not sure if the DRZ400S model uses magnesium side engine cases like the DRZ400E does. :confused1: These Mag cases are super soft. My shift lever punched into mine ... minor crack ... but leaking vital fluid out. Temporary solution? Chewing gum!! Worked perfectly, was on there for a week!

Finally got round to pulling the cover off and using JB weld on the inside.
Job done. Permanent fix.

So little ever breaks on the DRZ's (unless you crash hard) I'm amazed any repairs ever needs doing. Over loaded luggage racks will crack on any over land bike used off road. No surprise.

I carry two types of wire in my "misc." kit. 10 gauge plastic covered and thin safety wire. Used it only once ... saved the day.
Yes i agree nothing really breaks (the above is just what i added to the bike) only other issues was rear rack bolts which where very brittle (stainless but not 316 grade) and snapped often due to cyclic stress

However i snapped mirrors and indicators often so now i just consider them as consumables but i lost a metal reinforced hand guard after one large fall off but got my moneys worth out of it.

The engine cases for both the E/S/SM are the same and crack easy when dropped, the engines are the same for all the bikes apart from the E being slightly more powerful by 4hp due to a few slight changes (cams,thin base gasket,pipe,ecu ect ect) including the FCR carb.

Pretty bomb proof bike shame oil changes are low miles, i was doing my changes at 3000 miles but now will do it a 2000 miles due to loss of oil towards the end of my trip and false oil level readings
Reply With Quote
  #6  
Old 9 Dec 2013
mollydog's Avatar
R.I.P.
Veteran HUBBer
  
Join Date: Aug 2003
Location: california
Posts: 3,822
Quote:
Originally Posted by WesleyDRZ400 View Post
The engine cases for both the E/S/SM are the same and crack easy when dropped, the engines are the same for all the bikes apart from the E being slightly more powerful by 4hp due to a few slight changes (cams,thin base gasket,pipe,ecu ect ect) including the FCR carb.
Sounds like your using your DRZ properly
Glad you mentioned the engine difference or E vs. S model. Having ridden both back to back ... and astounding difference in feel. Not just power ... but the E feels so much lighter. Quite a lot of differences in the engine even beyond what you've listed: Piston and cam too. The FCR carb makes quite a difference ... but a friend installed an FCR on his S model ... sadly, it was still a dog compared to
well tuned E model. I owned my E for 3 years. Never traveled on it ... just local Desert rides and once to Baja for a few days. Good bike over all but the S is the better overlander I guess. My E never used oil, valves stayed in spec and battery never went flat (no kick start). I changed oil about ever 600 to 800 miles. Mine had a very easy life.


Struggling through the sand on my former "E" model DRZ
Reply With Quote
  #7  
Old 24 Feb 2014
Registered Users
New on the HUBB
  
Join Date: Feb 2014
Posts: 16
Quote:
Originally Posted by WesleyDRZ400 View Post

The engine cases for both the E/S/SM are the same and crack easy when dropped
You can get aftermarket engine covers in carbon or aluminium, might protect a bit against harsh drops.
__________________
DRZ400 and Africa Twin
Reply With Quote
  #8  
Old 24 Feb 2014
Registered Users
Veteran HUBBer
  
Join Date: Jan 2013
Posts: 289
Quote:
Originally Posted by mollydog View Post
Sounds like your using your DRZ properly
Glad you mentioned the engine difference or E vs. S model. Having ridden both back to back ... and astounding difference in feel. Not just power ... but the E feels so much lighter. Quite a lot of differences in the engine even beyond what you've listed: Piston and cam too. The FCR carb makes quite a difference ... but a friend installed an FCR on his S model ... sadly, it was still a dog compared to
well tuned E model. I owned my E for 3 years. Never traveled on it ... just local Desert rides and once to Baja for a few days. Good bike over all but the S is the better overlander I guess. My E never used oil, valves stayed in spec and battery never went flat (no kick start). I changed oil about ever 600 to 800 miles. Mine had a very easy life.


Struggling through the sand on my former "E" model DRZ
Yes cams have higher lift on the E model but i thought the piston is the same as the S model?

Mollydog where are you getting your information for this as i would like to read up on it
Last edited by WesleyDRZ400; 24 Feb 2014 at 15:34.
Reply With Quote
  #9  
Old 24 Feb 2014
Registered Users
Veteran HUBBer
  
Join Date: Jan 2013
Posts: 289
Quote:
Originally Posted by Paulharris View Post
You can get aftermarket engine covers in carbon or aluminium, might protect a bit against harsh drops.
I fitted them and are alot cheaper than new engine case's
Reply With Quote
  #10  
Old 24 Feb 2014
mollydog's Avatar
R.I.P.
Veteran HUBBer
  
Join Date: Aug 2003
Location: california
Posts: 3,822
Quote:
Originally Posted by WesleyDRZ400 View Post
Yes cams have higher lift on the E model but i thought the piston is the same as the S model?

Mollydog where are you getting your information for this as i would like to read up on it
It's been a while Wesley ... I sold my DRZ-E in 2003. You could be right, but a quick look at piston part numbers may answer your question? Or could be it's a different HEAD design (higher compression on E model?) and Piston is the same?

Lots of info can be found here:
DR-Z 400 - ThumperTalk

The kids there talk about ALL DRZ models (K, E, S, SM).
I attended the DRZ400S intro in California ... the Suzuki guys covered some of the differences ... and can't recall every detail but do remember I was astounded just how different the bikes really are. (I think that was in 2001)

USA models had to pass our EPA/CARB regulations ... but I think the S is roughly the same world wide. The E model is Off Road Only ... so fewer restrictions.
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes
Linear Mode Linear Mode

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Found a Suzuki DRZ400 in Malawi larrysimpson Travellers' questions that don't fit anywhere else 8 27 Feb 2019 18:44
Zurich Switzerland: Bike Parts DRZ400 and Gear Ladies for sale muppet8mycat TRAVEL Equipment for Sale / Wanted 0 28 Aug 2013 19:14
Help with Suzuki DRZ400 chain & sprockets Brian and Tanja West and South Asia 2 23 Jan 2012 13:50

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 19:26.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top