DRZ400S prep, Going a bit mad here. What do I reasonably need to replace?
 

Hey all,

I'm prepping a 2011 DRZ400S for cross-SE asia and perhaps longer. The bike was purchased used with no maintenance history, and from what I can tell it was very well taken care of, however, based on the setup it seems like it was used for hard dirt riding with up to 14000 miles on the clock.

assuming no obvious current issues with the parts, what of these should I replace BEFORE the trip?

- Fuel Line
- Spark Plug
- Wheel Bearings
- Air Filter (TwinAir)
- Clutch Cable
- Brake Lines
- Bulbs
- Battery
- Anything else?

Brakes, Tyres, fluids, and frequent maintenance items (oil filter, etc) are obviously going, and I'm upgrading the sprockets/chain from the o-ring to DID X gold. Reading thumpertalk, they can be a bit over the top with parts replacement, and I don't want to waste money that I can use to keep the trip going!

Thanks a bunch! :D

I would ..
Dismantle and re-grease the rear suspension knuckle and swing-arm.
Service the rear shock.
Head bearings - check and re-grease; maybe renew.

I'd question the need to replace the brake lines.
How are the fork seals? I'd certainly carry a spare pair and dust seals

Did you even so much as glance at the top of the page in the Suzuki forum?
http://www.horizonsunlimited.com/hub...d-set-up-82596
Dave Lomax is a DRZ master ... his brief notes there is just a start. Lots more if you actually want to learn that bike. Adam (JediMaster) is another who has done lots aboard DRZ, traveled the world.

If you're doing lots of MUD it will NOT be a waste to buy a DID X ring chain.
I've done over 250K miles on them ... not one failure or problem and barely an adjustment.

Check the valve gear specs, give it a good listen, make sure Carb is dialed in.
Maybe bring spare pilot jet and Accel pump kit. Keep air filter CLEAN, decent quality oil ... should be OK.

I ran into lots of mud in Thailand and Vietnam ... bring spare rear pads. They wear out from drag.
bier

I've read that post so many times I practically have it memorized! I've already got the tank, bash plate, case savers, radiator guards, handguards, sprocket cover, seat, luggage, etc etc, but specifically wanted to know about parts replacement because a lot of guides (mostly elsewhere) are prepping for baja or other very aggressive desert off road, and because if i summed up the total of what every guide recommended I'd be out a lot of money and have some sort of bionic bike.

Anyway, thanks a ton for the advice so far, it's been very helpful

So is your DRZ in SE Asia now ... or in London? Where was it ridden mainly?
Are you shipping it to SE Asia? If so, IMO, that is a mistake as good, inexpensive bikes are available there. Shipping cost is HUGE ... and just dumb to do.

With so many km I'd also check the Swing Arm bearings and suspension linkage bearings. Any bike ridden in rain or done lots of stream crossings, those bearings will be rusted out. May as well check Wheel bearings and head bearings as well.

Good luck! bier

Bike is in London, but it's an import (being a 2011 in the UK) - I think from Australia given the tank and screen are from Oz.

I actually got a decent sea freight quote to Indonesia, and plan is to ride at least to India and decide what to do from there, possibly going straight back to the UK, possibly shipping onward from India to Africa or South America. In theory I suppose I could pick up and drop bikes the whole way through, but there's something about being on the same bike :scooter: .