Hi Everyone!
Never done anything like this before so hope I'm on the correct bit of the site to ask what mods people would suggest for my DRZ400 (2002) for a 3 week trip to Morocco this Autumn. This trip is an experiment for a 6 month long trip next year. Any help appreciated
Dave

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Pre 2003 suffered with failing auto cam chain tensioner so change it for a manual one or a newer post 2003 auto cam chain tensioner as in 2003 Suzuki updated the ACCT to utilize a ratcheting mechanism, which prevents the tensioner from retracting in the event of spring failure

Must haves if i was going

case savers both side
Radiator guards
good bash plate
larger fuel tank (i prefer the IMS 17L tank to the others)
wider seat
hand guards
Loctite all bolts associated with the stator as they come lose and the stator fails, for your long trip take a spare stator to be safe

if this is a new bike then when you do a oil change check there is still a small rubber o ring sitting inside at the back as alot of people forget about this, make sure there is a copper washer on the sump drain bolt

oil change at 3000 miles max, check oil daily also 10/40w semi syn, clean and oil air filter if traveling in dusty areas and wash it often if dirty..... as if sand gets in it will need a new barrel and piston

nice to haves

wider foot pegs
bar risers you can move forwards and back
small plastic wind shield
metal oil filter so it saves you carrying lots of spares, also filters finer
better headlight as the standard headlight is crap but if you don't ride at night don't worry about it
Standard forks/shock are fine if you set them up right and you travel light, that's is on the S model as the SM model (USD forks) fitted with 18/21 is shocking to ride and handles crap

Also the 3x3 airbox mod with correct jetting & aftermarket pipe/can is a noticeable difference in power and worth it but depends if you care really as fine without

Thanks Wesley
Sorry for delay in replying but I'm not particularly tec savvy and had difficulty locating my original post!!
But thanks again
Dave

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Definitely take heed about the stator, they tend to fail regardless of the electrical load being placed on the system. My thoughts are that over time the oil temp breaks down the insulation on the coiled wires. I would be inclined to change out what is there for a new stator and maybe carry the old one as a spare.
If you can get hold of the headlight assembly from the Japan only release DR250 Djebel it makes a great replacement unit and also gives you somewhere to mount a screen. I used a BMW F650GS screen on mine and it worked a treat until I went through it.
I'm on a long trip on my bike through some pretty harsh country and apart form the stator the bike has been flawless, even up to altitudes of 4600m in the Pamir. Japan to Russia to Mongolia then Central Asia, now waiting for the ferry to Baku. You might also consider dropping a few teeth on the rear sprocket, I found a 41 worked fine but would have liked to try a 39. Of course that will depend on how much technical off-road riding you intend on doing.

It wouldn't hurt if a mod was to come along and move the thread into the Suzuki tech side of the HUBB from this HUBB Pub.

That's a good check list for the weak points of the DRZ.

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Dave

As for the stator issue i got hold of a electrosport stator which according to some of the guys on the USA thumper talk forum is the best stator you can get for a DRZ400, they state "winding configuration that offers about 40% more output over stock "

I brought my stator new from the UK on ebay for £80 which also came with the upgraded rectifier.

However i have not seen any more apart from in the USA for $140 direct from electrosport

I am fitting this to my DRZ470 when i finally get round to finishing it.

Buy New Stator Suzuki DR-Z400 DR-Z400S (00-11)


ESG180 is a higher output stator that replaces the OEM stator in the Suzuki DR-Z400 and Kawasaki KXF400 models. ESG180 is manufactured on a modern stator core with the highest grade copper wire installed using modern computer controlled winding machines.

The new core offers super low magnetic resistance and the high grade copper wire offer low resistance and therefore comparably low heat generation in the windings. We chose a winding configuration that offers about 40% more output over stock which works very well with these engines.

ElectroSport installs very high grade lead wires on these stators that are abrasion and heat resistant. These lead wires do not nick or get soft during operation, even with the high output used to the max.

ESG180 is a plug in replacement and offers superior output and reliability compared to the OEM stator.

Like all stators manufactured by ElectroSport this ESG180 also comes with a full one year warranty.

Suggestions for Suzuki DRZ400 mods There was a pun in there.

+ They have some very useful tech info about charging systems.
http://www.electrosport.com/media/pd...ng-diagram.pdf

http://www.electrosport.com/technica...ting-guide.pdf

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Dave

Yes the price is higher than most but as the stator is the weak link on a DRZ i suppose you get what you pay for on this replacement part as it has many high reviews compared to other aftermarket stators which fail before the standard (+20,000km)

I knocked this out when I was bored a few years back. It's got most the mods covered.

http://www.touringted.com/drz400s-overland-prep

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Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

Yes i used this checklist covering items on my DRZ 2 years ago.

The local Suzuki dealer stated the stator problem is the most common problem for DRZ's coming in the workshop back in the day.