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Diary - Project Dizzy - DRZ400SY
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TOPIC: Diary - Project Dizzy - DRZ400SY

Diary - Project Dizzy - DRZ400SY 5 years, 10 months ago #10717

  • Ben600
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So, as many of you will have seen, just over a week ago, I acquired Ferdie's DRZ400 which locked up at the safari in May, and would not change gear.

Thursday:
Thursday evening I went and met Ferdie with a friend in a van to collect the DRZ from him. surely an emotional visit on Ferdies part as it was his first bike (it's in good hands mate!). After helping him with a couple of bits on the TTR, which by the way is another cracking bike, we set on our way.
Upon arrival at home, I began the strip down, first off with the racks and numberplate holder, just for a view as to what I want to do aesthetically -


Fri,Sat, Sun:
The Friday was pretty uneventful, only to play around with the wheels to see if, out of curiosity, the Husky wheels fitted - they do.


Saturday, I embarked on getting the engine out. It was all going so well until I reached the last fixing, the swingarm pivot. Now, some of you may know that these can become quite well seized in there. I didn't until I found this one! no amount of brute force and penetrating fluid could budge it. even the biggest, heaviest hammer I could find would move it. So, I made a tool. A bit of 7mm threaded bar, with two locked off nuts one end and a big socket (bigger that the pivot's diameter) the other. With another nut after that.

This creation, along with a bit of a tap, cracked it out quite nicely. and so the engine was free!

after that the strip down began, but not until Monday eve.
One pic, that should explain the mystery of the low sitting DRZ -

I wouldn't have known these were like this until I stripped it! the needles were not letting the swingarm return to its proper position.

Monday:
The stripdown of the engine begins. Off with the head first - all in really nice condition, the piston relatively clean, if a little sooty. Cam Chain etc all good. now to strip the bottom!
I was quite surprised to find that very few bolts / nuts were to a reasonable torque - perhaps a side effect of vibration?
The strip was pretty straight forward. Off with the clutch, main crank pulley and balancer gear along with the gear shift mechanism. Then off with the left side case (starter motor comes with it), then its just 14 8mm bolts and a bit of very gentle persuasion and it looks something like this:

The first noticeable thing was that the selector forks were not located in the drum properly


At this point I must admit, I thought 'Result! that must be it' at which point I ran out of time so it had to wait...

Tuesday:
I rushed home from work to finish the strip (not much stripping, there are literally about 6 parts inside of the cases) and see if there was anything else amiss. I found this:

the Circlip for first gear crushed and mangled and the gear itself heat fused to the shaft - the cause of the lockup! (it should look something like this):

so onto eBay ! I ordered a full new Gearbox and whilst at it I ordered me a base gasket for the DRZ E model - these are about 3.5 times thinner than that of the S model (which this bike is) and is one of the differences between the two models (the S gasket is 3 parts riveted together, two plastic like parts with a thick metal in the middle, the E just a single thin metal). This 'mod' apparently offers decent gains due to raised compression I needed to replace it so why not!

Wednesday:
Not much, postie left me a calling card for the gearbox

Thursday:
Gearbox arrived with Gasket so on with the construction. All went together nicely, no issues. everything threadlocked where appropriate and torqued up. even setting the timing on these engines is a piece of p1ss - take the sight plug out of the left case, turn the engine until you see the line. In cam at 10 o'clock exh cam at 2 o'clock' push your finger in the CCT hole to tension the chain, if the arrows move from the horizontal, adjust by a tooth so they are level. put the cam retainers back on, the top guide and the cover on. done. at this point I notice the CCT (Cam Chain Tensioner) was knackered, so I've done a quick fix for now, pending a proper manual one.

Friday (Today):
Threw the engine in loosely and wired it back up - prodded the starter, nothing. Choke out, two pumps of the throttle.... Wooo! it lives! through the gears smoothly, neutral light works all good battery is a bit weak, but that'll be recharged fully - it's been sat a while!
Obviously, pending Swingarm bearings I've not ridden it yet. but it revs a bit more readily than it did, so I can only assume the gasket helps this.

Tonight I fitted my tail tidy to the rear end.



More to come when there is more...
We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<
Last Edit: 5 years, 10 months ago by Ben600.
The following user(s) said Thank You: DanH, East Coast, Twintec

Re: Diary - Project Dizzy - DRZ400SY 5 years, 10 months ago #10718

  • ferdie
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Well done mate. The mystery is solved!! Not long now and she will be away!! Roll on coastal camp.
Sometimes you're flush and sometimes you're bust, and when you're up, it's never as good as it seems, and when you're down, you never think you're gonna be up again. But life goes on.

Re: Diary - Project Dizzy - DRZ400SY 5 years, 10 months ago #10719

  • Twintec
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Great stuff Ben, and an excellent write up.

So when are you getting out of that office job and coming to work for me on the spanners?
If you only have one plug, it needs to be a good plug!
July 14 - still true, but now have two plugs!
The following user(s) said Thank You: East Coast

Re: Diary - Project Dizzy - DRZ400SY 5 years, 10 months ago #10720

+1 on what Tom and Ferdie said...

Just two questions if I may...the pic of stripped bike is sporting a blue coloured front mug guard...is that the correct pic or have you swapped it for one robbed off the Husky?

I wonder if the previous owner used the clutch to shift up and down, I often just flick it up and down without the clutch, moreso when on the trails though it's always at the back of my mind and haunting me that if I miss-time a down shift I could damage the gearbox and do even more damage to my bank account
Last Edit: 5 years, 10 months ago by East Coast. Reason: ADHD

Re: Diary - Project Dizzy - DRZ400SY 5 years, 10 months ago #10727

Well done Ben, as said now the swing arm etc is stripped it's time for preventative maintenance in the form of some grease nipples al la XR.
THE END OF THE ROAD IS THE START OF THE FUN

Re: Diary - Project Dizzy - DRZ400SY 5 years, 9 months ago #10804

  • Ben600
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Nick, that is the husky one. Just trying for size, as I like the shape (Yamaha yz426) and might sources yellow one.


Bit of a update, the bearings arrived and are in. The old, although the needles and inner case were destroyed, the outer cases were heat fused to the swingarm, what a bugger. TP and I managed to free them by cutting a slot and then peeling them out.

Also, the new gearbox, the threads turned out to havea little damage, where the breaker had hit them to free the shaft from the original engine. Again, we sorted these by using the engine power as a lathe and re dressing the threads

Last couple of silly (ocd) bits to go and I'll be out on it this weekend, all being well
We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<
The following user(s) said Thank You: DanH, Trevor Pastrami

Re: Diary - Project Dizzy - DRZ400SY 5 years, 9 months ago #10825

  • Ben600
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Taxed, Insured, coolant bled fully. just to swap the rear wheel (19'' is ridiculously big) and we shall be away in the afternoon tomorrow
We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<

Re: Diary - Project Dizzy - DRZ400SY 5 years, 9 months ago #10826

  • Ben600
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A good ride out on it today. About 30
/35 miles. Runs sweet, ive a few things I want to adjust, mainly suspension etc, but its such a different ride to the husky, its sooo smooth and simple, like a mountain bike!
Oh and the button, that magic button... Love it, especially with my love of axle deep mud!
Pics to follow when the laptop is fired up later
We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<

Re: Diary - Project Dizzy - DRZ400SY 5 years, 9 months ago #10827

  • Ben600
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We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<

Re: Diary - Project Dizzy - DRZ400SY 5 years, 9 months ago #10832

  • hornet
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Dirty boy

I might need to ask a few questions Ben as your clearly talented with a spanner. Just completely stripped my 2010 DRZ00E as after 4 long winters of lanning and commuting she really needs some additional TLC . I always do all the required stuff but hate the bike starting to look a bit tatty.

Mike
Id rather be cleaning my very muddy bike than driving a car

Get riding or get dying

Re: Diary - Project Dizzy - DRZ400SY 5 years, 9 months ago #10833

  • ferdie
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Ben is getting to be the regular ' go to ' grease monkey on the forum. The man that CAN
Sometimes you're flush and sometimes you're bust, and when you're up, it's never as good as it seems, and when you're down, you never think you're gonna be up again. But life goes on.

Re: Diary - Project Dizzy - DRZ400SY 5 years, 9 months ago #10906

  • Ben600
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At the last meet, I had a go on Dave's DRZ 'e', it felt completely different, where my S took a bit of winding up and all the power was in the mid and top end, his was all low down and a wonderful ride. It is an almost identical ride to TP's XR400 actually. I needed some of that!

So, on with the first after meet mod, a 13tooth (dropped two teeth) front sprocket - my oh my, what a difference, now I can lift the front just before a big bump and sail over it, whereas before I didn't have the power there to do it - it was more a plough into and through it job!

The next mod is these rad scoops - just to freshen it up a little, though they're on hold until a plastic tank comes up or a plain tank - I went to remove the old decals, but there are OEM suzuki silver shapes beneath, lacquered on so I'll wait



The last mod, for this week anyway, and by far my favourite acquisition - DRZ400e cams! these are the same as hotcams stage 1, and for the price I paid a bloody bargain!!! they'll be slotted in tomorrow night, and should transform the bike. I need no jetting to fit them, just throw them in and off we go



For now, that will do... but I read somewhere that a larger carb of Husqvarna and KTM may fit....
We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<
The following user(s) said Thank You: Twintec, ferdie

Re: Diary - Project Dizzy - DRZ400SY 5 years, 8 months ago #10923

  • Ben600
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After 20 mins in the garage this evening, the cams were in It'd have been rude not to have taken it out for a ride....




It is quite simply an immense ride
We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<
Last Edit: 5 years, 8 months ago by Ben600.

Re: Diary - Project Dizzy - DRZ400SY 5 years, 7 months ago #10998

Yep I knew that!
THE END OF THE ROAD IS THE START OF THE FUN

Re: Diary - Project Dizzy - DRZ400SY 5 years, 7 months ago #10999

  • Ben600
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I next need to bodge a similar strength lamp into my ducati headlight, that headlight is no better than a candle!
We’re not here for a long time, we’re here for a good time.

My Mum is running the Peterborough 5k Race for life for forum member Trevor Pastrami (Dad) Donate Here>>> www.justgiving.com/dottyhagerty <<<
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