SUZUKI DRZ 400 SM 06

I bought a 2006 suzuki drz 400 sm completely stock. So far I have fitted an FMF exhaust. Work to be done:

Full Service,

Exhaust gasket,

Service rear brake

DRZ 400sm drz400sm Suzuki supermoto smf SM jap motorbike motorcycle

I have replaced the bulky stock mirrors with supermoto mirrors and a new kick stand spring so the safety switch is no longer activated over every bump

My Socket Set was looking a bit tired so I decided to CAD a new cover and then Laser cut it

The stock brake light is very bulky as are the indicators. I decided to replace it all with a tail tidy with integrated indicators.

Used some old shelving brackets to make a mounting point for the tail tidy

These are the resistors needed for the indicators to stop 'hyperflashing'. This happens because filament bulbs have a high resistance and LEDs do not. My new tail tidy has integrated indicators and they cannot 'hyperflash' or it will fail MOT.

In order to adjust the shock I needed to take the weight of the swingarm. In order to do that I needed a motocross stand or equivalent so I made one

Rear Brake Calliper has been completely rebuilt with all new seals and the whole system has been bled.

Rear brake is much more powerful and there is no more spongeyness

New CNC Levers

Panel Refurb

New Michelin Pilot Rear Tyre

New VS Old Airfilter

New 12K Headlight Bulb

Full service - bike now at 20,000 miles

New vs old oil filter

Countershaft sprokect seal replacement

DRZ Clutch Plate Replacement

New rear bake pads

New DID Chain and Renthal Sprockets

Sprocket bolts were seized on nuts. Had to grid the heads and then press them through to remove them.

New sprocket bolts and Rear disc brake bolts fitted

Trimmed the rear panels with a grinder then sanded for a more streamlined look

LED indicator relay so they flash the correct rate

Lasercut a sprocket cover

Wired a Civic horn as the old one was useless

Fitted New Blue Silicone Radiator Hoses

Fitted a New Headlight

New headlight and LED indicators fitted

Fitting a New tail light with integrated indicators and brake winker and a new license plate

Exhaust Baffle going back in as my hearing is only getting worse!

New mudguard to be fitted

Process of elimination, hopefully replacement radiator will sort the coolant leak

This is the frame oil drain bolt. Completely rounded. This is to be expected on a 11 year old bike that is ridden in all weathers. I had a shop remove it with a socket remover.

New oil and oil filter at 24,000. Took out the oil, screen and was completely clean.

Inspected magnetic oil bolt and minimal metal residue.

My bike was behaving weirdly and seriously juddering in 1st gear

It got progressively worse

I took it to Avsco and they said there was a fault within the gearbox and the engine would need rebuilding

To save on labour costs I attempted to remove the engine myself

Everything came off easily except this one bolt which holds the oil line in position

(the frame is used as oil storage on a DRZ

I tried an impact gun, mole grips etc no luck

Eventually I ground down the head and to my surprise after removing the oil line I unscrewed it with my fingers!

Engine finally out

after cleaning it I took it to TF motors for them to rebuild it

After stripping it apart they said it would not be cost efficient to rebuild due to the damage inside.

When I bought the bike it had a 440 bore kit on it. Whoever assembled this had done a bit of a bodge and missed a few washers in the gear assembly, however it served me well for 3 years and about 10,000 miles!

I use the bike for commuting so needed a replacement ASAP I managed to find a replacement with low miles and 2008 model so instantly snapped it up

By the power of facebook forums I managed to find a buyer for my old bike despite the engine failure. The buyer is based in Lithuania and has a rebuilt DRZ engine with a 440 bore kit but not bike!

So the deal was done and the bike is being transported as I type this

The buyer runs a motorcycle shop and will be rebuilding the bike from scratch with a FCR 39 mm carb and most power mods

After the buyer rove the bike over to Lithuania, he has rebuilt the bike with a bored out 440 engine, FCR39mm carb, Remus exhaust and black plastics. It is great to see it back in action.