DRZ400 engine prep

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phoo
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DRZ400 engine prep

Post by phoo » Wed Jan 13, 2021 2:32 pm

So, for those who didn't hear, my DRZ died on the KAT due to a partial seizure of the exhaust camshaft resulting in the sprocket being 90 degrees out of position (they are simply pressed in place, rather than bolted, apparently). So I have a new (to me) engine in the mail. Since the engine will be out of the bike, I figure this is the best opportunity to do everything "right" and hopefully never have to do anything else to it other than change the oil until I no longer have the bike.

The engine has a reported 14k miles. Of course, it was only used for commuting by a responsible adult who never wheelied, never rode it in the rain, and has never had a speeding ticket in his entire 40+ years of driving experience. :eyeroll:

So I already have top end gaskets and piston rings.

I'll do a valve adjustment.

Since it's fast and easy (though probably not relevant since it's a 2012 engine), I'll locktite the starter clutch bolts. https://www.createfixshare.com/articles ... bolts-fix/

What else should I do?


Thanks,

~Patrick
2003 Triumph Sprint ST :: 2004 Suzuki SV650R
2016 Beta 300RR :: 2006 Suzuki DRZ400SM
1975 Harley FXE1200 :: 2002 Suzuki SV650

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Firebolter
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Re: DRZ400 engine prep

Post by Firebolter » Wed Jan 13, 2021 2:38 pm

swing arm bearings, at least check them and packin' good or replace, same for the steering head bearings.

fix any oxidation or rust you may find in nooks and crannies of the frame.

Service the forks unless you are using the ones you have already that hold 10 QUARTS OF FORK OIL , THEN YOU ARE GOOD! :killingme:

Maybe look over the wiring loom and make sure all connections are clean and tight and no frays in the wires anywhere.

Thats a good list! Buy some beer, invite a couple of us up one day when we are not riding, and we could knock that out!
Lots of cool bikes---

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phoo
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Re: DRZ400 engine prep

Post by phoo » Wed Jan 13, 2021 2:47 pm

Oh, and "put in a big bore kit!" isn't in the list. If I could have bought a head with valves for less than I could buy a whole engine, sure, but that apparently wasn't in the cards.


~Patrick
2003 Triumph Sprint ST :: 2004 Suzuki SV650R
2016 Beta 300RR :: 2006 Suzuki DRZ400SM
1975 Harley FXE1200 :: 2002 Suzuki SV650

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phoo
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Re: DRZ400 engine prep

Post by phoo » Wed Jan 13, 2021 2:54 pm

Firebolter wrote:
Wed Jan 13, 2021 2:38 pm
Service the forks unless you are using the ones you have already that hold 10 QUARTS OF FORK OIL , THEN YOU ARE GOOD! :killingme:
SO. MUCH. OIL! I keep meaning to email the kid and tell him that the "busted" forks that he dumped off on me after he and his friends "broke" them was a simple, $0 fix. :)

Thanks for the list. Very good point that with the engine out, everything even on the frame is openly available and easy to work on so I'll give that a thorough going-over, too.


Thanks,

~Patrick
2003 Triumph Sprint ST :: 2004 Suzuki SV650R
2016 Beta 300RR :: 2006 Suzuki DRZ400SM
1975 Harley FXE1200 :: 2002 Suzuki SV650

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Boom Boom
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Re: DRZ400 engine prep

Post by Boom Boom » Wed Jan 13, 2021 4:02 pm

phoo wrote:
Wed Jan 13, 2021 2:54 pm
Firebolter wrote:
Wed Jan 13, 2021 2:38 pm
Service the forks unless you are using the ones you have already that hold 10 QUARTS OF FORK OIL , THEN YOU ARE GOOD! :killingme:
SO. MUCH. OIL! I keep meaning to email the kid and tell him that the "busted" forks that he dumped off on me after he and his friends "broke" them was a simple, $0 fix. :)

Thanks for the list. Very good point that with the engine out, everything even on the frame is openly available and easy to work on so I'll give that a thorough going-over, too.


Thanks,

~Patrick
Do those fancy Euro bikes that Bill rides need this much work? Asking for a friend..... :shrug:
2018 Montesa 300rr
Beta TR35 (garage queen)

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Firebolter
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Re: DRZ400 engine prep

Post by Firebolter » Wed Jan 13, 2021 4:03 pm

Boom Boom wrote:
Wed Jan 13, 2021 4:02 pm
phoo wrote:
Wed Jan 13, 2021 2:54 pm
Firebolter wrote:
Wed Jan 13, 2021 2:38 pm
Service the forks unless you are using the ones you have already that hold 10 QUARTS OF FORK OIL , THEN YOU ARE GOOD! :killingme:
SO. MUCH. OIL! I keep meaning to email the kid and tell him that the "busted" forks that he dumped off on me after he and his friends "broke" them was a simple, $0 fix. :)

Thanks for the list. Very good point that with the engine out, everything even on the frame is openly available and easy to work on so I'll give that a thorough going-over, too.


Thanks,

~Patrick
Do those fancy Euro bikes that Bill rides need this much work? Asking for a friend..... :shrug:
You bought one, you tell us! :loveit:
Lots of cool bikes---

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gots_a_sol
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Re: DRZ400 engine prep

Post by gots_a_sol » Wed Jan 13, 2021 6:42 pm

Wide ratio trans gears still a thing for the DRZ?
-Joe.

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Laoch
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Re: DRZ400 engine prep

Post by Laoch » Thu Jan 14, 2021 5:52 am

Six speed tranny?


New or upgraded stator.


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Re: DRZ400 engine prep

Post by smdub » Thu Jan 14, 2021 7:05 am

Good points. If you're already tearing it down to the piston, now is the time to put in that tall 5th gear.

But before you go that far (piston/rings), why not do a leak down test first? Used motor could be perfectly fine as is.
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Wingfixer
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Re: DRZ400 engine prep

Post by Wingfixer » Thu Jan 14, 2021 8:46 am

When I rebuilt the engine on my DRz I got it to this point:
Image
:deal:
F*** work.
Ride motorcycles.

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