Jump to content
Sign in to follow this  

DRZ400SM Jetting & Exhaust


JDinLakeside

Since there is soo much talk about jetting DRZ400's with air box mods and exhaust mods I thought I would post my recent results. The mods to my new 2006 400SM went for the most part well.. Learned alot of lessons with my DRZ-400S .The mod part list is: Yoshimura 2165500-SA, DynoJet 3110.001, K&N SU-4000, assorted 4mm Allen head machine screws, and a MotoBits footpeg eliminator stolen from S model. Ebay has MotoBits kits avalible.

1. First I removed all the plastics, seat and tank; I also temporarily removed a couple of the factor zip ties to make room to work.

2. Remove TPS from carburetor, gas line; removed vacuum line from gas petcock, removed vacuum line from gas shut-off valve.

3. Removed throttle cables from carb.

4. Removed gas tank.

5. Loosened right heel guard and dismounted rear break reservoir from frame.

6. Removed bolts at lower frame holding rear fender assembly.

7. Loosened the clamp of the manifold side of the carburetor and the clamp at the rear which connects to the air-box.

8. Raise rear fender – I used an old cardboard box to hold it up in place.

9. Rotated carb and wrestled that booger and out!

10. Installed DynoJet stage two jet kit – 155 main, DynoJet needle (2nd clip from top) and slide spring – when I removed the bowl – I used a needle nose vice grips to break the screw loose – then threw the screws away and replaced them with 4mm Allen socket machine screws of the same length.

11. Drilled out idle mixture screw plug – set idle to 3 ½ turn out from bottom.

12. Re-installed carb - (Note: I also replaced the screws for the TPS with 4mm Allen head machine screws, washers and lock washers.)

13. Removed factory header, exhaust can and passenger foot pegs.

14. Installed new Yosh header pipe – left loose.

15. Separated and installed Yosh mid pipe.

16. Installed exhaust can; tossed the steel spacer and installed the new exhaust mount to the hole rear of the factory mount – I think the Yosh directions may be wrong.

17. Reattached the rear break reservoir and installed and tightened up all remaining frame and mount points, then tightened the header pipe at the engine exhaust, and reinstalled the factory heat shield to the mid pipe.

18. Cut a 3 inch square template from cardboard and drew lines on top of the air box with a grease pencil.

19. I then used a sheetrock knife heated up with a propane torch to cut the 3x3 hole in the top of the air box.

20. Removed stock air cleaner element and installed K&N filter.

21. Reinstalled tank, plactics and seat, cleaned exhaust system with Windex.

1st Test Run

22. Bike was difficult to start –needed full choke (man I should have learned from experience with the DRX 400S!) I finally got it start- but it ran like crap.

23. Run the bike up the street and promptly run out of gas.

24. Roll bike back to garage and do a visual inspection.

25. Put the vacuum line on the gas petcock

2nd Test run

26. Bike starts easily, idles wells and runs great…

27. Removed rubber inserts in footpeg, passenger strap in seat, front reflectors, trimmed rear fender and applied appropriate decals. Performed 1st Oil and Filter change (it had a 100 miles onthe bike.)

If I left out some steps I apologize – but I think you can get the gist of things…

  • Like 1
Sign in to follow this  


User Feedback

Recommended Comments

There are no comments to display.



Create an account or sign in to comment

You need to be a member in order to leave a comment

Reply with:


  • Similar Content

    • By Aidan O.
      I have a 2004 jr 80 that has something going on with the clutch. The clutch turns over the engine when in neutral. This is because the inner basket doesn’t spin freely when in neutral. The inner basket spins when the nut is torqued down, and when the plates are in. It also spins freely when pressure plate is not screwed. The pressure plate seems to be applying too much pressure to the plates, that even in neutral it seems the bike is in gear because it turns over the engine. 

      All washers and bearings are accounted for. I’m very lost about how to resolve this.  Some help would be great. I’ve looked all over the web for solutions to no prevail. Thank you. 

       
       
    • By I can handle it
      I am interested in a couple old 2 smoker bikes , they are 01 rm250 and 02 rm 250
      i found a couple that are 03and newer, but I’m curious about the older one. 
      I am trying to be prepared when I get a new bike and I cannot seem to find Hardly ANY engine rebuild kits (wrench rabbit) for the 01-02 models or cannot even find even exhausts for those models or anything.  Was wondering if there is a certain company that hold engine rebuild kits and other parts for these bikes, or if I should just stray away from the 01-02 parts? Thanks for any help guys
    • By gibsten films
      I am doing a stunt build on a 2015 DR200s I don’t wanna use the drum brake tbh I don’t trust it and it’s not working to well when at balance point (I tighten it and it just locks up or won’t go where it needs too plus I’m doing a handbrake in the future for seat standers.) I need to know what swing arm will fit the dr200, I think the dr250 swing arm will fit and it also allocates for disc brake because the 250 uses disc, If I am right this conversion will cost me 650, ( not including hand brake. ) I wanna do this because I’ve never seen a stunted DR200s and I wanna be unique. I have the cash to do this I just don’t wanna buy the parts and then be out 650, I wanna buy it all at one time. (Handbrake after I get good with the foot brake after conversion) please and thank you all for the help. I just need to make sure before I buy, if not what will fit? 
    • By Leeb219
      So after finishing my 1992 RM125 project bike I decided to buy another RM. This time it’s a 1995 model I picked up for €100 (around $120) The bike was left outside for many years with the engine kept indoors after a powervalve slider broke. Anyway here it is & what I’ve done so far. The engine bottom end seems good, so I have ordered a new top end kit and a water pump kit. Once I know the bike runs good, then I will start ordering the behemoth of parts it needs. 












×
×
  • Create New...