DRZ-400 Rally Raid Big Bore Engine Build (Under 450CC)
I've been away from the forum for a bit, after I ran the DRZ into the ground and couldn't fix it until now. I've read through many posts about big bores, but most of them are aimed at max HP and things like that. I'm not looking to make 55HP, but my engine is done so it needs everything.
I ran the bike on the highway for too long, didn't check levels properly, vaporised all the oil and ruined the engine. The big end is gone, the cilinder wall is worn, the cams and chains are worn and even the valves are having issues. I ran it for a while with all these problems, since I had not other transport. Gotta love a bike on a budget....
For the last few weeks I've been looking for big bore kits and info on them. I want to build a DRZ that does a bit better on the highway, has more power overall but want it underpowered and overbuilt. Towards 50HP would be nice, but not a requirement. My budget is decent, but not endless, which gives me a problem: there are soooooo many brands and styles around, I can't see the forest through the trees. The prices differ immensely, as does quality. On top of that there are setups that just run on race gas, which I can't over here, so I'm looking for a streetable setup.
Since I live in the Netherlands, Europe, I have to ship everything over, and to save money in the long run I would rather spend a bit more initially and get it right, instead of getting three different kits.
Its a 2005 SM with a stock engine, I will get:
Big Bore cilinder (not set on cc's, but looking around the 470 range)
Stroker crank/rod (crank is most likely done)
Cams (don't need super hectic lift and duration)
Carb (39 or 41)
All the consumables and bearings
Its fitted with a Leovinci 3X, have the 3x3 mod, valve and other smog stuff is removed.
Not a brand fanboy specifically, I've looked at and could find out about them:
MaxRPM, both IceCube and the Stealth, looks great but pricey.
CilinderWorks, not sure what their quality is but they're cheap.
Athena, mixed reviews and medium pricing.
HotRods cranks, famous name but no idea on durability.
HotCams & Web Cams, I don't have a preference, whichever gets me the best cam.
And a bunch of brandless cilinders, packaged with branded items. Impossible to find out what the level of quality is.
Who can help me out on deciding on this setup? More top speed, more power over the whole range, but rather have less power and more reliability than maximum RPM. I know the best solution is OEM, but since I'm building it, I might as well add to it.
Looking to get my second dual sport. Ive been riding for 3 years on my DR200. I mostly prefer single track and technical riding.
I recently test rode the DRZ on dirt. I liked the extra grunt, but found it too tall for my legs and too top heavy for my riding style.
Anyway, I like what I've read about the KLX250's suspension and aftermarket mods. I see "easy install" kits and directions all over, but no information as to how the 2018 kid's EFI will change installing these kits.
Will it require an aftermarket EFI? Or possibly even a carb swap kit?
I blew up my '14 drz S a few weeks ago. Started, and ran cold up to to redline one the highway. I know it was dumb. But i have since installed a big bore kit and stroker crank. I also had the head serviced with new SS valves and had it ported and polished at Fastheads.
I was running the 3x3 mod, and a JD jet kit. Everything else stock.
Wondering if the bike will run well with stock carb and pipe, and what jetting to use.
If it will run like crap, what carb and pipe do I want to run? (I want a quiet pipe)
Normal operation is at 600 ft and cool, but do travel to colorado often.
I just bought a 1982 XT250 project bike. We had one of these in the family in the 90s, so I know the model fairly well already. I guess my plan is just to have a small, simple bike for shorter local trips, and maybe some light trail touring. I do know it has some known weaknesses, i.e. suspension, brakes, 6V electrics, corroding mufflers, and open frame/exposed engine cases.
So I am looking for tips regarding big bore/ higher comp pistons, camshaft (Web Cam) stiffer shock, fork springs, 12 V upgrade, and so on. I was also thinking about fabricating a stepped SS headpipe, and use a 1 1/2" inlet Supertrapp IDS2 muffler.
I guess the weight saving will be replacing heavy stock parts with lighter parts in alloy etc (Sprocket, handlebar, rear fender reinforcement for tail light etc), and using smaller/ lighter tail light, indicator lights. And also replacing the stock instruments with a digital dash from KOSO, Trailtech etc.
Any and all tips are welcome!