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Another build thread - 2003 DRZ400E

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Picked up this 03 DRZ.  It had seen better days but had been converted to street use at some point.  I might have paid a little more than I should have but it came with a lot of extras and new things.  It has already been through the plating process, which is nice.  And a clean title, which I've found to be a rarity when looking at used bikes.  It's a little rough on the surface, but underneath it's solid.  Engine sounds good. Clutch feels good.  Shifts nice.  

Came with all new plastics.  Unfortunately they're all black and it's not my cup of tea.  He also had almost all of the factory plastics.  New DOT dual sport tires (along a decent set of non-DOT dirt tires).  Trail Tech Vapor.  Aluminum guards on everything.  Rebuilt carb.  

Here it is when I picked it up.

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I rode it a little bit after I got it.  But it didn't take long before I wanted to tear into it and get started.  

The levers were wobbly, the light was horrible in the dark, and I quickly started to hate the way it looked.

Fortunately the yellow tank was in great condition under the black plasti-dip...

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So the planning began and then I went and made some orders on eBay.

Ordered a new Acerbis Supermoto front fender in yellow

New black side number plate panels.  The ones on there were new, but he had cut them for the rack and I'm not keeping that rack on there.

New brake and clutch levers and grips, in blue.

New decals

New red 13" shock sox

New headlamp (not going to show this one off until it's done. I don't know if anything like this has been done on a DRZ and I'm excited about it)

New Twin Air air filter

New oil filter

New handlebar controls

Here are the decals I'm going with...

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While I'm waiting on the parts to come in, I'm cleaning all the aluminum with scotch bright, and I need to repaint the frame in a couple places along with the exhaust.  Thinking about just painting the cases too.  

I'll post more as I go along.

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 I've had an 03E for 8years, I got it bone stock with very few miles and it's been a great bike. After owning it for a couple years I re-jetted the carb and un-corked the exhaust, runs very strong. I plated it 2 1/2years ago, a very good decision. Looks like you have an after market exhaust, I wonder how the jetting is? Does it run real good? Anyways, hope you don't need to do to much work to her, keep us posted and good luck!

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6 minutes ago, Dmouse said:

 I've had an 03E for 8years, I got it bone stock with very few miles and it's been a great bike. After owning it for a couple years I re-jetted the carb and un-corked the exhaust, runs very strong. I plated it 2 1/2years ago, a very good decision. Looks like you have an after market exhaust, I wonder how the jetting is? Does it run real good? Anyways, hope you don't need to do to much work to her, keep us posted and good luck!

Thanks!

I'm not sure what size jets are in there.  Throttle response feels good.  I'm coming from a CBR1000RR so even at full throttle it feels a little slow to me.  This is the first DRZ I've ever ridden.  Been on a few KTM450x bikes lately and they were obviously quicker.  

I thought this would pull the wheel up easier than it does with just the throttle, but maybe my expectations are a little high?  Haven't tried pulling it up with the clutch.  

 

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 I'm older and don't try to wheelie much, but when I'm off-roading and need to loft the front end, it does so pretty easily in 1st or 2nd gear

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is it an E or a K (icker) ?

 

looks like its had plenty of good upgrades rad guards, skid plat etc, nice to get those on the bike already.

front should come up no problem my S w CV carb has NP in ist or 2nd and third is possible w a bit of a road dip and timing  no clutch just gas,  The FCR carb performs well when set-up properly but can be finicky when not .

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It is an E.

Thanks for the info.  I wasn't trying very hard to get the front up and to be honest I've only put maybe 5 miles on it.  :blink:

Hoping to have it back up in running condition in a week.  Depends on how fast UPS and FedEx get things to me.

 

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Found this on the stock fender that I'm going to reuse.  Would be cool if anyone recognizes it.  The title says the last title was out of Texas. 

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Got a plan for the wiring. Wiring is something I have a lot of experience with so I'm not worried about it but I'm not looking forward to it either. 

Here's a picture of all my extra parts I'm going to sell, give away, or throw in the trash. Some of the plastics are in great shape. Got a clear tank too that I forgot to take a picture of. And I'm sure someone would love to have this rack. It's solid and I have all the hardware for it. But not my style.  I see where they sell for $125 or more.  

 

 

 

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Edited by JINXR

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 Looks good, but I prefer to remain lowkey, I have the stock yellow/white plastics with the factory decals peeled off. I smashed my white headlight shroud last year and replaced it with a black one with a white number plate decal, the black matches the seat and rubber fork tubes... looks good and not too flashy

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No shortage of cuts-jumps in that wire harness. Half of the fun of getting it right will be trying to figure out why it was. I do see a Ford analog directional can. 

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6 hours ago, Gary in NJ said:

No shortage of cuts-jumps in that wire harness. Half of the fun of getting it right will be trying to figure out why it was. I do see a Ford analog directional can. 

Yeah it's a mess.  It'll look a lot better after I'm done.  Headlight and handlebar switches came in today so I have some wiring in my future. 

Kind of nervous about this headlight setup.  We'll see how it looks when it's done.  I have another idea if I end up not liking it.

 

Edited by JINXR

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Haven't had much time to work on this.  I did try buffing the original rear fender but never could get it to look very good.  Ordered a new one.

I also got the exhaust painted and ready to go.  This took a lot longer than I figured because a stainless bolt broke off in the end cap flange.  I tried drilling it out and extracting it but my extractor broke.  Finally cut my losses and drilled and tapped new holes with new bolts.  

So here is the shortened exhaust.  I was able to keep the spark arrestor and moved the tag over for it.

I'm the worst at before shots.  You can scroll up and see the original exhaust on the bike though.  Cut 8" off of it.  I did take a picture of the tapered inner perforated pipe.  I was able to cut a slit on the narrow end and fit it around the end flange.  Worked out well.

 

Before cutting:

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Broken screw and broken extractor :thumbsdn:

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New holes tapped for new 1/4" screws.  I had to temp everything up on the bike and get the alignment right.  I just spun this piece around then drilled new holes in the outer skin for the rivets so that it all lined up correctly.  The spark arrestor insert is in it in this picture.

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Old piece cut off and the USFS tag I kept.

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Spark arrestor

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Buttoning it up.  For some reason Pro Circuit used screws on the pipe end and rivets on the flange end.

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All done:

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Oh and here is a picture of the header after I cleaned it up and painted it with 2000F temp primer and paint.  I painted the radiator guards the same color too.  Hard to tell and again I forgot to take pictures, but there was an 1/16" of rust / build up on parts of it.  Took a long time to clean up.  I hit it with a rust treatment before painting it.  The muffler pipe was also cleaned up and hit with a rust treatment too.  I decided not to paint it because it's stainless and I like the way it looks as is.

 

Only picture I can find of the rusty header before I cleaned and painted itWhen I got it.jpg

 

After painting:

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Radiator guards:

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Edited by Doc_Possum
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I also removed the tank only to find out the petcock doesn't really shut off even in the off position.  So I had to drain the tank.  It looks like I might have a WR400 petcock already on it.  The inside has a gasket with 4 holes.  The edges of a few of the holes were torn so I tore those slivers off and flipped the gasket over.  Working great, but I think I'll get a clear hose to go between it and the carb so I can keep an eye on it.

The previous owner said gas kept leaking and he had the carb rebuilt to fix it.  So I'm also a little worried about fuel in the oil and if he ran it like that.  I'm going to change the oil anyhow just to be on the safe side.  It ran smooth when I rode it but I'm glad I decided to tear into it before I rode it much.

 

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Got to work on it some more this past weekend.  Getting closer!

Going with the Edge 2 generic tail light since I have an E subframe.  I took some time to seal it up to keep water out.

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I'll put some heat shrink on this part

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New levers installed.  Turns out I do not have the factory front brake lever setup, so I had to modify that lever to get it to fit.  Works great now.

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Cut this part off....

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Here's how it fits.  I have new grips, but I'm going to wait until I put new bars on to install those. 

 

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Clutch lever was a direct fit.

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Edited by Doc_Possum
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Rear brake was pretty wobbly and I found it was missing the spring and the bushings were shot.  

Got lucky and found a 2012 lever on eBay for $33 shipped that is like a brand new one.

 

Old lever...

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