2019 DRZ400S Dream Bike Build

[Daniel Stephan]

From showroom stock to trail poaching beast...

Basically, the bike has been stripped down and built back up as a DRZ400S monster. 

Heres the list:

New black plastics

FMF Q4 exhaust (powerbomb header on backorder) 

Thumpertalk FCR39 MX carb full kit with all the options(which I highly recommend, extended flex air/ fuel screw, low profile choke knob)

JD jetting kit

Acerbis 3.9 gallon natural tank( not the 3.7) with locking cap

Protaper 7/8 bars and pad

Zeta integrated LED blinker hand guards with zeta triple clamp mounts, 12 o’clock industries LED blink rate plug and play module. 

12 o’clock industries , rear fender delete and LED blinkers / brake light

Subframe mounted rear rack

seat concepts (normal height) carbon fibre seat

Kriega front and rear fender pull straps. 

Kriega US 5 water proof rack bag

kriega bar mount pouch

Zeta clutch and front brake levers in black

Ram mount fold away mirrors

Ram mount GPS/ Cell phone mount

After Market Grips

JNS Engineering Full LED headlight kit

Devol Rad Guards

Devol full skid plate

Zeta extra wide footpegs

Zeta left and right foot levers

Thumper Talk case guards ( already came in handy)

Dunlop D606 front and rear tires

3x3 airbox mod

Zeta frame guards 

Zeta anodized bling plugs and caps

Moose Racing head lamp grill

Works Connection rear brake caliper guard and rear reservoir guard.

misc decal kit

Parts not yet on the bike ( fmf power bomb header,  Scott’s CNC machined one piece rear brake mount and disc bash guard)

Additional mods include:

clutch starter safety switch removal

Kick stand safety switch removal

I’ve been very impressed with this bikes performance, power, handling and look. With just a twist of the wrist, she throws rocks and dirt and is capable of power wheelies.

 I did however purchase a JD jetting kit for the stock carb in the event I want to realize better fuel mileage and go back to a tuned stock carb. 

 

 

Edited September 27, 2019 by Daniel Stephan

[bucket list]

Very nice, you almost don't want to get it dirty hey? And still probably cheaper than a Ktm/ Husky.

One thing, if you start riding it hard off road, hitting some bumps and obstical's at speed, your going to want to do the suspension. Increase the bottoming resistance of the forks and shock. Takes  the bike from scary to cush. 

[roleyrev]

That's a great build.  What sort of mileage do you expect from your carb and what sort of fuel range do you think you'll get out of the tank? Curious as I have a similar build going on.  I have a E version FCR39 and I'll be using my Safari tank (4.5 gallons). 

[Daniel Stephan]

17 minutes ago, roleyrev said:

That's a great build.  What sort of mileage do you expect from your carb and what sort of fuel range do you think you'll get out of the tank? Curious as I have a similar build going on.  I have a E version FCR39 and I'll be using my Safari tank (4.5 gallons). 

I’m running on the rich side with JD Jett kit right now for higher elevations 4000-7000. It’s a little Rich. I’m getting about 220km out of that 3.9g tank. I think that’s in the mid to high 35mpg. It will be better when I lean it out a bit which will give me a bit more power too. But overall it’s very torqued. Absolutely loving it. It’s my trail poacher. 

[dmoell]

Super nice bike, well done on the build.

 

[ohiodrz400sm]

Nice.

If I could make 1 suggestion I would recommend adding at least a stage 2 Hotcams intake cam. The off idle and roll on power will improve noticably. Adding both will cancel out some of the bottom end gain for more mid-range to top. Tight, single track type just get the intake. More open, western desert type riding get both.

[RetroRanger]

welldone  lookslike some thoughtful mods !!!

[Daniel Stephan]

7 minutes ago, ohiodrz400sm said:

Nice.

If I could make 1 suggestion I would recommend adding at least a stage 2 Hotcams intake cam. The off idle and roll on power will improve noticably. Adding both will cancel out some of the bottom end gain for more mid-range to top. Tight, single track type just get the intake. More open, western desert type riding get both.

The intake hot cam sounds like a good idea. I recently installed a stage 2 setup with a high comp piston in my CRF450r. Wow!!  What a boost for the dunes!

heres my question though... one of the main reasons I went with a DRZ400 was because the service intervals are extremely long. Low maintenance. This bike is eventually going to the far South Pacific islands where service is a novelty. Will HotCams increase the need for servicing? 

[Daniel Stephan]

11 minutes ago, RetroRanger said:

welldone  lookslike some thoughtful mods !!!

Thank you kindly. I’m adding new photos of new mods as they are completed. Just added one on a few moments ago

2 hours ago, dmoell said:

Super nice bike, well done on the build.

 

Thank you!

[ohiodrz400sm]

The intake hot cam sounds like a good idea. I recently installed a stage 2 setup with a high comp piston in my CRF450r. Wow!!  What a boost for the dunes!

heres my question though... one of the main reasons I went with a DRZ400 was because the service intervals are extremely long. Low maintenance. This bike is eventually going to the far South Pacific islands where service is a novelty. Will HotCams increase the need for servicing? 

I put Hotcams in very early on and graduated to Webs for the final 2000 miles of my valve trains 19k mile life. The rebuild was proactive since I was building a stroker. I never had to shim a valve other than when installing different cams. I talked with Brent from FastHeads after the inspection and he said everything looked to be in good condition.

Hotcams on paper are not that much different than stock E cams. I think most of the performance comes from the tighter lobe center separation.

 

 

[Ruggage]

Excellent mods and looks nice too. Looks ready for some fun. Also being a 2019 last year is cool. But I must be old school cause I miss the Suzuki yellow on the DRZ's. Just me on the color?

[mondrage]

Where’d you get the FCR39 from?
My DRZ400E came with a FCR39 that has never worked right.
I’m on the fence about just biting the bullet and getting a new one.

[topaz250]

On 9/26/2019 at 6:48 AM, bucket list said:

And still probably cheaper than a Ktm/ Husky.

 

Very nice absolutely, thinking no on cheaper than ktm/husky/honda. 2000 was a long time a go :-)

 

On 9/26/2019 at 7:37 PM, Ruggage said:

I miss the Suzuki yellow on the DRZ's. Just me on the color?

 nope, besides yellow was and is still the fastest.

[Daniel Stephan]

7 hours ago, mondrage said:

Where’d you get the FCR39 from?
My DRZ400E came with a FCR39 that has never worked right.
I’m on the fence about just biting the bullet and getting a new one.

Thumpertalk store sells it with all kinds of goodies 

[roleyrev]

On ‎9‎/‎27‎/‎2019 at 12:35 PM, Daniel Stephan said:

The intake hot cam sounds like a good idea. I recently installed a stage 2 setup with a high comp piston in my CRF450r. Wow!!  What a boost for the dunes!

heres my question though... one of the main reasons I went with a DRZ400 was because the service intervals are extremely long. Low maintenance. This bike is eventually going to the far South Pacific islands where service is a novelty. Will HotCams increase the need for servicing? 

Far South Pacific? Enlighten me I'm close to some of those. 

[Brick Top]

Very nice build. What about wide ratio gear set, best upgrade I have made to my scooter?

[Daniel Stephan]

Adding new pics and mods

[Daniel Stephan]

New Dunlop 606s , FMF stainless power bomb header and the Scott’s CNC machined one piece rear disc gaurd and brake mounting plate. 

[Daniel Stephan]

On 9/30/2019 at 6:08 AM, roleyrev said:

Far South Pacific? Enlighten me I'm close to some of those. 

Near Fiji. Where are you located?

[Daniel Stephan]

On 9/29/2019 at 2:02 PM, topaz250 said:

Very nice absolutely, thinking no on cheaper than ktm/husky/honda. 2000 was a long time a go :-)

 

 nope, besides yellow was and is still the fastest.

Still thousands cheaper than husky and KTM. The idea wasn’t to build a comparable bike though. Not going to happen. In the islands you want something robust , low maintenance and easy to fix with relatively easier to source parts from nearby first world countries. The DRZ fits this bill better than any other ”higher“ performance Type bike out there.  But yeah, even with all the mods, she’s still thousands less than the big boys.