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16 Tooth front sprocket install on my a DRZ400s (converted to an SM)

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I just, finally, got the 16 tooth sprocket on, and am in the middle of the install right now. I converted my 2001 DRZ400s to an SM and have the stock SM rear sprocket and a new chain with the stock number of links, and had the stock 15 tooth front sprocket.

The stock 15 tooth front sprocket has a rubber insulator and I wonder if it’s also a cushion of some sort where the torque of the engine passes through the rubber to a “tooth ring”… or if the rubber is just there to dampen noise… I’ll have to investigate. I bet it’s all metal from the shaft to the teeth.

Anyway, so far:

The swing arm rubber that sits right behind the sprocket on my bike needed to be completely cut out (just the area where the sprocket teeth will hit otherwise you’ll cut the rubber in half.. not good) and the 16 tooth sprocket actually wore a little of the aluminum off of the swing arm joint (it’s that tight of a fit).

Also, for those of you that have not tightened the three Philips screws that hold that rubber piece onto the swing arm (two screws on top, one on the botton); get out your screw driver. Mine were loose and they have never been touched. I have very low miles on the bike, was garaged for most of it’s life so those screws just have a tendency to loosen.

Anyway, back to it… more to come… I can’t wait to be able to go the speed of traffic on the highway (75mph) without hitting such a high RPM.

I’ll post how the 16 tooth front feels with the stock SM rear. I really want a nice highway cruising rpm.

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That sounds cool!!! I just ordered a 40 tooth rear sproket for my S model. I found a company in florida that will make sprokets down to a 36 tooth!!! I ordered a few of each and am trying to sell a few. They made me buy a bunch to make it worth their while. I am running a 15/40 set-up and it is awsome. I think I can acually run lower gearing and still pull with power. Let me know if anyone is interested. Send me a PM.

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I just, finally, got the 16 tooth sprocket on, and am in the middle of the install right now. I converted my 2001 DRZ400s to an SM and have the stock SM rear sprocket and a new chain with the stock number of links, and had the stock 15 tooth front sprocket.

The stock 15 tooth front sprocket has a rubber insulator and I wonder if it’s also a cushion of some sort where the torque of the engine passes through the rubber to a “tooth ring”… or if the rubber is just there to dampen noise… I’ll have to investigate. I bet it’s all mettle from the shaft to the teeth.

Anyway, so far:

The swing arm rubber that sits right behind the sprocket on my bike needed to be completely cut out (just the area where the sprocket teeth will hit otherwise you’ll cut the rubber in half.. not good) and the 16 tooth sprocket actually wore a little of the aluminum off of the swing arm joint (it’s that tight of a fit).

Also, for those of you that have not tightened the three Philips screws that hold that rubber piece onto the swing arm (two screws on top, one on the botton); get out your screw driver. Mine were loose and they have never been touched. I have very low miles on the bike, was garaged for most of it’s life so those screws just have a tendency to loosen.

Anyway, back to it… more to come… I can’t wait to be able to go the speed of traffic on the highway (75mph) without hitting such a high RPM.

I’ll post how the 16 tooth front feels with the stock SM rear. I really want a nice highway cruising rpm.

Did you have to grind your case saver?

I just saw a thread from a guy who did this conversion on his sm. Had to gring a bit of the case saver off. He popped the clutch hard on a start, chain broke, broke the weak case saver and popped a hole in his case!

Not sure what broke the chain, It was a new SM model but I was wondering if it was due to the over gearing. What is your current rear sproket?

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I run 15/38 gearing on my SM and it putts along just fine at 85 mph.

My speedo is an AceWell/Electrosport speedo, you can adjust the wheel diameter and get an accurate speed reading. So, I set my speedo to be dead on with one of those police radar stations they set up, to show you how much you are going over the speed limit in a residential area, anyway, I set the wheel dia. to match the speed indicated on the radar, DEAD ON.

The other day, I was on a straight downhill and hit 99:eek: actual MPH. I now know what a fast ball feels like. It was scary. I won't do it again. But the bike still had power almost to the limiter though. It was screamin' for sure.:applause:

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Something was wrong with the chain.

Even so, a ground down case saver isnt going to do its job. Just something to consider.

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Even so, a ground down case saver isnt going to do its job. Just something to consider.

Even a untouched case saver may not save the case. But it is better than nothing. The amount of material removed is fairly insignificant whan putting a 16T CS on.

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That's weird. I don't see how a SM could ever break a new 520 chain.

Must have been something wrong with the chain as Noble said.

The stock case saver is very, very weak, grinded or not.

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After grinding my case saver last night, I don't think it'll be all that good at saving the case. I don't think our DRZ's can bust a 520 chain. That chain that broke was defective or maybe if he didn't cut enough rubber to make room for the 16T sprocket causing the rubber to get caught between the chain and the sprocket, whipping it through, stretching the chain, and maybe that extra force popped it.

My rear is the stock 41T. I was thinking of going with a smaller rear but I want it to last a little longer so I thought it'd be better to have a larger front. And the front sprocket was only something like $10

I can't wait to try it out tonight after work. Was too late by the time I finished to go drive it around the neighborhood. :applause:

I had no problem going very fast on the highway with stock SM wheels/tires and the 15T/41T setup, I just want to lower the RPM.

Maybe 1st gear can get me through an intersection now without me wanting to shift once at a couple of MPH off the line.

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I don't think our DRZ's can bust a 520 chain.

Not a good chain, but it can certainly break an ailing chain... don't ask me how I know.

chain1.jpg

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Maybe 1st gear can get me through an intersection now without me wanting to shift once at a couple of MPH off the line.

What mph can you guys get in 1st? screaming mine i can get all but 40

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Some results are in and they be good results... :applause:

The 16T front and 41T rear sprocket is to shifting around on the road as the SM wheels where to making it handle better over the S wheels.

I'm very impressed. The only time I hit 5th riding around town tonight on my test run was to just see how it feels... 5th is definitely a highway or higher speed gear now.

It's going to rain here for the next forever (4 days or so) so I won't be commuting on it anytime soon BUT from the quick ride tonight, I'd say it's going to be perfect.

OR, you could do a 15T front and a smaller than 41 rear (whatever would match for the back... 38 maybe) but for the price of the front 16T (about $28 with shipping) you can't beat it.

I found the link for the sprocket on here somewhere but here it is just in case: sprocketspecialists.com 536-16 or 500-536-16. Mind you, you have to grind your case saver (and don't be shy doing so) and you have to cut out some rubber from the chain guide behind the sprocket. So far I can tell it was worth it though.

One last update to come after I commute on the bike.

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put 16 tooth sprocket on mine and love it. I mostly ride highway thats why I did it and it is great now. I can cruise at 85 if I want to without any trouble.

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Will a stock DRZ400S chain fit a 16/41

What about 16/47 (that's probably pushing it)

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I am using a 16/46 combo on my S. The snail is just on the number "1", I don't think a 16/47 will work - if it does you will be at the limit on adjustment. I bought the 46 rear so I could run the 16, or the 15, or the 14, or the 13.

Why the h#*l doesn't Suzuki put a wide range 6 speed in this bike. The DR350 had a six speed.

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...Why the h#*l doesn't Suzuki put a wide range 6 speed in this bike....
I second that!!!!!

I've changed sprockets for dirt, for the street when it was an S, now for an SM... if it just had a 6 speed, we could leave it alone.

I just have to reiterate; the 16T front and 41 rear really makes the bike feel like it was meant for the street and not an enduro with street tires. I CAN'T WAIT to drive it!!! Weather-man said it was going to rain today... it's been sunny all day and about 60deg F!!! I didn't commute in today on the DRZ because of the erroneous report :applause:

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Will a stock DRZ400S chain fit a 16/41

What about 16/47 (that's probably pushing it)

Stock SM chain will work . I've forgotten how many links difference there is between the two. I have room to move the wheel forward and back with my chain that has the same # of links as the SM.

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Stock SM chain will work

I run a 110 link on my S model. With the stock 15/44 gearing it BARELY fits. As a matter of fact, had I not used the new chain with my 15/41 SM gearing first to stretch it a bit, I'm not positive that it would have worked with the 15/44.

As near as I can tell:

16/41 yes

16/44+ no way

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