DRZ 400e Starting Problem (2004)

Hi there, my new (second hand) DRZ 400e 04 was running beautifully untill my mate dropped it fairly gently on the road when we were towing a bike back to camp (another long story where his wife's DRZ ended up in a river upside down...). When it dropped the left hand bar end hit the dirt road, he picked it up straight away.

From that point on it was hard to get the starter motor engaged, lots of noise from solenoid trying to throw the gear but kinda tapping it like it didnt have much power - once or twice it would just start and you could tell it had heaps of power.

I check all connections, pulled the started switch and the relay its connected to apart and check for anything lose, tried shorting out the connection to eliminate a dodgy switch.

Any idea on maintenance for a starter motor, or is it simply replacement time? Any idea where to get second hand?

Starter motors can be taken apart and cleaned and brushes replaced. Brush spring presure is critical. You really think it is the starter motor? More likely the battery, a switch or connection.

not the starter. Starter gets no power.

I press the start switch and i can hear the click of a relay behind the head light. I traced these wires back to something on the right hand side, attached to the frame, just under the seat. This is connected to the battery and the starter. When i hit the button my test light lights up on one of the wires coming from the front of the bike to this thing, but the starter doens engage.

Whats it called? I was gonna short out the 2 big wires, cos this is obviously what the switch does...but not sure if it does it with resistance or something...how safe?


It is the starter relay. A fair amount of amps travel through it. Put you + lead for your meter on the wire attached to the starter motor, ground the other, press the starter button. Get +12V?

I would check the wires from the clutch lever interlock switch though. They go from the lever to the wiring bundle behind the headlight. Disconnect and reconnect. If they are not connected, either re-connect or ensure the wires from the harness are securely plugged into one another (a bypass of the clutch switch).

Create an account or sign in to comment

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

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

  • Similar Content

    • By Markl5557
      Anyone’s air box smell like gas ? Is this normal ? Air filter is bone dry but it reeks in there .... I’m assuming cause of the carb being semi filled with gas ??
    • By Markl5557
      So I’m reading these horror stories of the stock vacume operated petcocks failing and letting gas into the oil .... how many of you guys switched over and is it worth it to switch to manual ?
    • By Markl5557
      Hey guys . I feel like I post here way to much lol 
      anyway after having my bike kn it’s side overnight to fix a cracked stator cover .... I come to find out that I also accidentally left the pet cock in the prime position .... constant gas flow to carb ... now my oil smells strongly of gas ... my question is ... was it the bike being on its side that made the gas get into the oil or the prime position on petcock that made this happen ? Or both ? I didn’t ride it much at all after discovering... I assume. I should drain the oil obviously but any other suggestions ? Always appreciated -mark 
    • By Praneeth143
      Hello guys , I have a suzuki drz400sm which is a 2009 model recently I purchased a rear sprocket which was a JT 41T , but I found that it did not fit to the rear sprocket hub of the bike and my drz has got the EXCEL TAKASAGO rims in it . How can I find one that fits and what sprocket brands and where can I buy it . I have attached pics of the current setup , please help me

    • By Surfman1
      Hello all, first time poster. Just bought this bike a few days ago it’s an 08 drz 400sm and am starting to notice it has a strange backfire at idle. I understand a little bit at decel might be normal, but at idle too?  It appears to have been jetted already, judging by the fact it has a jd jetting sticker on the bike itself. I know that it’s not an exact indicator it has but it could be. Has an FMF exhaust, it looks like a full system rather then a slip on but not entirely sure. A buddy recommended I mess with the air and fuel screw, haven’t done that yet. Just wanted to see if there was any other tips I should try.