DRZ 400 preparation for the Trans America Trail

[dougfromindy]

major work on that bike and its more than ready, looks really good. I would leave on a much less prepped machine, no worries, have fun.

[One Less Harley]

Originally Posted by dougfromindy

major work on that bike and its more than ready, looks really good. I would leave on a much less prepped machine, no worries, have fun.

Don't have the swing arm back on yet, so it might be a little difficult!!! Part of the fun for me is prepping the bike. As you can tell I like tinkering and modifying things. Taking the time prepping the bike will hopefully head off problems before they happen and make ridding more comfortable. I worked on a mount for the chart and Sopt holder. Chart holder is in position, couldn't mount the Sopt holder till the plastic cradle shows up.

Heck I can't leave until June sometime, so there's time to tend to the little details. Think of the modification post as something to be endure before the good stuff!!!

[Flyrotax]

My XR650L stock was 15-45. I had changed the 15 to a 14 for the ride, and thought that would have been fine. But during the ride there were several times when you almost lug and stall the motor going up very steep trails with sharp switch backs.You do not want to slip the clutch on a long ride through remote areas, having a reliable bike is the name of the game. I now run the same 14 on counter shaft and went to a 48 on the rear. That is equal to a little over 10% in lower gearing. the top speed of the bike is still 75MPH plus. Also the motor does not have to work as hard resulting in running cooler,and smoother.My 2 cents worth.
Bill

[Tall Mike]

If you have countershaft sprockets that will both work on that length of chain, you can go small in the mountains and put the big one on in the open country. A countershaft sprocket is a lot easier to change (and carry!) than the big ring!

I agree, you want slow speed on the mountains...there are some technical rocky patches and places you NEED to go slow!

There are several RR's with DR400's out there... (probably the most popular flavor of TAT bike right now!)

[Ed Muggles]

looks like your off to a great start i look forward to following you on this one :P

[One Less Harley]

Parts are coming in way to slow!!! Got the "new" radiator installed which was painless. Finished fabricating a mount for the Roll chart/ spot holder and took it to the powder coater. The 44T steel chain ring came in too, so it got slapped on, after cleaning up the threads to the bolts, plus a little lock tight on them. Also the carb float bowl gasket arrived, so that's in place too.

Extra clutch and throttle cables have arrived.

Thinking of mounting the eastern beaver fuse panel just behind the battery and in front of the tool tube. Of course it'll need a bracket, plus another box around it to protect it from the weather. I can't locate a potentially dry out of the way place for it, there just isn't a good spot for it.


Still no swing arm bearings!!!!

A note on the shock upper link bearing replacement from All Balls. The top bearing and bush are steel. The one in the bike looks to be stainless, beacause there is no corrosion on it. Also the outer race on the ball pivot looks to be split and rolled around the inner pivot. The is a very small hairline visible on the outer edge. Crappy!!! I'll be putting the old one back in w/ the new seals.

[mikegc]

I'm an old enduro rider and thoroughly enjoying reading about your prep work. "You'll do well, pilgram." Thanks for taking me along.

Mike

[One Less Harley]

OK, since some people can bare with my preparations, here's some more for you...

Here's a shot of the upper shock link, see the hairline crack in the outer race, and it's three pieces. Plus look at the metal compared to the original. I've noticed that Moose sell one that looks like the original. Also it's all one piece!!!



Oil on the bearing makes it look worse than t really is.



Stock one piece upper shock link bearing. I'll be reusing this!




The outer swing arm pivots were shot, full or rust and zero movement of the bearings!!




Knocking the old one out.




Another issue w/ the All Balls bearings, the spacers, just aren't like the stock ones, No side needle bearings in the kit, instead there is a teflon coated shim. Not saying that is bad though. I don't like the all balls bearings, they are a compromise!!! Wheel bearing and head set are fine, but don't use the swing arm or shock link kit.

More info on the All Balls bearing kit (here).

I screwed up one of the swing arm pivot bearings, so things aren't going back together......

[Highside>Lowside]

Yep, best to try to keep your motorcycle money as motorcycle money. I would be silly enough to attempt the TAT on that little MT. (I still miss my MT125, but I'm not 5'7" and 155lb anymore)


Oh, and Subscribed.

[Bob]

Nice prep work.

[One Less Harley]

Prep for the day, added grease fittings to the swing arm and pivot links. Plus made a heat shield out of some scrap stainless steel. Added an insulating layer to the back. It's not quite done yet though. Don't think I'll paint it. John Delorean would be proud.

[red bud]

[QUOTE=One Less Harley;15691917]. John Delorean would be proud.

[One Less Harley]

Guess what what's used for muffler packing......never can tell, it's good as cash and can relieve the stress and pain from a days ride too!!!

[blaisew]

[QUOTE=One Less Harley;15679016]Parts are coming in way to slow!!!

Isn't it fun getting ready to go! Two of us are prepping our WR250R's for the TAT starting first to second week of June; 'going all the way. You made the right choice on the bike, and good preparation too. Maybe we'll see you out there! (by the by, I'd almost swear that's my backside in Sourjon's CO pic)

Ken

[Sourjon]

Originally Posted by blaisew

I'd almost swear that's my backside in Sourjon's CO pic

Ken

Hehehe! That it is Ken! See you in Moab!

John