2002 DRZ400E mini project.

I picked up a well used 02 DRZ400 E last week (Oct 9th) My plans are basic, clean it up and dual sport it.

Here it is as I bought it.

Got it home pulled off the stickers already improvement in the looks. Discover many very loose spokes (unsafely loose) and a trashed chain.

Took is apart to work on the spokes and clean it up as much as I could.
Ugh


Went to the DMV to get the restricted plate, but was given this instead 8)

Started the weekend like this

Then this

Parts ordered (waiting sucks) but its much cleaner now. Carb is off to add JD jet kit


And today is looked like this, just a test

Valves were checked, still in spec. Will change the oil after its back together. Waiting the carb kit, chain, dual sport kit and headlight
I am happy how it cleaned up and I am still on budget. Spokes all tightened up nicely had one one problem child. I am looking forward to putting some miles on it.

 

Stock 14/47 gearing. Yes the shifter has impacted the case at some point in the past. I plan on adding case guards before too long. I have inspected for leak and cracks found none but I will keep an eye on it.

 

Thanks I will let ya know how it goes. I have a bunch of parts coming in so I am getting excited. I went ahead and ordered a stiffer rear spring, I am "slightly" over the weight of what the stock spring liked.

I am most interested in the carb kit, remote fuel screw and the crf accelerator pump diaphragm, really I am only a bit nervous of the jets and picking the right ones.

 

Parts!



Installing the Tusk kit is taking me longer than I thought but I am well over halfway now. Not sure I am sold on the headlight I picked but I wanted DOT approved



I am liking the taillight nice and simple

 

FYI I mistakenly got a battery pack and a extra brake switch ( I ordered an extra for a total of 2, however I got 3)

Anyone need either let me know and I will pass them along, RocyMTATV did not want them back.

I am looking to see how i can dump the tusk on off switch, that seems like a dead battery just waiting to me. I want to power the main tusk kit with key on power only.

 

I have read to use the taillight wire as it is not used in the tusk kit and its all LED. Since a previous owner decided to cut the stock harness I will try that 1st.

Thanks for the 2nd option idea

 

like my homemade and crooked plate mount