DRZ400 expedition build for OVERLAND EXPO trip

[mcgovski]

More stuff!

Today I was delighted to get a call from my local moto shop to let me know that my Wolfman expedition saddle bags and side racks had arrived. I will post up some pics tomorrow, this stuff is impressive. First look, these bags are better quality than my Ortliebs...time will tell. The side racks look stouter than my touratech, which I just re-welded and added some gussets to repair a broken joint (that was my fault or fall that caused that) Just saying. Super impressed, cant wait to install.

thanks Wolfman

 

[MarcFJ60]

I had the Happy Trails racks on my DRZ and was happy with them. But if those Wolfman racks had been available at the time I certainly would have gone that route. They look REALLY good - beefy, but not bulky, they really seem to hug the bike.

I wish they made them for the XChallenge.

 

[mcgovski]

delay

Sorry for the delay on this thread, but I have realized that my order of mods was way out of whack. I have to remove the gas tank to do the emissions removal and jetting...but I dont have the new tank yet. No point in doing double work. So I am holding off until the tank shows up. The new IMS 4 gallon tank should be here any day...then I can get all these parts out of my living room and onto the bike!

progress will resume soon!

 

[mcgovski]

wolfman pics

here are some pics of the wolfman expedition dry saddle bags and side racks

 

[mcgovski]

IMS 4 gal

the tank has arrived!

 

[Oni]

Ooooh, nice looking tank!

 

[mcgovski]

Thanks Oni
now i just need some time and my friends garage! I really hope to get all this stuff on the bike! Its killing me having sit here in the living room.

 

[turner]

Nice! I have an 08 dizzer as well. S model, and I love these bikes. They aren't light for single track, but I'm 130lbs, and do it often. I would recommend case savers, and if that is the stock shifter grind down the little tab on the side so it doesn't punch through your case. Very cool build!!

If you are looking at a new seat, I would really consider the Renazco seat. I have the Corbin and hate it.... I wish I had the Renazco and will prob end up buying it.....

For handguards I have moose, but think the Cycra are the best looking. That said, I am prob going with the Zeta with the blinkers in the handguards. I'll be following this build, and envy you and your wifes trip! Be safe, and have fun!!

 

[Every Miles A Memory]

the tank has arrived!

Next on the long list of add on's for my DRZ. Will this one fit on the SM Version?

 

[mcgovski]

Tomorrow I have garage time at my buds house!!! hopefully we get some work done.
turner. case savers are on the way and the shifter has been repositioned and filed. the seat...i dont know what we are going to do yet...
everymiles a memory- From my understanding this tank will work for the S and the SM but not the E.

Some work on the bike and some pics tomorrow!

 

[mcgovski]

its begun!

Alright! work has begun. I started by stripping down the bike and removing the emissions stuff...there are two lines off the emissions, one was a fuel line which was completely disconnected and the other was a vacuum line, which was capped off at the Carb. Next, I need more air. 3x3 air box mod...I removed the little snorkel out of the top of the box and relocated the little computer thing

 

[mcgovski]

After removing the snorkel, I opened up the air box. I took a utility knife, heated it up with a torch and sank the hot blade into the plastic and followed the lines I had scored into the top of the box...3"x3". the hot blade worked awesome, not bits to clean out of the airbox. I did take a lose blade and cleaned up the cut from the inside removing any bits that were hanging on.
next the carb got rejetted. this was the most stressfull part for me, because I had never done anything like this. (i failed to get pics) Removal was okay. I removed the through bolt connecting the rear of the frame from the front of the frame to get a little bit more room to wiggle the carb out. There are 2 c clamps that connect 2 rubber boots at the front and the back of the carb. remove those and start wiggling the carb out.
Carb out, fuel is drained and the top of the carb is replaced the needle is removed and replaced with new needle with the appropriate settings. This was nerve racking (because I read too much about it on the internet) but there is a little spring that can get away from you and a tiny o ring that can go missing. not a big deal, just take apart carefully and place parts on the bench in the order of dis assembly.

 

[mcgovski]

hmm, pics did not post for second post...2nd try

hmm, pics did not post for second post...2nd try

 

[mcgovski]

okay, after the new needle was reinstalled on the carb, the new jets went on. this was simple, remove and replace. JD jetting kit was easy. The carb was wiggled back into place and the clamps secured around the 2 boots. sweet. next the IMS tank install. pretty much just a bolt on thing. plus, installing the stock petcock and fuel lines. The worst part is the brackets for the back of the tank to the frame, a S style clip, did not make it with my order...I just fashioned some out of some 14g strips of metal. DONE!
the last thing I did was disconnect the kick stand relay thing.

 

[mcgovski]

Ran out of time yesterday. I hope to get some fuel in the tank to make sure everything is working, and get the luggage racks installed!