Tip & How-To about 2004 Suzuki DR-Z 400 E

How to reduce front sprocket wear on Suzuki DR-Z range

On suzuki's DR-Z range, the front sprocket is covered behind and enclosed panel. This panel doesnt allow for mud to exit, and builds up causing excess wear to the chain and sprockets.

One way to fix this with out discarding the cover is to cut slots into it. You will notice that their are 3 moulded slots running diagonal across the cover. Using an approximate 8mm drill bit, drill a hole in the both ends of each of the slots. Use a rats tail/round file to file out the material in between the 2 holes. It does not require much effort to file.

Re-fit the cover, it now will allow dirt build up to exit, access to the sprocket with the hose for cleaning and for inspection, and looks really good aswell!


Before Picture

After Picture

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How do I change a front sprocket?


Thank you for contacting FixYa with your inquiry.
Go to this link and drill down to below indicated: http://cyclehuttktm.com/FicheFinderNew/FicheFinder.aspx 2001 > 400 SX RACING > ENGINE > TRANSMISSION II
You can loosen the chain tension from the adjusters at the end of the swing arm. Then remove the mud guard (If exists) covering the front sprocket. Remove the M10 X 18mm bolt holding the sprocket. Slide the sprocket and chain off the spline and change out. If unable to slide off the spline you can always open the master link on the chain and do same step.

Use reverse process to re-install new sprocket. Readjust chain tension and make sure to re-tighten axel nuts. Good idea to use Locktite on the 10 x 18 bolt and spring washer holding the front sprocket. Replace mud guard or leave off as to your preference.
Kind regards,
TF



Jul 21, 2011 | 2001 KTM SX 400 Racing

1 Answer

got a weird nosie coming from the front sprocket wen the sprocket is turned.. could this be the sprocket bearing ?


A bad bearing is a possibility alright. Also check the chain. is it free or does it want to kink up? Is it rubbing anywhere on the side case or side case cover? Remover the cover to check. Has mud built up around the sprocket shaft?

Apr 05, 2011 | 1988 Yamaha FZR 1000

1 Answer

IV A PROBLEM WITH MY 91 SUZUKI DR 650 I JUST FITTED NEW STARTER CLUTCH AS I THOUGHT THIS WAS MY PROBLEM BUT IT ISNT,WHEN YOU HIT THE START BUTTON TO START THE BIKE THE SPROCKET BEHIND THE FLY DOESNT SEEM TO BE MOVING.AND IT ISNT MAKEN THAT PROPOR TURNING NOISE SOUNDS MORE LIKE A DRILL.


Sounds like your starter solenoid is not engaging. Try tapping it with a dead blow hammer or a hammer and block of wood (gently! Not to hard!) If it bumps over that is your problem. Also check all connections to solenoid and starter.

The whirring noise you are hearing is your starter motor but your bendix gear is not engaging.

Hope this helps!
Rob

Sep 21, 2009 | 1990 Suzuki DR 650 RS

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