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Old 09-15-2012, 12:48 PM   #15751
Cobra5150
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Killing rectifiers-

I'm new to this forum, love it BTW, and posted in the general area and didn't know to post in bike specific threads. After replacing the battery and rectifier the RR only lasted about 24 hours.
Here's the post:

I recently bought a DRZ400 and it has a problem charging. The rectifier checked bad so I bought another, installed it and everything was working fine. Less than 24 hours later-no charge again. Recheck the RR and it shows bad. All the wiring and connectors look to be in excellent condition and I used dielectric grease on the connections. It has a new battery as well. I was hoping to get out in the trails tomorrow but this issue is keeping me home. Aside from possibly a bad RR is there anything in particular that could be killing it? Stator shows good AC voltage 80-100 volts, resistance right on spec and no short to ground.
Thanks.

It's hard for me to leave something sitting when I suspect there may be a problem. I have checked the connections and grounds and they appear fine. Even though the stator checks fine I wanted to see what shape it was in, maybe when it warms up it might be breaking down?????? Besides it gives me a chance to see how this bike is put together, better in the garage than on the trail somewhere.

Here's what it looks like, does anyone see any evidence of heat damage? If not, hopefully it was a bum RR and the next replacement will do the trick.


http://s15.photobucket.com/albums/a3...EC6D0956F1.jpg
I've had the bike for a few weeks now and ready to get on the trails.
sorry for the crappy cell phone pic
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Old 09-15-2012, 03:13 PM   #15752
One Less Harley
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post on Thumper Talk under the DRZ 400 forum, you'll get way more help there.
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Old 09-15-2012, 03:19 PM   #15753
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Need a quiet muffler

I blew the guts out of my FMF today so I am looking for a replacement muffler. I don't really want a stock pipe but it needs to be quieter than the FMF. What do you recommend?
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Old 09-15-2012, 03:54 PM   #15754
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I don't think you'll find quieter than the FMF Q4, most others will be louder. I just put the Q4 on mine and it's very close to the same noise level as stock.

By guts d you mean packing??
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Old 09-15-2012, 04:09 PM   #15755
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Quote:
Originally Posted by One Less Harley View Post
I don't think you'll find quieter than the FMF Q4, most others will be louder. I just put the Q4 on mine and it's very close to the same noise level as stock.

By guts d you mean packing??
The one that is on it is an old round one and not the Q4. My end cap ripped off with my quiet core insert, threads aren't looking good.
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Old 09-15-2012, 06:23 PM   #15756
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woo, have you notice someone break into the house last night


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sounds like an amature militalia operation will be blaming on other pricks, hollywood style of course

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Old 09-15-2012, 06:53 PM   #15757
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Quote:
Originally Posted by blaster11 View Post
I blew the guts out of my FMF today so I am looking for a replacement muffler. I don't really want a stock pipe but it needs to be quieter than the FMF. What do you recommend?
When I bought my DRZ, it had a white brothers exhaust. Loud as hell, and annoying to ride. I just went and purchased a stock exhaust off ebay and ordered a high flow spark arrestor. I wont be able to test it out though until I'm stateside next week.
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Old 09-15-2012, 06:54 PM   #15758
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While doing an oil change, I decided to pull the clutch side cover to make sure all was well with the oil pump gear.



Im glad I did.
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Old 09-15-2012, 07:04 PM   #15759
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Quote:
Originally Posted by JustGreg View Post
While doing an oil change, I decided to pull the clutch side cover to make sure all was well with the oil pump gear.



Im glad I did.
Is that sucker plastic
Why the heck would they make out out of anything but metal

I know the answer will be forthcoming from some quarter of the planet

OH! and how many kilometers/miles are on it ????
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Old 09-15-2012, 07:13 PM   #15760
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.....just shy of 5000 miles. I guess the "plastic" gear is designed to be the weakest link in case of debris getting into the oil pump and locking it up. The gear shears teeth instead of the clutch basket etc. Its too bad the cams, piston, cylinder and crank/rod bearings will be toast before you know theres a problem.
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Old 09-15-2012, 08:45 PM   #15761
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pro circuit 496 pipe has quiet core and sprak arrestor I am keeping mine
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Old 09-15-2012, 08:49 PM   #15762
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The FMF Q4 (about $288) is not a straight through muffler, and should bolt right up to an E or S/SM head pipe. A good chance it'll bolt up to you existing FMF header. It's pretty quiet with the spark arrestor and a little louder (deep) with out it. Lighter and a wee bit shorter than st stock can.
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Old 09-15-2012, 08:52 PM   #15763
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when you need some torque, roll on throttle it gives very robust sound too. I am very happy with the 496 system
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Old 09-16-2012, 09:38 AM   #15764
buls4evr
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Quote:
Originally Posted by 955616846 View Post
Just about every OTHER aftermarket exhaust is a straight through design which will never make it down to acceptable noise levels without throwing away its number one benefit and causing other problems like the one that you have already experienced. Tuning a muffler to the primary exhaust pulse frequencies of a thumper is a difficult task. More often than not noise requirements are met at the expense of back pressure which when combined with a strong primary pulse can quite literally tear a lightly built muffler apart.

My suggestion... The Suzuki 35F0 from an 01-02-ish GSX-R 600/750 is a quality built muffler that flows well, has an acceptable noise level (I too like civilised noise levels) with a little thumper character. These are louder than stock, but quieter than FMF, won't blow out (typical FMF, but they're not alone here) and doesn't need repacking.

The downside is that at 120mm diameter ( length is 450mm + tip btw) it is quite a large muffler although only slightly larger than the late model OEM DR-Z mufflers with the tapered tip... much larger than the FMF. It will need a flange (+ gasket), a new or modified link pipe which your local exhaust shop should be able to build plus either a new mounting lug welded to the sub-frame (recommended) or a relocation bracket.
It is not only huge....but has no spark arrestor! Useless for all but street use in the states. My buddy has one on his DR650. Biggest problem is no one builds a SA for it. It does make nice power though. A lot louder than stock also.
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Old 09-16-2012, 10:21 AM   #15765
One Less Harley
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Quote:
Originally Posted by 955616846 View Post
They still have a habit of blowing the end off the can.
Are you talking about the Q4 or another FMF as I don't see how the end can blow off with the four rivets around the side holding it in place. If someone has taken it apart and not used long enough rivets then maybe.

Four rivets to hold cap in place , I doubt the end cap has slotted holes for the rivets which could allow the cap to blow off.



Inner Baffle, one could drill out the holes a little for more flow.



Spark Arrestor-



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One Less Harley screwed with this post 09-16-2012 at 10:41 AM
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