This is how to install a kick starter on a DRZ400S

Discussion in 'Thumpers' started by Mr. Cob, Jun 24, 2004.

  1. dasvis

    dasvis Been here awhile

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    Sorry, it's been two years & many lost brain cells since I did the install.... I don't remember!
    Dasvis
    #41
  2. Mr. Cob

    Mr. Cob Howling "Mad", Adventurer

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    Howdy All,

    Install the spring assembly just like I show it in the photos, there MUST be tension on the kicker return spring for it to function properly.
    #42
  3. peteFoulkes

    peteFoulkes Been here awhile

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    Outstanding instructions. Thanks for documenting.
    #43
  4. Flatop

    Flatop n00b

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    Hi guys, we have 2 of DRZ400S that I would like to install the kickstarter on. Does the year of the machine matter or not? Mine are 2003 & 2004 units. :ricky
    #44
  5. dasvis

    dasvis Been here awhile

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    Nope
    #45
  6. KLXmcrider

    KLXmcrider Been here awhile

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    Thank you, I too am thinking of installing the kit on my new to me '00 E.
    I believe the current Suzuki part #26300-29813 but says '06-up .So it will fit.

    Again thanks for the info...David
    #46
  7. Flatop

    Flatop n00b

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    Thanks Dasvis, nice avatar.
    #47
  8. geoduch

    geoduch Adventurer

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    Great write up and pix. I just picked up a 2001 DRZ440E and want to do this mod. Is there only the one Suzuki OEM kit available? The only one I have come across is Drz 400 Kickstart Kit 26300-29813, but some sites say it only works on 2006 and up models.... is this true?
    #48
  9. kcomst

    kcomst Adventurer

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    The issue is that newer models have a compression release. If your bike is older than this, you can still install the kickstart; just leave out the comp release. That's what I did on my 2000. The DRZ is harder to kick than my YZ450F, but when you need it, it's nice to have. This didn't happen to me until over a year after I installed it. In fact I forgot I had it. I was downtown and my battery went dead, tried push starting (it's hard to bump start too; you need pavement and a long hill or start in 4th/5th gear and get a lot of speed up on gravel) and was getting ready to call my daughter to come get me in my pickup truck. Then I remembered I had it. All of a sudden I was glad for spending the $200 and about 3 hrs of my time putting it in. I might also add that, since this thing is hard to kick, don't shorten the lever more than absolutely necessary if you have the Clarke tank.

    Other issues people have mentioned:

    Weight: some will disagree with me, but I do not consider the DRZ a dirt bike. My YZ450F is a dirtbike. The DRZ is a heavy dual sport. Adding 3 lbs is not going to make a significant difference. You can't do long jumps on this bike, it doesn't have the suspension. At one time I started installing aftermarket bling and trying to get my bike lighter, but gave up by the time I realized I had put $1500 into a $3000 bike, and still had not installed the other things I wanted - aftermarket pipe & muffler, oversize tank, FCR carb, inverted shocks, more comfortable seat. By the time you do all that, you may as well buy a KTM! The one thing the DRZ has over buying a KTM is low initial cost, and I believe it is more reliable and easier to maintain than the high performance bikes.

    One person asked what else you should fix while you have the clutch cover off? Excellent question! While you have the oil drained and the side cover off is the best time to perform the water pump fix mentioned at the bottom of the DRZ mods page:

    http://www.4strokes.com/tech/suzuki/drz400su.asp

    Here are instructions and pictures:

    http://www.thumpertalk.com/topic/194044-detailed-instructions-for-the-water-pump-fix/

    Suzuki may have fixed this in later years, I don't know. But my DRZ like many others seems to mysteriously lose slight quantities of coolant and periodically needs to be topped up. I ran into this fix right after I had finished doing the kicker and wish I had known, I would have done it then.
    #49
  10. motoraptor

    motoraptor Adventurer

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    #50
  11. N-m

    N-m Captain 2 Sexy

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    Is this mod possible on all the variations of the 400 by Suzuki and Kaw? I would think since you have the same drive train.

    Thanks for the great pics.
    #51
  12. Simple_One

    Simple_One Adventurer

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    IS the DRZ-400SM, the same deal as the S?
    Can you install a kick start on a 2008 model, or did they add decompression or something else that complicates the works?
    #52
  13. dasvis

    dasvis Been here awhile

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    No problem, it will work fine.
    #53
  14. Simple_One

    Simple_One Adventurer

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    Good news, thanks for that.
    #54
  15. bajadog

    bajadog Running around knees bent

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    Followed Mr. Cobb's excellent photo instructions to a tee (I thought) on my
    riding buddy's 2006 DRZ400s.

    The kick start lever does not spring back
    up after kicking it.

    I did not have the spring retaining collar at around 4'oclock position because it required
    winding (adding tension) the spring.

    Does anyone remember if adding tension is required? I put the kick start shaft/gears/spring assembly clock
    in so I would not have to wind the spring.

    Thanks for your time.
    #55
  16. Mr. Cob

    Mr. Cob Howling "Mad", Adventurer

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    Howdy bajadog,

    YES, you must wind, pretension the spring for it to work properly.
    #56
  17. bajadog

    bajadog Running around knees bent

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    Dave, thanks for the quick reply and PM.

    Oh well time to pull it all apart again (should be quicker :D) .

    Marco
    #57
  18. bajadog

    bajadog Running around knees bent

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    What a difference a quarter rotation on that spring
    made!

    Now I just have to find why his idle is crap.

    Thanks again Dave.:D
    #58
  19. KI6HNB

    KI6HNB Been here awhile

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    I'm working on installing this kit right now. What is the recommended shade tree way to re-torque the clutch nut without having the wiz bang factory clutch holder tool?
    #59
  20. intotheabis

    intotheabis High on life!

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    I put a little "blue" loctite and hit it quick with the impact while holding it with my gloved hand.

    It was so loose when I removed it I figured that would be fine.......time will tell
    #60