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DRZ400: Engine

Suzuki DRZ400 is the off-road kick start only model.

Electric start model: DRZ400E | Street legal model: DRZ400S

Sold in the US 2000-2003

Chain Size:        Front Sprocket:        Rear Sprocket:        Front Tire:        Rear Tire:        Spark Plug:
520x112 14T 47T 80/100-21 110/100-18 CR8E

 

Engine

  • Direct bolt-on, ready-to-install cylinder; requires no replating and looks virtually identical to the OEM
  • Nickel Silicon Carbide plated for long life
  • Honed to exact size for easy piston installation
  • Big bore cylinders do not require any machine work
  • Come complete with gaskets, cylinder, 94mm piston, rings, pin and clips
$629.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Big Bore Kit, 440cc Athena

DRZ400 '00 - '22
  • Includes aluminum cylinder, piston kit, and special gasket set designed for larger water jackets
  • Bolts on with no machining required
  • 94mm big bore piston
  • Aluminum cylinder designed with wider water jackets for better cooling.
  • Forged hi-compression piston
  • Includes all necessary Rings, Clips, and Gaskets.
$789.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Big Bore Stroker Kit, DRZ462

DRZ400 '00 - '03

All in one package.

  • Hot Rods complete +4mm stroker crank assembly
  • 94mm big bore cylinder and piston kit
  • Complete gasket set with seals
  • Includes new crank bearings

We suggest adding a set of HotCams camshafts and a new clutch kit for the best results.

$1,099.00
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Piston, Replacement Wiseco

DRZ400 '00 - '03

Stock bore replacement pistons from Wiseco. You have your choice of the standard compression ratio of 12.2:1, or a high-compression ratio of 13.5:1.

This high-compression kit will run perfectly with standard pump Premium.

Kits include piston, rings, wrist pin and circlips.

Choose Option
$181.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Cam Chain Manual Tensioner

DRZ400 '00 - '03

Solid reliability and easy installation. This manual tensioner is a good upgrade for any modified motor, especially if it is ridden hard. A new gasket is included.
 

Add Gasket
$62.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Cam Chain Tensioner Gasket

DRZ400 '00 - '22

A Suzuki OEM gasket for the Cam Chain Tensioner. You are going to need it if you work on your starter motor. It is not a good idea to re-use this gasket. If it blows out, it will dump a large amount of oil onto your right foot.
 

$4.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Cam Chain Tensioner Tool

DRZ400 '00 - '22

Your automatic cam chain tensioner is spring loaded. This can make it difficult to install as it wants to extend before you have it bolted into place. This handy tool will back off the cam chain tensioner mechanism and hold it for you. No more awkward 3-handed contortions are required to get the tensioner installed.
 

$84.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Cam Chain, Wiseco

DRZ400 '00 - '03

A high quality cam chain from the folks at Wiseco. New cams, big bore kit, high-mileage motor, you might want to think about a new cam chain. Direct replacement for stock unit.

Add Cam Chain Manual Tensioner
$71.95

As the leader in innovation, design and development of aftermarket high-performance camshafts, Hot Cams is certain to provide the added boost that enthusiasts are looking for.

Designed, dyno proven and made in the USA, Hot Cams performance camshafts are one of the most economical, reliable and easy to install ways to add a 5-10% power gain to your bike.

Stage 1: These cams provide better low RPM torque, pulling power, and throttle response.

Stage 2: These cams will provide improved full throttle torque and horsepower starting at 4000 RPM and up.

Choose Stage
Add Cam Chain, Wiseco
Add Camshaft Installation Tool Kit
$349.95
  • Hot Rods complete stroker crank assembly includes +4mm stroke for maximum power and performance output.
  • Hot Rods constructs their complete stroker crank assembly to meet or exceed OEM specifications for maximum durability.
  • Hot Rods stroker cranks are completely rebuildable and have been trued to within 0.001" from the factory.
  • The Hot Rods stroker crank increases the stock displacement to 424cc when used with the stock bore piston or 462cc when used with a 94mm big bore kit.
  • Main bearings sold separately.
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This Will Not Fit The DRZ400 Kick Start Models Nothing Available For The Kick Start Models

$399.95

New Bearings for your DRZ400.

If you are in the lower end doing work, new bearings are cheap insurance for all that hard work.

$64.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Kickstart Kit

DRZ400 '00 - '03

Add a backup kick start system to your electric start DRZ400. Complete with everything you need to add the kick starter to your bike.

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This kit will fit all DRZ400s but the manual decompression lever can only be installed on the 2006 to Current DRZ400 E models.

$249.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Valve Shim Kit - 9.48mm

DRZ400 '00 - '03

Includes three valve shims of each size from 1.20" to 3.50in .05 increments. 141 shims in total.

$79.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Radiator Cap, High Pressure

DRZ400 '00 - '03

Higher pressure in the cooling system, raises the coolant boiling point and increases protection from coolant loss due to overheating.

23 PSI - 1.6 Bar.

$19.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Clutch Kit, Complete EBC

DRZ400 '00 - '03

Replace your worn clutch plates and springs to reduce fade and slip.

  • Complete set of friction plates, steel plates, and springs
  • Heavy-duty springs help prevent clutch slip
  • Restores proper stack height, fixes clutch slip caused by wear and tear
$109.95

A complete set of gaskets, o-rings and oil seals. Everything you will need when doing a complete engine re-assembly.

Add Gasket Remover
$88.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Gasket, Engine Cover

DRZ400 '00 - '03

Outer Clutch Cover O-Ring, Inner Clutch Cover Gasket, Stator Cover Gasket.

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Sold individually, not as a kit - Select options below.

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Click the image for a larger version to be sure you order the correct part.

Choose Gasket
$7.95

Billet plugs for your left side case. Includes both the timing mark plug and the crankshaft access plug.
 

Choose Color
$39.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

O-Ring Kit, Oil Change

DRZ400 '00 - '03

Always a good idea to put in a new set of Oil Change O-Rings at the first sign of any leakage. This package gives you the three most important: oil filter cap and the one behind the filter as well as the one on the filler cap. All are new OEM Suzuki O-Rings.

$9.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Oil Filter Magnet

DRZ400 '00 - '22
  • Reduce wear, and significantly increase your engine life.
  • Easy to install. Place on outer side of filter.
  • Powerful magnet traps abrasive metal particles down to 1 micron. OEM oil filters only filter particles down to 90 microns, leaving behind the most harmful particles to circulate through your engine.
$5.95

Made from laser-cut, medical-grade, 304 stainless steel micronic filter cloth, this filter provides 200% more filter area over many paper filters, catching debris down to 35 microns. The FLO filter pleat seam is welded and able to withstand up to 600 deg. F. Filter maintains consistent flow under all conditions including extreme heat, the presence of water and cold start-ups where paper filters can flow so poorly that they often cause the bypass valve to open and allow unfiltered oil to enter your engine.

This cleanable oil filter should be the last one you ever purchase.

$29.95

Providing unbeatable performance and exceptional value, Hiflofiltro is the best-selling brand of aftermarket filters for motorcycles, scooters, and ATVs worldwide. The filters are also supplied to original equipment manufacturers as well as private label brands.

You pay $3.50 per filter with our value 10-pack!

$34.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Drain Plug Washers, 10mm

DRZ400 '00 - '03

It is a good practice to replace your sealing washer with every oil change. These 10 piece kits are made up of 5 Copper washers and 5 Aluminum washers. The manufacturer recently decided to make half of the kit Copper washers as that is the material of choice for many OEM manufactures. This gives you the opportunity to decide which you prefer, but either will work great at creating a leak-free seal between the case and the drain plug.

$5.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Drain Plug Washers, 12mm

DRZ400 '00 - '22

A 10-pack of drain plug sealing crush washers. Replace your sealing washer at every oil change to prevent a leak.

$6.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Drain Plug, Magnetic

DRZ400 '00 - '03

Extra protection for your motor! Strong magnet at the end of the plug picks up ferrous metallic flakes in your oil, protecting your engine!

$15.95

Hardened chrome vanadium steel with built in rubber insert to hold spark plug steady.

Thin wall bi-hex sockets designed to access narrow spark plug holes.

Fits 3/8" square drive and hex drive, 16mm, 18mm, 21mm.

Choose Size
$11.95

Keep your motor running right with a fresh plug.

A Dual Electrode spark plug will last longer than a single electrode plug because the wear is shared between the electrodes.

Choose Spark Plug
$9.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Spark Plug, E3

DRZ400 '00 - '03

E3 Resistor Spark Plugs

  • Unique electrode shape maximizes the power created by the spark plug – Diamond Fire technology
  • Electrode is a combination of performance and technology that results in an improved flame kernel shape
  • This flame front ignites the bulk air/fuel mixture faster, moves heat into the combustion chamber faster and creates a more localized pressure front for faster pressure rise during the cylinder power stroke
  • The result is more complete combustion and an improvement in engine performance
  • A truly premium performance plug
  • Sold individually, unless otherwise stated.
Choose Spark Plug
Add Lubricant
$9.95

Iridium spark plugs are made with premium quality materials.

Iridium plugs last longer than standard ones, meaning you won't have to replace them as often.

  • The ultimate in the evolution of spark plug technology and performance from an industry leader
  • The iridium electrode is 25% smaller than a platinum electrode, and it's just 1/4 the size of a conventional nickel electrode
  • Ultra-small diameter center electrode reduces voltage requirement and extends ignition system life
  • Metal shell plating has enhanced anti corrosion qualities

Sold individually, unless otherwise stated.

Choose Spark Plug
Add Lubricant
$10.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Spark Plug, Standard NGK

DRZ400 '00 - '03

Keep your motor running right with a fresh plug.

NGK Spark Plugs is the largest OE supplier and manufacturer of spark plugs in North America.

  • Superior construction for serious power
  • NGK makes plugs for almost every application and riding style
  • Versatile plugs with wide operating heat ranges prevent fouling from running too cool and preignition from running too hot
  • Feature high alumina ceramics for improved heat dissipation and electrical insulation, deep-seated copper core for a wider heat range and a nickel alloy tip for longer life

Price reflects the quantity of spark plugs required for your make and model.

Choose Spark Plug
Add Lubricant
$5.95

Clymer repair manuals provides step-by-step procedures based upon the complete disassembly of the motorcycle. This hands-on experience combined with extensive research results in a manual that is both user-friendly and detailed. Hundreds of original photos and illustrations guide the reader through every job.

 

$36.95

Includes degree wheel, dial-gauge, multi-position stand, extension, 3-sizes of positive-piston stops, and a handsome wooden carrying case.

$199.95
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Clutch Holding Tool

DRZ400 '00 - '03

Need to remove your clutch assembly? This holder is the quickest and easiest tool out there to get a grip on that hard to handle hub. Laser cut to the exact pattern that EBC makes their clutch plates from, it makes loosening and re-tightening the clutch nut easy. All of that and no worries about doing any damage to your expensive clutch hub.

 

$18.95

Made from medium carbon steel with hardened jaws. It features spanner pins and the jaws open up to 5" wide. It's ideal for holding clutch hubs, flywheels, gears, sprockets, etc. Made by Motion Pro.

$28.95

This tool is designed to separate vertically split crank case halves on two and four stroke engines. Adjustable arms allow it to be used on multiple bolt patterns found on a variety of makes and models of motorcycles. Industrial grade steel construction with black oxide finish for long service life. Comes with 8mm mounting bolts and 6mm adapters. Protective carrying case included.

$79.95

For easy removal of recessed oil filters.

Conical point screws pierces and grabs the metal end cap of the filter.

reduces potential damage to the engine cases.

NOT for use on re-usable oil filters.

$9.95

A 3-pack of easy to apply strips measure the temperature of engine, suspension, and radiator components. Temperature range 146° to 248°

$14.95

Thread Chasers are designed to clean and re-cut damaged aluminum threads.

this kit contains the two sizes most common on metric motorcycles, M6x1.0 and M8x1.25.

Thread Chasers also remove dirt and metal shavings that become captured in thread grooves.

Uses 8mm or 10mm hex sockets, a Must for all tool kits.

$4.95