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wide ratio gearbox
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Share your modifications both the ones that worked and ones not worth doing.
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TOPIC: wide ratio gearbox

wide ratio gearbox 5 years, 4 months ago #3432

  • xrman
  • Gold Boarder
  • Posts: 182
I have just got my bike back fro the bike shop after having a ACT wide ratio gear set fitted.

In case you are interested the total cost was $1880

Break down is as follows:
gear set and two modified shift forks form USA $870 au

10 hours labour $800

gasket kits/ seal kits $200

oil/ coolant/ misc aprox $50

So if you were a good mechanic you could do this for around $1100.

I will get her out for a run on the weekend and report how it went. I was running 15/45 sprockets to get a decent top end speed for cruising, but I found first gear too high for tight terrain. Hopefully this will give me the best of both worlds. Or it could be a waste of time/ money!

Re: wide ratio gearbox 5 years, 4 months ago #3436

  • drztroy
  • Gold Boarder
  • Posts: 294
Very interested on how that goes

Re: wide ratio gearbox 5 years, 4 months ago #3437

  • Bala
  • Expert Boarder
  • Posts: 56
By the specs i found 1st is the same and the other gears are spread a bit, It looks like it can only be good.

Probably a bit like having one up on the front but with 1st gear the same.

Its not cheap, but thats up to the individual as to how they use the bike and their bank balance.

Re: wide ratio gearbox 5 years, 4 months ago #3444

  • xrman
  • Gold Boarder
  • Posts: 182
I had my first ride today.

The terrain was a mixture of roling hills, flat roads and enduro track tight stuff.

Sprockets used 14/45 today as comapred to 15/45 that I had been using before the wide ratio gear box mod.

Changing through the gears under moderate throttle, I got to about 25 kph in first and changed into 5th at 100kph. It took a little longer in each gear to get to the change point as you would expect. 1st gear was a fast walking pace and in 5th I was sitting on 120 kph at what I judged to be the same revs that i would be at 100 KPH with the original box. It was still pulling away when I stopped the trial so don't ask what the top speed was. 5th gear felt like an over-drive.

To be honest I felt the bike didn't like sitting on 100 kph (the Victorian limit) and we also have a lot of roos about in this area so I am not into speed.

I am going to go back to 14/47 ( standard sprockets) and I think this will suit my needs better. If I was in SA and had no hills much to climb or tight trails to explore I would leave it at 14/45. At 110kph it felt happy and kept climbing upward easily.

In summary damn close to perfect for a small adventure bike now that I have modified suspension and the gear box, the two areas Suzuki should alter to prolong the DRZ400's model life.

If I was just riding the DRZ off road and at low speeds I would not bother with this mod. But commuting on a freeway and longer rides; yes I would.

Re: wide ratio gearbox 5 years, 4 months ago #3445

  • DRZ2011
  • Senior Boarder
  • Posts: 42
Good report, I was so close to doing this.
Do I really have to go to work on Monday

Re: wide ratio gearbox 5 years, 4 months ago #3446

  • Bala
  • Expert Boarder
  • Posts: 56
From a little bit of research it looks like 4th is only slightly less that 5th was before the new box, so your feeling of having an overdrive would be right.

Changing the rear a couple may just make it right for you.

Thanks for the report.

Re: wide ratio gearbox 5 years, 4 months ago #3471

  • xrman
  • Gold Boarder
  • Posts: 182
I have changed back to 14/47 sprockets and fitted a Kenda trackmaster rear trye.

I have been busy with Rotary club stuff this weekend and next weekend. I have to scuff the rear tyre up a bit according to the manufacturer ( 160 km) prior to giving it full throttle and hard cornering. I will post how it goes in a few days, time permitting.

Re: wide ratio gearbox 5 years, 3 months ago #3507

  • xrman
  • Gold Boarder
  • Posts: 182
OK the 1600 km. test ride is over.

The gear box works a treat. You can climb steep snotty hills and yet still blast transport sectiosn without revving the crap out of the motor.

kenda trackmaster is a nice tyre. At 1600 km it is about half wornout.

Re: wide ratio gearbox 5 years, 3 months ago #3521

  • Iggy
  • Junior Boarder
  • Posts: 11
Hi Guys,

I was concerned with the revs when travelling on the highway as well. I have changed to a 16-42 for highway use and change to a 14-48 when I want to go bush. The highway gearing has really made a difference and sounds similar to your specs, changing from 4th at about 100kph and sitting on 100kph at about 5700rpm in 5th (it like having another gear). It only cost about $170 for parts from the states.

I have a 2nd chain when changing to bush gearing and considering it only takes about 30-60mins to change everything it is not really that annoying.

Anyway hope this helps and would recommend this to anyone doing more road than off road.

Re: wide ratio gearbox 1 week ago #16596

  • cai123
  • Expert Boarder
  • Posts: 97
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