I wanted to add a couple of thoughts on installing the ACT Wide Ratio Gears: 1) I am mechanically inclined, but had never split a case before 2) I have installed the first set in my DRZ400s with no issues. 3) I am installing the second set on my wife's DRZ now. In fact, I just finished modifying the case, and the 3rd gear shift fork. Going to fit the second shift fork when I finish adding the comments What worked very well for me was to use the "Dentist fitting a filling" approach. I marked the area of the described interference with a black sharpie. Installed the gear or shift fork, spun, removed, looked at the sharpie mark where the interference would wipe away the sharpie, grind a little in that area, re sharpie, re install, etc...and repeat until clearance is made. This method actually prevented me from damaging my case, as once 5th gear was close to fitting in the case; I was still getting some interference, BUT the sharpie mark wasn't showing any bright marks where the gear was touching. The issue was the bearing retainer tab directly at 3 o-clock from the noted rework area. The tab was a touch wider and I just had to touch it with the grinder to break the burr on the edge of the retainer. If I wasn't using the sharpie, I may have continues to grind the noted area. more than needed. As a comparison I was running 14/47 with ACT gears and my wife's was stock 15/44. With the ACT I rarely get into 5th gear when tooting around with her in 5th in the 40 - 60 MPH range. Great addition to the bike and pretty easy to install.
Busted my third gear by accident, which was a perfect excuse for me to buy this kit😄. Just received it, so now I only have to clear the workbench and do some grinding.
@@mt1885 , sorry, no I have no youtube channel or the right equipment to do a proper comparison review (action cameras, microphones, video editing software, digital rev counters etc). But there are other videos on youtube, where they compare the wide gear ratio kit to original gearing. What I have discovered so far is that when you split the engine casing, there are also other parts that might need to be exchanged after a gearbox incident like I had. Metal debree in the gear shaft bearings and gaskets that needs to be replaced. So if you’re in the same situation as me, be prepared that it might be some extra work an cost involved besides the wide gear ratio kit.
I'm a little hesitant trying to grind those materials off the shift forks. The secondary shift fork looks really skinny. Grinding the case isn't too bad. Are you guys planning to offer the complete ACT kit with the proper shaved shift forks along with it in the future? That way, the amount being shaved off of them is consistent every time.
Thanks for your concern. We have not seen shift fork failures. If you would like to see more, there is a photo on our website or email info@advancedclutch.com and we would be glad to send more photos. The wider ratios are not possible without machining the shift fork to clear the larger fifth gear. We sell both new or used modified shift forks to be sure the minimum amount of material is taken off to accomplish this and there are detailed instructions also available for the do-it-yourselfer.
Dont found many videos about customers that run the kit.is it durabel for though offroad tracks and heavy load on the street when i want to use it as an Adventure bike?
These gears will be perfect for adventure riding. If you search up ACT wide ratio DRZ gears you will see quite a few reviews on the forums also information on changing your sprockets after doing the gear change. If you cannot find any look on thumpertalk.com
These gears are wide ratio. First gear is still stock DRZ, second through fifth gear are considered wide ratio. Usually for drag racing you use close ratio gears to keep the engine in the happy rpm range. Running a wide ratio gear will give you a higher top end and longer gears. When you shift it might fall out of your desired powerband when using wide ratio gears for drag racing.
Louie, I think you are talking about the 5th gear shift fork @4:34. If you don’t know what to look for it might be hard to see. We are sorry for that not being clear. We do sell modified OEM shift forks if you do not feel up to the task. You can email us at sales@advancedclutch.com if you are interested.
@@AdvancedClutchTechnology Yeah I agree if you miss the massive chunk eaten out of that shift fork maybe sell your tools and buy something with a warranty 🤣
I wanted to add a couple of thoughts on installing the ACT Wide Ratio Gears:
1) I am mechanically inclined, but had never split a case before
2) I have installed the first set in my DRZ400s with no issues.
3) I am installing the second set on my wife's DRZ now. In fact, I just finished modifying the case, and the 3rd gear shift fork. Going to fit the second shift fork when I finish adding the comments
What worked very well for me was to use the "Dentist fitting a filling" approach. I marked the area of the described interference with a black sharpie. Installed the gear or shift fork, spun, removed, looked at the sharpie mark where the interference would wipe away the sharpie, grind a little in that area, re sharpie, re install, etc...and repeat until clearance is made. This method actually prevented me from damaging my case, as once 5th gear was close to fitting in the case; I was still getting some interference, BUT the sharpie mark wasn't showing any bright marks where the gear was touching. The issue was the bearing retainer tab directly at 3
o-clock from the noted rework area. The tab was a touch wider and I just had to touch it with the grinder to break the burr on the edge of the retainer. If I wasn't using the sharpie, I may have continues to grind the noted area. more than needed.
As a comparison I was running 14/47 with ACT gears and my wife's was stock 15/44. With the ACT I rarely get into 5th gear when tooting around with her in 5th in the 40 - 60 MPH range.
Great addition to the bike and pretty easy to install.
Busted my third gear by accident, which was a perfect excuse for me to buy this kit😄. Just received it, so now I only have to clear the workbench and do some grinding.
Do you got a TH-cam channel and or place to report your comparison (looking at this kit as well)!
@@mt1885 , sorry, no I have no youtube channel or the right equipment to do a proper comparison review (action cameras, microphones, video editing software, digital rev counters etc). But there are other videos on youtube, where they compare the wide gear ratio kit to original gearing. What I have discovered so far is that when you split the engine casing, there are also other parts that might need to be exchanged after a gearbox incident like I had. Metal debree in the gear shaft bearings and gaskets that needs to be replaced. So if you’re in the same situation as me, be prepared that it might be some extra work an cost involved besides the wide gear ratio kit.
Hi ACT - any new updated videos on the DRZ 400S gear sets - EXCELLENT videos!!!
Why not just include new shift forks with the kit?
Because some people are happy to modify the selectors themselves and avoid paying more
You can buy them modified with the kit, at least you could last time I checked.
I'm a little hesitant trying to grind those materials off the shift forks. The secondary shift fork looks really skinny. Grinding the case isn't too bad. Are you guys planning to offer the complete ACT kit with the proper shaved shift forks along with it in the future? That way, the amount being shaved off of them is consistent every time.
kolo I agree the amount being removed from the fork concerns me. Some kind of uniform specifications seems to be necessary.
say please what gear ratio was in stock and what is with this kit?
What is the Application?
Would see work ok with the Drz400sm stock gearing?
Would like to get a better look at the modified fork on the secondary shaft. It seems to be very slender and prone to failure.
Thanks for your concern. We have not seen shift fork failures. If you would like to see more, there is a photo on our website or email info@advancedclutch.com and we would be glad to send more photos. The wider ratios are not possible without machining the shift fork to clear the larger fifth gear. We sell both new or used modified shift forks to be sure the minimum amount of material is taken off to accomplish this and there are detailed instructions also available for the do-it-yourselfer.
does the fifth gear reduce engine RPM's on the highway ?
Yes. If you use the same sprockets there is a 21% reduction to RPM's in fifth gear.
thank you!
no chance of fitting a sixth gear ?
what do you need a sixth gear for?
@@WhiteGravey sm model need a cruise gear ?
Dont found many videos about customers that run the kit.is it durabel for though offroad tracks and heavy load on the street when i want to use it as an Adventure bike?
These gears will be perfect for adventure riding. If you search up ACT wide ratio DRZ gears you will see quite a few reviews on the forums also information on changing your sprockets after doing the gear change. If you cannot find any look on thumpertalk.com
close ratio or wide ratio for drag race 500meter ? For the best power and top speed
These gears are wide ratio. First gear is still stock DRZ, second through fifth gear are considered wide ratio. Usually for drag racing you use close ratio gears to keep the engine in the happy rpm range. Running a wide ratio gear will give you a higher top end and longer gears. When you shift it might fall out of your desired powerband when using wide ratio gears for drag racing.
How much are a new set of modified shift forks?
These are $144.00. Here is a link. www.advancedclutch.com/product/shift-forks-drz-modified-100drzsf-1
@@AdvancedClutchTechnology ACT any new videos and/or other mods yall doing? Awesome gear set (got a DR650e and just got a DRZ400S) -
Hi I have a drz 400e 2002 will this be compatible? Also how much does it cost if I do it myself thank you Harsha.
Hi Harsha! Yes this is compatible with the 2002 DRZ 400E. You would need part number 100WRSZ1. They cost $689.00 USD.
do you have a link for the gear sets
Here you go! www.advancedclutch.com/products/motorcycle-gears/gear-sets
are these gears availabel in europe?
nope, oderered mine from usa and it took 3 months until they came :D
No, we can't see the difference in the shift forks because you only hold them 5 feet from the camera for 2 seconds at a terrible angle. 🤦🏻♂️
Louie, I think you are talking about the 5th gear shift fork @4:34. If you don’t know what to look for it might be hard to see. We are sorry for that not being clear. We do sell modified OEM shift forks if you do not feel up to the task. You can email us at sales@advancedclutch.com if you are interested.
@@AdvancedClutchTechnology
Yeah I agree if you miss the massive chunk eaten out of that shift fork maybe sell your tools and buy something with a warranty 🤣
This is extremely easy wow