DRZ400 Starter Clutch Bolts Fix

Early models of the DRZ400 were subject to the starter clutch bolts loosening, backing out and then contacting the stator. The end result was normally a destroyed stator and metal debris fed through the engine. 

Suzuki is very good at identifying issues and fixing them in future models. The failing cam chain tensioner issue is a good example. The starter clutch bolt issue has also been identified by Suzuki and all new models have Loctite applied to the starter clutch bolts to avoid this happening.

If you are unsure if your starter clutch bolts have Loctite applied, it is worth the 15 minute job to check. This may save you a severe headache on the trail, and a hefty repair bill after you cart it back home. 

Photo 1 of DRZ400 Starter Clutch Bolts Fix
This is an example of the DRZ400 starter clutch bolts loosening, backing out and then contacting the stator. A fairly disastrous result. (Photo courtesy of Muller @ bamarides.com).
Photo 2 of DRZ400 Starter Clutch Bolts Fix
The fix simply involves removing the gearshift lever, the left side engine case (magneto cover) and adding Loctite to the six bolts indicated in this photo. The DRZ400 Clymer manual states to torque the starter clutch bolts to 26nM.
Photo 3 of DRZ400 Starter Clutch Bolts Fix
If your bolts don’t have Loctite, then you should apply Loctite Threadlocker Blue 242. If you don’t have any, there is a link below.
Author of this article: RMOTO