I own a Suzuki DRZ400E 2002 and I think the cylinder needs to be bored. Is the cylinder on this bike plated? Would it need to be bored and sleeved if so? I know that the OEM parts are just standard size.
The cylinder is plated and under normal circumstances can not be bored. There are many aftermarket companies that offer a lot of choices for your engine as far as re-plating, boring,complete cylinder and piston kits and boring with a re-plate. You will have to do some research to see which choice best meets your needs. As for the factory Suzuki parts they are meant to be replaced when worn out, our trouble shooting guide is just a general guide to get you pointed in the right direction, so in your case when it states a damaged or worn cylinder should be replaced or bored you would go with the first choice since that is your only option with the factory parts. Our manuals are based on factory bikes and factory repair information, there is no way we could keep up with all the after market companies out there and especially not for a bike as popular as the DRZ400. While you’re deciding the best way to fix your bike keep in mind that the life of the engine gets shorter with high performance parts.
Greg Gardner | Senior Technician | Cyclepedia Press LLC
Cyclepedia Press, LLC
42 Wooten Cove Road Suite 2
Weaverville, NC 28787 · USA