Suzuki Drz800 Madasuki

 Caballo de Hierro, together with for 2020 nosotros decided to create a tribute to the Rally bikes amongst our MadaSuki.

Choosing the donor wasn’t difficult… what was the most controversial Dakar wheel ever? What was our favorite Dakar Hero? Both questions got speedily a reply: the Suzuki DRZ800 together with Gaston Rahier.

So nosotros went on a Suzuki DR800BIG every bit donor model, nosotros selected a SR42B 1990 model because of the large bore 779 cc engine (the SR41 was 750) together with maintain a closer shape than the SR43 to the original 1988 DRZ800 Dakar.

Honestly I have got years without working on enduro bikes together with never worked inwards a rally wheel before, but nosotros got something together with therefore clear, the wheel should live a truthful rally bike, non alone an aesthetic recreation.

The Definition of the shape was non a problem, Mihaela got clear from the offset nosotros should maintain the large tanks together with the duck olfactory organ but slimming the dorsum for getting a lite shape.

For functioning reasons nosotros decided non to impact the frame, the DR800 has amazing riding capabilities that nosotros didn’t desire to break, this thought that seems simplifying the run was the opposite, getting a novel nurture trunk elements inwards the Mihaela’s proposed shape without interventing on the frame was a lot of work, nosotros used a rattling lite aluminum alloy for the tail, undertail together with sidepanels, rattling tricky for working on because doesn’t perform every bit normal aluminum together with nosotros got to a greater extent than or less pieces broken on the means until I larn used amongst metalshaping this material.

Along this weird twelvemonth nosotros passed for a lot of downward moments amongst the pandemic, unopen downward together with lack of supplies, also all shows were cancelled, nosotros had previewed to liberate the wheel at the Bike Shed Show together with when the cancellation was announced was a sort of slap on our faces, but fortunately our partners inwards criminal offense inwards this projection continued working together with sustaining us, together with nosotros decided non to halt the projection together with accept wages of the province of affairs for getting the wheel every bit closer to perfection nosotros could.

Performance was a priority together with therefore nosotros decided to inquire for assist to those that actually know most this bike, the response wasn’t far, nosotros got it inwards Deutschland at Hessler Rallye Team, I contacted Stefan Hessler, the alone 1 sorcerer of Big Ducks together with at 1 time he became together with therefore interested inwards our adventure, nosotros should thank you lot this guy together with therefore much for months of help, tips, tricks together with all materials provided for making our MadaSuki the closest affair to the original DRZ 800 from the technical signal of view.

The 779cc engine has been overbored to 809cc, the cylinder bore plant was made past times Hessler inwards Deutschland piece nosotros worked hither inwards the cylinder head, planishing it, polishing ports, novel valves, guides, etc, next the Stefan’s indications. The piston is a functioning CP Carrillo made on demand, all internals of the engine were reviewed together with refreshed, novel timing together with balancing chains, novel racing functioning camshaft, novel rocket arms, novel bearings, novel stator, novel EBC functioning clutch amongst hydraulic Magura HYMEC actuator together with original cyl, novel cooling lines, a consummate overbore together with overhaul together with therefore the wheel nosotros tin consider is create novel from the engine signal of view.

For feeding the monster nosotros trust on a dyad of Mikuni apartment slide carbs mounted together with laid upwards also past times Stefan Hessler, the best means of feed that torque hunger large single. We combine it amongst a custom intake piping together with a foam UNI filter pod.

On the exhaust side nosotros are using a custom inox header combined amongst a bespoke functioning Sebring muffler also nether the blueprint of Stefan.

This combo is a blast, the overbored large unmarried is at nowadays giving lxx hp (vs the stock 50hp) amongst a monster torque that makes the wheel a rattling nervous demon!!

For supporting the upgrade nosotros implemented a upgraded YSS forks amongst a nurture Wilbers total settable stupor that let us to play amongst the suspension a lot. Front brake was also upgraded to a 320mm total floating rotor amongst a iv pistons calipper commanded past times a Magura original cylinder, all reinforced amongst corresponding forks lower bracket. The nurture brake is the touchstone plenty amongst the 280mm rotor together with the double piston calipper 1 time upgraded amongst a functioning EBC rotor.

Another of import chapter on a rally wheel are electrics together with controls, nosotros discard the sometime electrical wiring a made a create novel 1 using siliconic cable, the primary electrics are commanded past times a Motogadget Mo.Unit together with the wheel controls are inwards the correct side of the bar integrated on a bespoke force push switch setup made past times our friends of 0711Motorcycles also inwards Germany.

A primal business office of the electrics were the instruments, nosotros needed existent rally instruments on this wheel together with therefore nosotros installed a rally tower amongst a Hessler electrical roadbook device, together with for navigation nosotros inquire to our Castilian friends of GZ Parts, these guys are producing high character rally equipment developed past times themselves from their sense every bit rally riders, they are rattling good know inwards the rally raid championships inwards Spain, they also became together with therefore interested inwards our projection together with furnish us 2 OdoCap rally computers amongst their corresponding bar remote controls that are placed on the left side of the handlebar, the OdoCaps are 1 of the most accurate devices inwards the marketplace combining the traditional wheel sensor applied scientific discipline amongst the GPS technology. The wheel dashboard is at nowadays a Daytona Asura estimator that give us a rattling exhaustive information of the wheel inwards a clear way, rpm, speed, hours, petroleum temp, ambient temp, odo & trips, alert lights, voltage.

The decisions amongst paintings, every bit always, were taken past times Mihaela, together with from my signal of persuasion is 1 of her best works, the colors together with lines are exactly immaculate providing a rattling aggressive together with fashionable await at the same time, the duck olfactory organ modernistic amongst the double headlights together with the clear windshield are exactly awesome, together with every bit required on a rally bike, all trunk is mounted amongst a quick liberate arrangement that let us to disassembly the whole inwards less than 10 minutes. Also, fifty-fifty the lite shape, the wheel is laid upwards to have all rally annexes, beingness previewed on it points for asset tool box, pannier or additional fuel tank together with also protection crashbars if required.

At the end, the Covid era allowed us to create the most perfect wheel nosotros ever built.

This demon was previewed also to participate at the Romanaian Moonride 2020 that was cancelled together with other events that never took house but, looking at the brilliant side that volition let me to ride its initiatory of all kilometers together with getting it laid upwards for giving its best adjacent year, together with yes… the wheel is addictive, can’t larn downward of it fifty-fifty I await pocket-sized similar Rahier on the DRZ, hahaha!!!!

Special thank you lot to Hessler Rally Team together with GZ Parts for their technical together with fiscal back upwards along the way.

Photo credits: Mihaela Lopez Photography @lopezmihaela

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