Just finished making the aft rack from 3/8 id stainless. Bags I sowed from 18 guage polyurethane coated fabric.
Here is the full rundown of what i did.
The only thing so far that i did was the airbox mod with the sewer hose to block the sound. That restored the bike from running rich to normal maby a bit lean at 4000 feet and 90-100 degr. I felt that there was more to be done. In went the k&n su-4000 filter.
Dynojet kit for the drz400s. From the kit i installed the following parts: Big spring, needle, clip for the needle. I changed the pilot jet to a 25 from stock 22,5. Installed the kientech fuel screw, and put in kientech stainles screws for the bowl. I decided to leave the stock main jet 142,5 i think. I really like the results. When i pull up the highway 5% grade to 5500 feet the bike for sure pulls stronger at a lesser throttle setting. 0 to1/4 throttle good response and pickup with only little backfire closing the throttle. 1/4 to 3/4 throttle wery strong pickup especialy from 1/2 to 3/4 throttle. Maby a bit room for improvement about 1/4 throttle. when the needle circuit picks up at 1/4 throttle there is a tiny hesitation, maby so little not worth mentioning. I think i have to run it a bit more to home in on it. And then figure out what to change...maby try lowering the needle 1/2 step with the suplied spacer. From 3/4 to 1/1 throttle the bike pulls strong. So i belive the choice of main jet is fine. In the next day or so i will do a spark plug test. I left the fuel mixture screw at 1 1/2 turn.as per kientech recomend. It needed a bit more fuel from idle to 1/4 throttle so I ended up with fuel screw 2 turns out.....nice.
I am in the process of taking all the covers and make a negative fiberglass mold, in which I will produce a carbon fiber replica of the original plastic cover. Have one done so far....looks nice. The pdf slide show is of the rack and bags. I welcome any questiones at: ebrabaek@sbcglobal.net enjoy