2003 Suzuki LTZ400 engine assembly short block

[@QuadGarageATV]

I came here while starting the renovation of my LTZ ​​400. It helped me a lot, the ATV after the renovation works perfectly.

[@amapowersports1479]

Thank you! It takes allot of work to make videos and I have tons to edit and post. Comments like this makes me feel it was worth it. I'm happy it helped!

[@Andrew-mn6em]

Thanks for the awsome video lol u helped me allot love were u get straight to the point and no talking love it😂‼️

[@amapowersports1479]

Yes! Im glad you agree, you search how to replace a light bulb and then spend 20 min listening to the guy talk about how the socket is made. Lol happy you like it im going to keep rolling that way with assemblies..

[@zacklamers1734]

very helpful video, thanks for taking the time to film this

[@amapowersports1479]

No prob I hope it helped. I'm still new at posting vids so my editing still needs work. Lol I hope a video without all the unnecessary chatter made the job go by faster for you. Thanks for watching i hope you subscribed I got lots more to post!

[@amapowersports1479]

I'm sorry I didn't answer your question, did you find out where it went or do you still need help?

[@damienvizer375]

Great video thanks alot!

[@nathanross8276]

Hey, Great video, currently using to help rebuild my Z400! Question - at 4:00 is that an O-ring you install? I cant see that in the manual. If it is what is it for? Thanks!

[@amapowersports1479]

You know what I'm glad you pointed that out because I've never seen that in other engines either. Lol I also could not find it in the manual. These videos were intended so the customer can see their motor being assembled. Im still new to posting them on utube.. In this case there was already an old o-ring there so I put a new one back. This particular motor had been rebuilt before so I was afraid if I didn't install a new one it may lead to a specific issue with this specific engine that somebody added to resolve. If that makes sense... I forgot to edit it out for the utube version. Sorry I caught most of the unique stuff and removed it but Thanks for the feedback a diff set of eyes can catch these sort of things... someone also mentioned a tab lock washer that I installed after recording then posted the wrong clip lol.. you can see in the comments below, don't forget it.. again sorry this is only like my 5th video but I hope it is helpful. im working on allot more coming soon with better details & editing... thanks!

[@fauchon6857]

Hey the shaft that you put at 1:20 for me is too low so when you put the washer abd the gear,it rub on the 5th gear help

[@brokewheels5]

Good video

[@hunter031798]

Did you isntall the 2 spacer rings with the clutches or did it not have them

[@amapowersports1479]

Ugh! Sorry this was my first video and I been trying to resolve an issue with the mem card corruption that happens to a few videos each session. If you look at that again you will see me tighten the clutch hub nut and then if you look at the base during the first carbon you will notice a steel plate is now there. I didn't catch I'm missing a clip. Under that is the wave washer, washer plate (spacers) and the one special carbon drive plate. I apologize for the issue, any feedback on preventing files from being corrupted on memory cards will help me have more accurate videos in the future...

[@itembuyer895]

Hey just putting mine together I’m at the shift forks and the shaft. I have two thin washers that fit only that shaft perfectly and they were on top but I feel they go on the bottom of the lowest shift fork out of the two on that shaft. I don’t see any on yours or in the manual??? Thanks

[@amapowersports1479]

If it's the shaft I'm thinking of then watch video at 9:32. After the spring and clip you put one washer on, the smaller one, then slide shaft thru crankcase. The other larger one then goes on, covering the seal and finally a clip. Good luck I hope this was helpful and you subscribed lol..

[@Kyle_gallegher]

Did he pull the two cases together by tightening?

[@amapowersports1479]

Sorry this was like my first video and I learned allot. If your asking how to get the two cases together you have to use some spacers and a nut to press the crankcase onto the crankshaft. See 5:20 mark then right after read the blue print across the scene which explains the part installing the case bolts was corrupted from the memory card.... hope this helps, subscribe my next ones are much more detailed!

[@Kyle_gallegher]

idk but not using tht tool means u might untrue your crank which is like why buy a good one or have it balanced. Ijs

[@amapowersports1479]

I thought I answered your question but now it looks like you don't actually have one? Are you implying something is wrong with the way the crankcase was put together?

[@Kyle_gallegher]

@@amapowersports1479 Dont take it all personally but ya dude i literally just said what I said the tool puts even stress and ur spending money good money on cranks righf so it makes sense to just use the tool

[@amapowersports1479]

I'm not taking anything personally I was looking forward in offering assistance for your engine build... not whatever this is... as i said before The tool WAS used to pull the crankshaft thru the crank bearing after 5:20 as stated before and as shown in the suzuki service manual. I don't know how else to communicate this. But, Thank you for your feedback we appreciate it, I'll let the crew know.. ✌️

[@manenemy7406]

Correct me if i'm wrong but it looks like you didn t bent the lock washer in the clutch. Great video though thx!

[@amapowersports1479]

Thank you for the feedback! This Is an "edited video" and there are some labor designated things that are not visible. This was due to either being not visible in the shot/angle, the data was corrupt or it was cut for reasons like video size or speed. Im doing all my own editing, audio and filming so I'm still learning as I go and I'm still really green to utube. I'm also trying to run a very busy Powersports business by myself. if only I had a way to post the work being done each day. My main objective in this video was to show each part as it was installed so the viewer could do the same. Hence the slower speed when the part comes close to the camera and then it's applied. I felt this info would be the most useful for someone without all the unnecessary chatter. I been applying this method to my videos since. This is my no means a video for someone that has no mechanical experience to fill in the blanks like lock tabs, torque specs and patterns. As I get better at filming I will get better at the details 😉...thanks again for your feedback i hope the video was still helpful..

[@philiproark3102]

Grate video ..question iv got a big problem..i recently bought an 03 z while removing throttle cable im pretty shour the small brass piece that holds the end of the cable in the carb fell in to the oil vent hose below it.the one that gos in to the base of the cylinder head!!!!..sounds dumb but i must have blinked while geting out of the carb,it sliped ot of my fingers and diapered..i lookt everywhere found nothing.. so i hoped i just lost it but when go to ride it my clutch feals funny and it poped out of gear twice.!.! so how far am i going to half to tare this engin down to find it ? or what do i do? please/thankyou

[@amapowersports1479]

Aw man that sucks! I been there, ugh. Well you can try changing the oil first and see if it comes out. Next, try pulling the side covers and looking in the little valleys along the bottom of the engine block. If that fails then the brass, being soft metal, probably smashed somewhere in the trans fork/ shifter drum valley... that's worse case and to get to trans you would have to do everything I did in the video. You do have to split the cases to get to the trans.. sorry. Good luck, I hope you find it sooner! Let me know if you have any more questions.

[@philiproark3102]

@@amapowersports1479 will do thank you so much for speedy response

[@Not_Tony]

I cannot get the nut at 6:45 to come off, I needto change my timing chain. Any tips? I put a socket on the crank shaft from the cover plate on the other side of the motor but it still spins.. Also I know its reverse threaded. I'm debating on splitting the case the motor sat with the jug off of it for probably 10 years. theres stil some oil in there so i doubt its rusty but im more worried about debris. Think I should go ahead and split it or just flush it out with oil?

[@amapowersports1479]

Well, first on the question for breaking the nut lose. You can leave it sit overnight after spraying some brand of nut buster on it. Apply several times heavily. but my main suggestion would be using an air impact with a min strength of 400 or 500 psi . I usually just hold the connecting rod in one hand to prevent spin and hit it with the impact in the other. Just be careful how you lock down on the connecting rod you can break it that's why I usual just hold it. The nut buster would still help. There are also many forms of tools you can buy to lock the gears from turning. On the question of whether or not you should split the cases id say it depends on these factors. First, do you have a press and the tools to preform the job throughly? These customers are spending allot of money on these projects so they don't want to risk getting finished and the motor wears out in a year or two, they plan to keep these bikes. By splitting the cases you can replace the crankshaft and all the bearings/seals to "reset the clock" on an used engine. The main other reason to split cases is to replace damaged parts or transmission like an R6 video I'm working on now that broke off the sprocket to the chain. Finally there's high performance reasons. Some of these videos are replacing the stock crankshaft for a stroker and OS piston. If none of these apply to you i wouldn't go that far. So if you don't plan on keeping it long or don't have damaged parts or don't want high Performance parts then just flush it out really well while you have the engine open. Hope this helps!... let me know if you need better details. Also you can call us directly www.amapowersports.com the numbers listed on the site. Good luck!

[@Not_Tony]

@@amapowersports1479 dude! thanks for the fast and well detailed reply especially at midnight. I will try again tomorrow to get the nut off, I was even trying with my 1200 FT/lbs impact. I just couldnt get it to quit spinning. Also I do not believe I possess the necessary tools to properly split the case. So I think it would be better for me to not go that far. Especially since I dont plan on replacing anything in there. thanks bud!

[@Not_Tony]

@@amapowersports1479 woo i got it off. really easily this time.. I just stuck a screw driver in between 2 of the gears. impact knocked it off like it wasnt even on tight. another question. I noticed after getting a good light and looking into the case from the top hole where the crank comes out of, there doesnt seem to be any large debris but looks like a lot of dust and lint. what would be the best way to flush all of that out? and will it hurt anything with it in there?

[@amapowersports1479]

Awesome! Glad it helped. Sitting years with the jug off should Def be flushed out. If you sit the motor upright... piston top pointed to the ceiling, then you'll see along the bottom of each side there's open slots that allow oil to sit along the bottom of the motor. You can leave the side covers off and flush in thru the cylinder as it flushes out those bottom openings OR put side covers on temp then fill up motor thru cylinder. Next day, drain and flush the first way. We use desiel and kerosene to flush them out.. good luck I hope you subscribed!

[@Not_Tony]

@@amapowersports1479 thank you and i will sub, idk why i havnt yet.

[@hellquadtuning-berlin9121]

Wo ist der Schraubensicherungslack der an einige Muttern und Schrauben gehört? Warum wurde nach dem Zusammensetzen der beiden Motorhälften nicht die Befestigungsschrauben angezogen damit die Gehäuse auch Dicht sind und bleiben? Ebenso vermisse ich den Drehmomentschlüssel. Wenn dann der Motor im Betrieb Geräusche macht oder etwas auseinander fliegt wissen wir ja warum. Den kleinen Schrauber für die Pleul Mutter ist ja wohl ein Scherz oder. Ansonsten Danke für die nicht ganz Vollständige Montageanleitung per Video Ansonsten

[@amapowersports1479]

Sorry I don't speak... is this German?

[@amapowersports1479]

Sorry I don't speak..... is this German?

[@hellquadtuning-berlin9121]

@@amapowersports1479 jes this is German

[@amapowersports1479]

OK your first question isn't translating correctly. But if it's the lock washer your asking about another person asked the same question. It's basically edited incorrectly it's a long story. you are supposed to bend that tab. The second, about the two halves not being tightened together, i can answer. A note shows up on screen stating this part of the video was a corrupted file and to Make sure you follow proper torque and tighten sequence. which I'm sure you can find online. Sorry I'm still pretty new to the utube experience but I am upgrading gear as I go to provide better videos. Hope this answers both your questions, thanks!

[@hellquadtuning-berlin9121]

@@amapowersports1479 1. Why are the two halves not screwed together after applying the sealing paste? 2. Why is a suitable torque with a torque wrench not used for the important drive nuts. Workshop manual? Where is the screw locking varnish on the Phillips screws? This is very important because they cannot be tightened so tightly if you do not exchange them for an Allen key. If noises and damage occur during operation due to loosening screws, the reason is clear. Sorry but German accuracy! Google Übersetzer

[@razor825000]

Hi I'm Ed what kind of price range to put a output shaft and do valve shims gaakets and seals in a drz 400 ID send complete motor to you basically same job in video

[@amapowersports1479]

Hello sir, id have to ask which shaft specifically, is it a trans output shaft or you talking about the crankshaft. We charge based on how deep we go. Heads, piston, crank and trans. I can supply a hot rods complete engine rebuild kit if you give me a year, make and model. If it's the crank your asking about. Finally there's allot done to that motor that's not in the video, I'm still learning to edit lol. But that brings me to the head, so you want the valves lapped and grind, head planned and blasted or just leave them in. Help me with those answers and I can get you a estimate. Thanks!

[@razor825000]

@@amapowersports1479 2007 drz 400 s sprocket shaft valve shims gaskets seals leave everything else alone bike runs fine stripped sprocket shaft threads is problem and needs replaced and due for valve ajustment light ticking under load

[@amapowersports1479]

OK, I don't know if you have the parts but If not I have an imput shaft,oem, for 179.19. A complete engine gasket and seal kit for 101.80. You may want to consider having us replace the bearings and piston while we are in there but that's completely up to you. The labor for the current job would be 710.00. Let me know if you wish to proceed. Thanks again!

[@amapowersports1479]

Ed I apologize I realized when giving a estimate today I over estimated yours. 710. Is to pull it out of the bike. For 250.00 we split the cases and got 250 we lap valves, plane head and sandblast. So your estimate is 500.00 not 710.00 sorry.

[@southsidetj]

Where did you get the rebuilt kit ? Top and bottom end

[@amapowersports1479]

We stock all the parts needed and then discount it as a "kit". Usually it's all "cylinder works", "hot rod" and "hot cam" brand parts so they are made to go together. If you like you can call the business at 757-794-3272. We will help you decide on your own kit, you can pay directly over the phone, we offer free shipping in the US and if you mention this utube video we will give you another 100 dollars off! You can also check us out at www.AMAPowersports.com we are a legit business and look forward to helping everyone with there Powersport needs... thank you for your feedback!

[@dirtrider6090]

Hey what is that washer you are installing at 4:00 min. I can’t find it

[@amapowersports1479]

That's the same rubber o ring a previous subscriber asked about. Please disregard.. if you wish to know the details I explained it further in the comments below. I hope it didn't hold you up. I apologize, again you do not need that o ring. Thanks for the feedback!

[@dirtrider6090]

@@amapowersports1479 ok thanks man this video helped a lot my customer bike blew up and is missing a few things. I was confused the o ring was for. And also the counterbalance and crankshaft doesn’t have a mark right? The marks are on the 2 gears at 7:30min?

[@amapowersports1479]

@@dirtrider6090 yes the two gears have marks on them to align the crankshaft with the balancer. The o ring clip has no back ground music, I was supposed to edit it off I keep kicking myself in the ass for forgetting to remove it.

[@flyingkitty900uc]

Hey how do I get the shift pawl on it the right way I did it like the video says but it won't shift please help

[@amapowersports1479]

Can you post a pic of your shift pawl so I can see how you installed it

[@amapowersports1479]

Also allot of people lose pieces to the shift pawl. If you remove it off the bike there should be two lock tabs that can fall right out. They have a round side and a flat side. The round side goes into the pawl itself will the flat sides should be pointing outward. Also behind both those tabs should be a small push pin and a spring to push the tabs outward so they lock when shifting. If you sing have these two springs or pins it will not work.... let me know

[@flyingkitty900uc]

@@amapowersports1479 yea I have the 2 shift tabs everything is there but it doesn't shift they spring outward and grab the drum but when I tighten the lil plate it doesn't move

[@amapowersports1479]

If your talking about the plate that holds it all in its not supposed to move. Go to manualslib.com and download the free service manual for your bike. Compare to those pics or use the names it shows in the manual so I know exactly what your talking about

[@flyingkitty900uc]

@@amapowersports1479 the plate doesn't move but the problem is that when I tighten the plate on the assembly the assembly doesn't move like it's stuck or something

[@BoBBy_Loko]

The first Z400 came out in 2003

[@sdqsdq6274]

same engine as drz 400 ?

[@amapowersports1479]

Its in the middle of the night here so I'll do my best lol. I believe internally they are the same. You couldn't swap one for the other due to some drive differences but the video would still be helpful with assembly. I always recommend following the service manual of your vehicle for things like torque specs and how to tell what needs replacement from wear. That being said maybe the video can help you simplify assembly but if you do run into a difference refer to manual. You can find a free pdf of your service manual on manualslib.com. the two tools together should Def help you with the task at hand. Good luck!

[@oyeah7863]

Hey man my name is Nathan do you want to fix my quad my chain came off and hit the shifter And it broke the case

[@amapowersports1479]

We are a shop located in Toano Va. We can repair most broken cases.

[@SheeS_mine]

hello ... I have the problem that my circuit diagram is reversed after rebuilding

[@amapowersports1479]

Circuit diagram?

[@SheeS_mine]

@@amapowersports1479 gear 5 is at the bottom 4 3 2 1 then up 

[@amapowersports1479]

Wow, well honestly it's 3:20 am where I'm so forgive me I'm half awake but I'll see what I can find out when I get into the shop tomorrow. That's one I haven't had happen yet. I hate to say it but your going to have to go back in and see how you flipped it. I'll get back to you. When it's in a gear like 1st is the sprocket spinning in the correct direction as you crank the motor?

[@SheeS_mine]

@@amapowersports1479 I think the motor is turning the right way around, only the gear lever turns the adjustment in the wrong direction

[@oyeah7863]

Will pay you

[@amapowersports1479]

What are you looking for?