What’s Inside this 20 Year Old Suzuki Z400 Engine? (Not Good)

[@MichaelSabo]

Signed Dash Cover (at 40:45) - ebay.us/QBRtYA - Auction ends Feb 20th at 1PM Besides the clutch side of this engine, do you think it was ever opened up? Thank you for watching my video! If you enjoyed, hit the like button and consider subscribing 🤘😎

[@philipjohnshire]

dude, found you on youtube like 6 months agp and binged watched ALL your content haha love your videos, keep it goingggg! :D

[@MichaelSabo]

@philipjohnshire I appreciate the love man! Thanks for binge watching my stuff 🤘

[@philipjohnshire]

much love! @@MichaelSabo

[@MichaelSabo]

@mostlymotorized facts. My hand drivers are JIS but God only knows what those Milwaukee bits are.

[@boostlife6669]

nah u did great love it! but for the phillips screw u should buy a impact screw driver it would save you lots of headaches in the futur build! besides thats keep it as it ur the best

[@hennessyremy4970]

This is the best weekend ever!!! I have my favorite in-laws in town visiting. I’m out at a steak house as we speak. And not for nothing. It’s MF SUPER BOWL WEEKEND!!! Thanks Mike!!!!!! You’re the man !!!!

[@MichaelSabo]

Dude this is an awesome comment and compliment; thank you 🤘🤘

[@justinmochi7323]

Bro THIS is the super bowl

[@MichaelSabo]

@justinmochi7323 my maaan, thank you for saying that

[@wicziwajcha8]

Jesteś jednym z najlepszych youtuberów w tematyce quadów w USA. POZDRAWIAM Z POLSKI

[@MrCrabs441]

I was bored and looking for something to watch! Not any more! Thanks for the content 🤙

[@bigfootandbananaman4746]

I assume ART is a factory piston. The factory pistons out of my Tacoma engine were made by ART.

[@MichaelSabo]

Thank you for that info man!

[@Donny_Buysall]

Art metal Co. LTD, Japanese OEM piston manufacturer.

[@SOMNIOHM]

*_Someone abused the absolute hellllll out of that clutch! That is beyond smoooooked!!!_* _(I do not everrrr recall seeing a clutch pack with that much burnt on oil, and discoloration!)_

[@danielgomora7455]

Someone get my boy a 3/8 Milwaukee Stubby impact 😫That thing will make your tear downs so easy. Awesome content as usual Sabo!

[@roberturmosi-dirtbike-atv]

This is what my Doctor ordered to watch, thanks to uploading it, saved life! 😂

[@MichaelSabo]

Haha, you're the man Robert, thank you for watching 🤘

[@NateG3678]

For the oil pump with Phillips style, I always use an impact driver first so you always get a down force blow with a twisting motion. I use the driver on all Phillips style to loosen them up so there’s very little chance of the tool slipping and messing up the screw. Just my two cents, and I thoroughly enjoy this channel and what you do.

[@braxtonliddell5962]

My 04 swing arm was cracked all the way through and I welded it and it is still holding up perfectly and I ride that quad hard

[@powertripr164]

Mike you need a good quality hand held impact driver for those Philips screws. It makes quick work of those pain in the but screws. If you do get one, hold it in the neutral position and smack with a hammer to shock the screw, then turn to the loosen direction and smack again and they come right out everytime.

[@Max-ye9xg]

I love the boxes underneath the workbench that's the way to totally organize it

[@blessedinjax]

I think these engine tear downs are probably my favorite

[@Stuckin330]

Another thing about these z400s the timing chain tensioner spring are to stiff on these causing timing chain to wear faster I like the manual tensioner for these it’s the best upgrade besides the rear swing arm and carrier . I kno your trien to keep it original resto but it’s a good upgrade for these an will save you a lot of problems an double the life of timing chain an guides . I deff learned a ton when I had my z400

[@Marts1499]

As I’m watching this I notice you run into the common issues I always have like the timing plugs 😂 the stock can chain tensioners are absolute junk. I would suggest a manual tensioner

[@michaelpresey2273]

And also I would recommend getting a manual impact driver if you dknt have one ! They work reakly well for the screws inside a motor even for the screw you damaged on the pump im sure a manual impact will take that right out ! Thanks for the content Mike cant wait for the next

[@jcaashby3]

29:00 Always opt to use a impact driver to get those phillip head screws out! The oil pump and shift drum cover always will tend to strip if you do not use a impact driver.

[@jessemcbride6567]

Glad to see I'm not only one get a hard time with some of my engines

[@RealSuburbanCowboy]

You can always hit the end of the flywheel puller with a hammer (metal, not plastic), and the shock will frequently bust it loose. Love the channel.

[@bigfootandbananaman4746]

My z400 swingarm was cracked way worse than that one. I ground it out with a cutoff wheel and a welder I know welded it up for me. I'm still riding it with no issues and that was almost 2 years ago.

[@Stuckin330]

I really miss my 2004 ltz400 hands down the best quad I’ve had from factory . Mine was show room condition an low hours when I got it and very snappy for the 400s lil bit faster than 400 ex but I’ve always wanted to build a 440 ltz and line it up against a 440ex

[@mrhzk35404]

The case issue is common for the ltz400. For some reason nobody knows how to tighten or maintain the chains on these. They also never seem to spend a few bucks on a case saver.

[@1187titanium]

Map gas torch helps alot on things like flywheel taper and stuck case plugs

[@elvisregalado3340]

Hey Michael. Will strongly recommend you get an impact driver set. Snap on makes the best one I own so far part number (208EPIT). Awesome videos by the way!!!

[@Dromnivo]

OMG as a DRZ owner I have been waiting for you to tear down one of these engines. This is gonna be great.

[@kingkracker1998]

12 point socket WILL strip a 6 point bolt. should always use the correct sockets for the bolts.

[@jcaashby3]

The only time I use a 12 point is if I have a 12 point bolt to remove. Like some suzuki engines have them for the connecting rod bolts.

[@canadiantechprep]

I just took my DRZ400 engine apart and ran into the same issue with those screws on the oil pump. I ended up using a hand impact driver and it worked perfectly as it applies rotational torque while being hammered. I don't think I will ever try using an impact driver on these types of screws again, as stripping those screws can end up stalling the entire build/teardown. I will be posting a video soon. Nice work.

[@jordanpanich]

The discoloration on the clutch makes me think it got really hot from partial slippage due to no cable free play or because someone didn't know how to ride with a clutch very well. Time to invest in some JIS bits/screwdrivers! Those screws won't give you much trouble then. Rad project!

[@jcaashby3]

Or a impact driver to easily remove those screws. Using anything else is asking for them to get stripped.

[@_Otaku-kt8be]

You should always use 6 point sockets on 6 point bolts to avoid rounding them.

[@jeffdavison8421]

Hey Mike, When its time to reinstall your torque plates in the case I highly suggest using Allen style fasteners any and all. Ive ran into to many stripped screw heads or fucked them up myself in a tear down. Sage advise from a old man at 63 years and counting. Working diligently like you today on a 93 RMX250 restoration. Hope you locate a good case half. Jeff Davison, Saginaw, Mi.

[@mikewisher4083]

Rox makes parts for sleds . Glad to see u don't edit the bad times . Going to another killer build when done

[@jetskihoarder]

Art makes a lot of oems pistons

[@4thdimensiontravels855]

I absolutely died when you mocked the engine buildrs, reminded me of me and my brother. Weve done that since we were about 7 or 8.

[@toddlloyd9161]

So glad you are doing a Suzuki finally

[@bryanjetboy7814]

At 20:14 I can see the starter clutch gear rotating CW behind the alternator rotor when you are using the impact on the gear puller. perhaps hold the rotor rather than the crankshaft rod?

[@chrisyeahbuuwassrileegowyn9279]

Another straight legit "Real Deal Sabo" video! You know how many KZbinrs just cut out any mistakes they make? Most of them.... I will never understand the use of the screw headed fasteners in high strength "bolt" applications (Japanese Industrial Standard) but it is what it is at this point. I highly recommended using a manual impact driver (hammer-to-turn style) with an actual high quality JIS bit. I still am actually relearning this occasionally as I must be a bit dense.✌🤘

[@zach38z]

Kids went to the grandparents house and its raining so what better way to spend the saturday than feet kicked up with taco bell and an awesome mike video! Perfect timing lol

[@shonrob1620]

When the air compressor goes off lol every time

[@doomdestructer-t5630]

10:21 “seems overly complicated” Well, it does say Suzuki on it😂😂 Loving the project man

[@gamerX-wk7ct]

the ltz 400 is one of the easiest engines to work on

[@democratsaretheDEVIL]

The first models had bad timing chains, my 04 kfx did. Awesome bike and enjoy the builds. The best look is the orignal look.

[@blessedinjax]

Johnny bravo out here saving quads 😂

[@purebloodheretic4682]

A Propane or Butane Torch is handy to pursuade a tight tapered flywheel to let go & free bolts that have been Loctited - best to lightly heat before using the flywheel puller - it works for me anyway - Can't wait to see you work your magic on the LTR 👍

[@Bl8nkk]

Always a good day when Mike uploads

[@garagemcmatt]

Every ltz,kfx,dvx I've had come through my garage had a broken case in the same dam spot bro. Just a week point, might need to go aftermarket on the case saver for that part. I'm sure everyone will understand that not being oem

[@gamerX-wk7ct]

some of the costumers i had to deal with from 92 till 07 had me chewing my tongue off . come in with the case broke and a broken case saver and im looking at it and know right away what they are saying is bs you can not run a worn-out chain or a chain not adjusted right and think nothing will happen.

[@garagemcmatt]

@@gamerX-wk7ct can't take the dumb out of some people bro

[@RJL1983]

Both anxiety and curiosity is at PEAK levels when I tear into the engines on old atvs I buy lol

[@WilmaFingerFit]

I’ve had a clip fall down in bottem end and fished it out with a magnet got lucky lol

[@briandilse4216]

Very glad your back to weekly content

[@Rich1776-]

Probably won’t see this but. I definitely recommend investing in a set of JIS screwdriver. Help to save those Philip fasteners.

[@nolanmeyer4052]

Loving the build!

[@michaelmitchell5909]

Man this thing is gonna be absolutely bad ass, I love watching you build these quads man. Always a thumbs up from me Mike...

[@strykerentllc]

The reason those Phillips head screws fought you so hard is due to the thread locker. For future teardown notes, degrease the interior of the case with non-chlorinated brake parts cleaner and heat the heads of screws with a micro torch. The heat will liquify the thread locker and the screws will loosen with minimal effort and you won't trash the slots.

[@scottcollamore3609]

I’m wondering if someone put the clutch basket from another machine to save money ! Love your videos bro just more to learn and trust I absorb this stuff in my sleep as well lol cars too

[@BentleyCoachworks]

Bro my tensioner was the exact same when i did my top end!! I was also shocked

[@I509_carlos]

Used to have one too lots of problems lol but loved it

[@gabrielruiz-yt2fh]

The amount of work mike puts into these projects and the videos is incredible i have been binge watching everyday more an more videos i love your work and craftsmanship im builidng a 400ex stage 2 hot cams kibble valves and big bore 426cc with tripple rate shocks new grips graphics, tail light clutch line and levers got the engine painted today with high heat new nerfbars fat boy handle bars gonna be putting new gaskets in due to an oil leak and shes almost ready to rip. Anyways love the videos and the content mike. Dont ever loose that motivation your a good mechanic and good guy in general we all have love for you. SUPER BOWL WEEKEND TMM! Hope you have fun an spend some time with family.

[@jake_beforeiturn]

That is indeed an OEM piston!

[@warrenfranklin7579]

Hey man, thanks for your efforts. It's good to learn new things. Wicked content keep up the good vids

[@NOTTApro142]

Looks like your in for a good build! Though if your going with an 05 frame, get the shocks if your still going for the showroom floor look

[@jeremyleis5415]

Michael, you really need to look into getting an electric induction heater for those stubborn bolts and such. No flames to have issues with and still gets the shit loose. The one in our auto shop gets used often to avoid heating things not intended to melt. Can even used around a fuel tank, from experience. lol

[@15brucet]

Usually put the pressure on the flywheel and tap the end of the puller with the hammer usually the shocks will pop it off

[@Aden_lr]

Mike your vids have inspired me to do a build on my Yfz450r that I wreck so far I’ve replaced everything broken and add some upgrades 🎉

[@ivanovandermescht5143]

Hey sabo,man thanks for everything,i have asked for so long and im sure you have seen one of my comments i have been supporting you for supper long can you please do a trx450 after market build please man

[@wyattcitizenzap4539]

i have one i need to rebuild. ALSO I HAVE THE ORIGINAL CYLINDER RIGHT NEXT TO ME! the ART 3 is the original piston. mine also has that on it.

[@blessedinjax]

You know what I just learned Mike Not to mess with one of them I’m watchin the goat struggle rn

[@DeckerVit]

Stripped a head bolt on my CN250 yesterday - I think the neighbors heard my F bombs. Good stuff!!

[@justsomeone6835]

Loved my 06 Z 400 liked it more then my 03 660 raptor bought both new just my opinion

[@amossaundersiv5116]

This build reminds me so much of much of my 05z400 rebuild !

[@jmaxim80]

Love ya brother, you definitely got your work cut out for you on this one. I went oem on an 85 honda 200x, and like you said, some of the parts are unobtainium. I remember it was missing the air intake tube, and it was one of the single year jobbies. But I found one over in Europe, and that's where the fun began trying to get it shipped, but she finally made it state side. And now it's one of my favorite bikes to ride, I just need a new set of tires, and she'll be mint.

[@Stuckin330]

Hey you should build a 440 big bore ltz and compare it to a Honda 400ex with the 440 . That would be awsome . I built a Honda 440 engine an it was a monster that come alive lol . I’ve never built or rode a ltz400 with the 440 so I’m very curious as to see which quad will be better from low end to mid range an on the wide open range !!!!!!

[@AndyGump36]

Hopefully it’s easier to put back together because I would’ve gave up as soon as my bit fell off in the case 😭🤣 love your work buddy can’t wait for the finished product 🤛🏻

[@MrMecano]

Brother, go get that M12 Fuel 3/8 drive impact, you'll never swap impacts ever again! Keep up the good vids!

[@ricku4856]

Mike you have to get a hand inpact screwdriver. One smack with a hammer and those phillip head screws will pop right out.

[@GhostedEgo]

I believe that whole clutch and basket come out of another quad

[@nevillegoddard4966]

Good job mate! 😃👍! Glad to see you didn't bust up the case halves with that forgotten E-washer! Phew!

[@justindurand9110]

You should use a breaker bar to break those bolts loose you'll have a much lower chance of stripping something or chewing up the hardware. Also, an impact driver (the one you hammer on) will (usually) get those Phillips heads out without damaging them.

[@Tay_2_raww]

I thought I was going to need your video to build mine but I the blaster content helped me build multiple bikes now But keep up the good work 👍🏾 your work inspires me to build a lot of bikes

[@GrandPappySmooth]

The z400s were bad for those starter clutch bolts snapping the heads off. I had it happen on 2 machines. I'd recommend replacing them for sure. they cause a lot of damage when they snap off

[@landonkulas2968]

I love watching your videos Joe, really amazing your ability to do all this and it’s a true gift. Been here since you riding with your brother days haha

[@mathisbelair416]

Sometimes everything goes well.. and sometimes we're all doing shit like that lol. Great job! one of my favorite channels!

[@johndalton1359]

Make sure you upgrade those starter clutch bolts. Notorious for the the bolts breaking

[@slammin_gears]

ART is an OEM supplier that makes most of the pistons for Japanese manufacturers.

[@mxthunder2]

I feel like using those allens with a drill is just asking for trouble. If I know something is going to be troublesome, I will use a regular allen wrench on it vs a impact/drill

[@jcaashby3]

Yeah Mike got lucky on a lot of the bolts. Anything that is 4-5 allen sizes one should really loosen them with a ratchet. A impact is overkill as they are not torqued enough to need it.

[@StaticVapour590]

That discoloration on clutch pressure plate seems to be from deposits of the oil itself, maybe the clutch was slipping badly previously and was clutch plates were replaced, but damn that scuffed inner hub

[@maxxisrazr2012]

You're a legend man! Love the video and had a good laugh 😂

[@nathanhayek3024]

Patiently waiting for Mike to do a 04/05 trx 450r

[@BrocleeWrenches]

looks like automotive friction reducing oil was ran and the clutch was wearing if you look it over it will feel slimier than just oil. just a thought could just be olddd oil and the heat from the clutch baked it into the pressure plate and hub?

[@Barrymckociner074]

Looks pretty good to me michael, glad atleast somthing looks clean on this machine. 😂

[@njmxjunkie3128]

That burnt oil color is exactly that. It’s just old burnt up oil and clutch material. I’d assume that bike’s been through a few clutches and lots of high temperatures.

[@njmxjunkie3128]

Also that’s either an ebc or Chinese cheap clutch and partially why you’d have that discoloration, mostly tho from high temp and old old oil

[@dirtinburton3301]

Mike never disappoints man I’m telling ya!! Also liking the weekly uploads even though they are shorter than normal I’d rather have a vid every week that’s shorter than bi weekly longer vid, but anyway killer content man can’t wait for the next one!!

[@Charlie1993ohio]

Im watching because its informative. however it figures when you finally get to my machine youre going to stock as much as possible lol i was hoping for inspiration hahahaha

[@mariomessinese5287]

Yes ART is the manufacturer of OEM pistons

[@Dr650rob]

Use a torque punch that you hit with a hammer to loosen the screws and use a jis bit

[@andrewbroeker6039]

Impact screw driver, and not using chrome sockets for impact would be a couple suggestions from me.

[@austinburton6631]

Thanks for the website! That's going to be real helpful for me

[@brianthompson4234]

Just out of curiosity, on these more in depth quad restorations, by the time you add up all the parts you have to find and buy, how does the cost compare to buying a new quad or even a used good condition quad? Awesome builds, tons of great info on your channel MichaelSabo

[@XJonAye]

Six point is all i use, ive stripped out so many bolt heads.

[@michaelboots7690]

that never happens 🤣love how fresh that thing is.

[@Trick2stroke]

I think they either slipped the hell out of the clutch all the time when this thing was running or they towed something with it and cooked that clutch. Only thing that makes sense to me for that burnt/discoloration.

[@blueballs_m135i8]

Great Video Michael love all your content I have watched you for a long time keep it up

[@breakfree4177]

So do you think we are just not going to ask about the Vette?! I am a hunter, so I have a decent amount of patience. But your content is the kryptonite to my patience. I can’t wait for each damn video!