Seller Gave Up On This Quad So I Got It CHEAP

I buy a 2004 Suzuki LTZ400 quad that the seller gave up on. Let's fix it. #Suzuki, #Quad, #Fix,
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The following video features activities performed in controlled environments by knowledgeable persons. DO NOT attempt to duplicate, re-create, or perform the same or similar activities at home, as personal injury or property damage may result. 2vintage( Joe Weber, the persons shown in this video and ANY CONTRIBUTOR, ARE NOT LIABLE FOR ANY such injury or damage. ALL 2vintage( Joe Weber) CONTENT IS FOR ENTERTAINMENT PURPOSES ONLY.
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[@GaryGilbertbigG66]

Hey Bud, that metal piece is the gear dog from 2nd to 3rd gear. You are going to need to pull engine and tear completely apart. Then you can weld that aluminum piece on. I know you don't want to, but has to be done correctly.

[@alienchaser636]

Happen to my Dr800 4th gear in half with a chip like that... yep full engine pull down

[@1ralton1]

Well spotted. I also don't like the thought of just tapping out the existing aluminium casing instead of rewelding the broken off post. Surely someone could reweld that on?

[@eddies]

Yep. That is a complete case split. I suspect other damage in there too. That case is $60 on ebay right now so it's worth splitting it to inspect the gears and replace the case.

[@Claude-om9og]

I agree it looks like a piece of gear dog but how did it get from inside the transmission to inside the clutch area?

[@chernorizetzhrabar1313]

@@Claude-om9og there is a common oil hole that connects the inside case with the clutch case as they use the same oil after all. That metal piece (it's no aluminum because it sticks to a magnet) went through that oil hole and ended up in the clutch case.

[@owensbama1923]

That is clearly one of the three dogs on a gear from the xmsn that holds them locked together.

[@jakessakzn8861]

Yep I agree

[@colinlogan4879]

100%

[@jsvallee567]

100%

[@u2pda]

100%, but since the broken piece is out, it might shift OK part of the time, but there will definitely be intermittent shifting issues that could lead to a more catastrophic failure.

[@u2pda]

bottom line, time to split the cases. Also, I have straightened bent shift shafts using a press and various methods with great success. They have very little movement, so absolute perfection is not necessary. Saves a few bucks.

[@brian770]

i am happy that you are now washing them off before you start working on them !!! always a good idea.

[@jmudd5449]

Now if he would start using proper tools.

[@sandbar521]

Leave Joe alone, he does perfectly with what he has and uses so stop being armchair mechanics and/or tool snobs and just enjoy his content! If not then stop watching it or make your own!!!

[@kindnuguz]

and a small cheap Harbor Freight (for now) CENTRAL PNEUMATIC 40 lb. Capacity Floor Abrasive Blast Cabinet $199 CENTRAL PNEUMATIC 50 lb. Portable Abrasive Blaster Kit $24.95 until big boy tools can be bought (which is better but) VHT Weekend Warrior $2,864 VHT Hydro Blast High Pressure Parts Washer $7,000 As much work as he does on machines, one would think a machine like those mandatory

[@jacksat2252]

@@sandbar521wow, what is wrong with you??? Using the right tools for the job is not being a tool snob, and cleaning parts before you work on is good advice, not criticism.

[@Sryously]

@@jmudd5449 Nah. If you're buying cheap then you probably don't have $5,000 in tools, so he's proving you don't need anything fancy to get stuff running.

[@roberttdubel]

Gear dog or part of a shift fork

[@novascotia2stroke]

those 2 screws have the dot on them wich means they are jis not philips thats why those are hard to get out its the wrong tool for the job love your content bro

[@mattcurtin3185]

it is literally incredible to me how you are basically always fixing all these crazy problems. I wish I would be like that one day.

[@CostaMesaPhotography]

It reminds me watching one of those mission impossible-type moves...there's an insurmountable problem but somehow the hero figures it out!

[@strangeuniverse1199]

If you have the temperament to do this all all day then you are a grade A mechanic😎. Making any mistakes with mechanical work can turn into a disaster. Doing complex mechanical work is like doing open heart surgery, you better know what you are doing beforehand.

[@nicholasletourneau3880]

Buying working machines doesn't make good videos.

[@pjm204]

That part is coming from either #3, 15, 16, or 19 on the fiche. Definitely a shift dog from one of those gears. Looks like you will be splitting the cases! Also. While you have them apart, please get the part that broke off welded back on by someone skilled at welding cast aluminum. The case is going to be really thin there and tapping it doesn't seem like the right way to repair it.

[@riverakers]

At least this seller was honest at the start.

[@abw121]

Enjoy watching your channel! Keep up the content! May I suggest some small things when your tearing apart these Japanese machines? First is JIS screwdrivers as compared to impact screwdriver? The Vessel brand JIS screwdrivers are the best for Japanese screws! They also use a hammer to give shock to screws. And not strip out like impact screwdriver will. Second in my time working on these quads, the factory uses plenty of loctite or screw glue on small screws. So heat is your friend! A Torch with Mapp gas or my preferred method in small areas is Induction coil heat. Where you concentrate heat into steel screw and surrounding aluminum? Then a wack with JIS Vessel impact screwdriver and bang your done! Been working on Japanese and German rides along with American brands for 50 years! Again keep up the wrenching!

[@Skidderoperator]

Great tips!

[@six4standingtall]

Good advice. But he must put that claw hammer in the kitchen cabinet and get a good hammer that will transfer the energy needed for the impact driver to shock and drive as intended to do.

[@abw121]

We all start out as crawlers and then we learn to walk then run! Yes this young man needs to upgrade some tools? But he has some great diagnostic skills! But must learn the bull in the China shop method will cost him more in the long run? The smaller the fastener the more trouble it will bring! When I apprenticed in a shop, I was told “You know what the difference between an apprentice and a journeyman is Kid?” I had no idea? The answer is “The journeymen knows how to hide all his mistakes!” We all learn as we go along! It’s the ones that retain this knowledge that go the distance!

[@jerrybigrig9475]

​@@six4standingtall😎🤣👍

[@davesplace1307]

Joe almost never uses a heat gun. Me personally with all my engine builds ever nut and bolt inside gets atleast blue loctite. Even if theres a lock washer or something similar. I tear down engines and see loose bolts or missing bolts that get shredded more than blown engines. Youd be surprised what 10 seconds from a torch will do to loctite. Night and day difference

[@kyleholmes5624]

Joe, you gotta watch the language man.. "aw shoot" is just unacceptable 😂

[@walk4718]

This young man is exceptional; never shows anger, even when he’s been obviously lied to. Never has to bleep out expletives. Would love to hear the backstory to his gentle manner 👍

[@allan9603]

​@@walk4718 It all starts with wonderful parents..

[@markr.1984]

@@allan9603 I cuss all the time. So you're saying my parents weren't wonderful? My dad and mom never had a dirty word come out of their mouths. It was in high school hanging with certain kids my brother started cussing and I learned it from him. Parents don't always have anything to do with it.

[@gutsngorrrr]

Next time you get a situation with a stuck bolt/screw like this, always try a bit of heat before going mad, just in case thread locker has been used. As you saw, just from the heat from drilling the bolts in this case allowed them to come out easily.

[@yvonfaub]

Im starting to beleive this guy is not human. To me it looks like this guy is buying bikes and Quad and fixing them 24/7. Pretty usefull hints to catch from this guy though! Would like to watch a video from him taking appart and rebuilt boat motor as well just for the sake to learn their specifics caracteristiics from the technical and competent perspectives brought by 2Vintage ! That would be great!

[@ryt2carry]

I’ve always worked on my own stuff, but I’ve learned a ton watching your videos and I really appreciate your hard work on these basket cases.

[@opiumdealer]

To check the oil on the LTZ 400 properly: let it idle for 3 minutes, then let it sit for 3 minutes and check. The oil in the reservoir needs to be filled up first. Otherwise you will not measure anything :)

[@CB-jq7fe]

Man... I need to show my mechanic this channel... salute to the commenters... very capable people... g'day and God Bless.

[@jacobcox198]

that broken piece is the shift fork so internals are broken buddy but when yah wreck people needs to check over the whole thing when they wreck out but just blow it up n diagnose huggs keep the vids coming buddy ttyl

[@shotgunz1248]

Like how u been cleaning them up some before working on them good job

[@xl600mine]

I was thinking the exact same thing! nothing better than working on a clean bike/quad

[@lawrencemacdonald-yz4vn]

Clean freaks

[@Anticidal25901]

All of our commenting finally worked lol

[@AnthSmog92]

is that not common sense? 😂

[@nitrotmann]

One of the shift dogs. That case needs to be split and trans fixed properly.

[@ricmndy1]

it's amazing to me that with all the tools you have invested in, you don't have a spark plug socket. Sure makes getting them out and in so much easier

[@AnthonyRufo-rc1zm]

I've never stripped out a screw when using an impact driver. It's best to hit really hard with the hammer, ranther than a few small taps.

[@dennishall9260]

Looking through the comments I'd have to agree... looks like a piece from the end of a shift fork. Great video, great little machine!

[@hoppiemacv8604]

Michael Sabo would have loved to of gotten his hands on this one!

[@Smokin_daCatnip]

Check the swingarm over real good. Flawed design from Suzuki, very prone to cracking on or around the welds. Learned the hard way

[@jameshedrick605]

That's how i got my 1st ATV. Was told it wouldn't go into gear got it home and looked at it a couple days later and found the drive belt self destructed. Lost that in storm after a tree fell on it and got my Bruin 350 last year from a friend and going to put nee cv axles in it later today after they get delivered

[@nunyabizznizz7326]

love the nervous laughter in your videos....we can all relate on some level

[@tonygriffiths2485]

If you know this already ..... apologies. In WW2 the early Spitfires had a negative "G" failure when the pilot pushed his stick forwards and went straight down. This would starve the engine (Rolls Royce Merlin) and it would cut out, somewhat awkward if you had Jerry on your tail trying to kill you ! One of the female transport pilots who used to fly just about everything at one time or another, would fly them to their fighting bases. she was a mechanic and fitted a diaphragm in the carbs. This then allowed full stick forward and a nifty escape from Jerry, because none of their aircraft could keep up. I have seen you service and get going loads of these ATV's now and suddenly I remembered this story today. The Female pilots name was Schilling, so they called the modification Mrs Schilling's Orifice :)

[@thebigguy8306]

Thank you for sharing that wonderful tidbit.

[@stuartmiles1401]

Close, Miss Shilling was an engineer at the Royal Aircraft Establishment - en.wikipedia.org/wiki/Miss_Shilling%27s_orifice

[@eddiestonerbud7188]

I wonder how many people have seen mrs schillings orifice

[@georgesimmons4923]

I had an 08 with reverse. Someone had put a big bore kit on it. Ran good. Reliable machine. Never left me sitting.

[@jamescorth9930]

For some reason I can’t hardly ever find the second parts to your Videos. Probably something I’m not doing. great videos. Thanks.

[@Sunspot-19]

Joe, it appears that somebody stood on the shift lever, trying to get it to shift. You are spot on in thinking that stray piece may have jammed things up. Well done, sir!!

[@Mich1gen]

Hi Joe. You don't check oil on Z400 like that, when it's cold. You have to start a quad, run it for 3 minutes, shut it down, wait another 2-3 minutes and then check the oil. Mine, when cold, didn't show any oil on a deepstick whatsoever, even if I filled 2.1 or 2.2l in a quad (don't remember exact number).

[@Adam-banshee-man]

You might want to check the swing arm really good on it because the swing arm on those bikes are absolutely notorious for cracking I guarantee you there will be a track somewhere in the swing arm I've had about eight of these bikes and every single fucking one of them had a crack somewhere in the swing arm

[@UnclePhilPhil]

I’m so proud of you, Joe. I’m pretty sure everybody knows what I’m talking about.

[@snowyowl7042]

???

[@gilberthathaway1655]

Hopefully because of becoming MAGA smart?

[@zackk695]

You know your s….! Love seeing a mechanic that can diagnose as good as just fixing the problem. Very awesome

[@user-hj5ml8rr8u]

that large chunk looked like the end of a shift fork...surprised it shifted afterwards...

[@woodardhsd]

No way that's an end of a shift fork, completely different shape. Gotta be a dog off one of the gears. Not sure how it made it's way to the outer porion of the case though.

[@user-hj5ml8rr8u]

@@woodardhsd you are probably correct... I R a dummy.

[@davidronneberg2643]

I know ppl have pointed this out in the past but I’ll say it again! I like the process you go through when digging into the bikes you buy, it’s very methodical! Good on yah!

[@GNX157]

Was very surprised to see you power wash it before working on it, instead of the usual afterward.

[@calebparkman6902]

29:47 that vascularity and bicep sheesh Joe been hitting those weights

[@DealinDmg]

You washed it before starting the tear down👏👏. That's always a good start. It's unfortunate that a small piece of the case broke off. I was reading some of your other comments. Some think you might have to pull the motor and complete a full rear down. Probably be best to make sure everything is good. Well, looking forward to the next video

[@leewaken5059]

Please tell us you will not move forward without first, "correctly" addressing the severed transmission piece that was found floating about the engine cases, ok? My guess is...the mystery piece is off of one of the gears, 3rd, 4th or reverse (split the cases to confirm) and somehow migrated from the transmission side of things over to the clutch area. Who knows but, let's find out before you begin the assembly process.

[@Motoxr32]

Great job as always! Absolutely love you are washing them before working on them now! I use degreaser first around engine area if needed then the hot soapy water!

[@toyhunterslasvegas]

I had a white LTZ 400. It was a pretty good quad. Raced at Red Bud. I had to get a kill switch from Digger Doug in order to race. Good times.

[@robertfinnerty7201]

Joe look up a tool called the Shake N Break. It is an attchment for an air hammer that will take a screw bit. it allows you to provide turning action while vibration down on the screw. I have the impact breaker you use but when that doesn't work easily i go directly to the Shake N Break. The tool is around $60. Thank you for the excellent videos.

[@stkyfngrszmooth]

I got the very first quad built, which was the Quadrunner 125. I really enjoyed it, but it was a rough ride with no suspension. After that I was bumped up to the 185 which had front suspension and I thought it was the greatest thing ever, but after that everything changed when I got the very first version of this quad - the 1985 Suzuki QuadSport 230. I cannot put into words just how fun that little quad was. I would get all bundled up at midnight in the middle of the winter in New England just so I could go down to the barn and look at it. My father, brother, and myself would go on midnight rides on the snowmobile trails that ran right through our property, and we'd be on them for hours. My brother had the 1985 Honda ATC 250R and I was tired of getting smoked on the QuadSport so I traded it in for the QuadRacer 250. That was an awesome quad, but it just wasn't as fun as the 'Sport, but it was too late to go back. There was something about that 230 that made it the most fun machine I ever had. I would give anything to be able to go back to those days and do it all over again. Anything.

[@btj1844]

I too had an LT 230, great quad. Bought it for my wife and I continued to run my Honda 200X three wheeler which was a heck of a machine as well. Both great machines.

[@stkyfngrszmooth]

@@btj1844 My son had a 200X. He rode the wheels off of that thing. Rock solid machines.

[@u2pda]

Thanks for the memories! I worked at a Suzuki dealer in the 80s and also have fond memories of the release of those quads. 125 was cool, 185 lots more power, 230...gamechanger with its power and suspension. I raced an 85 quadracer 250 flat track. Fun times.

[@cadman9615]

My first quad was an 86 230 Quadsport. Bought it in 93 for $800. Def a fun quad

[@kartguy]

Great deal! I paid $1100 for one that needed another $1000 put into it and I thought that was a good deal! I got mine and had to rebuild the head and few other things! On my channel, but man would have loved to got one like this for $1000! Always finding the good deals buddy!

[@user-fi3fx5my2s]

Rubber grommets didn't want to let go of the valve cover caps. Lube em on return.

[@bradfrye8297]

Pretty sure that found flat metel peice is a gear dog.. it looks like your missing the upper shift detent pin. the flat shift pin on the shift detent. And if you put some heat on them screws it will make it alot easier. They have thread lock on them.

[@BlairGuinea]

Thanks Joe, another great vid, you the smart guy diagnosing the problem,

[@Charles53412]

Michael Sabo just finished restoring a LTZ 400 which turned out really good! The LTZ is a lot of fun to ride and strong!

[@peterstacey3720]

New engine cases needed now after miss using the impact driver. 1 good hit with the correct bit will break things loose. Always push driver hard onto screw then twist it in the direction you want it to turn until i clicks . This shows the driver is loaded one good hit causes it to use its spring action to unscrew he item. Hope this helps.

[@W.A.R.R.]

Tip on tight phillips screws, use a normal screwdriver while putting pressure on the end by hand turn the screwdriver with a wrench. Gets them loose every time.

[@miscprojects9662]

Recently stumbled upon your content. Quite the gold mine.

[@fetus2280]

I wish I had the technical experience doing this. Wold have saved me a Lot of money. Ha to take my ride to the Dealership for repairs cpl days ago, couldnt figure the problem out myself. There goes $1000 on parts/labour/transport hire. Hopefully I keep watching you and ill know enough for the next time. Thanks for what you do mate. Cheers.

[@rocketpocket99]

It was a good day! Found the problem worked through it much respect have a plan I like that

[@AZVIDS]

Nice video, enjoy watching you diagnose problems and ways to repair👍👍

[@craigkoch4277]

It's a part of the gear that is used when shifting gears. The lugs on the side of the gears that engage into the adjacent gear.

[@donpampel3332]

Joe Look at this screw remover By far the best investment I made working on old stuck screws. Shake N Break Air Impact Screw Remover.

[@thebigguy8306]

Once cleaned up, a good-looking mid-sized quad. Lots of teaching moments. Always appreciate good diagnoses

[@billkinsey2690]

😅

[@Chazydau]

When I spray my yahama warrior off I use the wax setting at the car wash. If you’ve ever noticed the wax is mixed with hot/warm water. I noticed once when I was using it on my truck the spray wand was warm to the touch. Helps get grease off and the wax doesn’t hurt the machine.

[@zackk695]

If an engine hasn’t run for a very long time it’s good to add a small amount of marvel mystery oil to the gas to which allows it to line up and also helps clean everything. About a 1/4 cup per gallon. It will smoke bad but it really helps a motor that has been sitting. I would also run that tank through then run some injector cleaner through a tank to clean it up

[@terrykuehn2686]

Hey Joe! You could probably use that induction plastic welding unit to heat up those little screw heads to loosen the lock tight and spin them out easy! Loving the videos bud and content!🤔😉👍📹💯✔️👋👋👋👋

[@brianmckenna3440]

Another great video love watching you dissect a quad

[@dave1135]

Hate to say, that broken piece of metal looks to be one of the engagement tangs on one of the gears. It probably broke off, floated around, then jammed under the shift drum and bent that arm. Me, I'd split the case and find exactly where that came from

[@rintin1874]

Brilliant video Joe watching from Edinburgh Scotland UK 🇬🇧 👍

[@AvaPxiaO]

it looks like a synchro dog from a gear, you know the ones inside that mesh with three slots of the next gear? You'll never know till you open it, but if you can get away with it some alum grinds will not hurt the box, use some cheap thin oil, run it easy for 1-2hr shift up/down, then rinse it off with fresh oil and filter. If you split the cases find some insert sleeve with cap and drill through and cap it from the otherside then thread the broken piece replacement back. That sleeve will have to be knotched and locked in place if the bolt is ever to be taken out again. Machine and press fit through it maybe. I am thinking steel (hardened) thin cap on the other side, 1-2mm set pin to keep from turning press fit with red-LT

[@coltangraves2236]

Your videos are my favorite, keep the camera rolling man.

[@Adam-banshee-man]

I have a spare bottom end if you need parts I also have a ported top and it's completely ported on the exhaust side and just cleaned up on the intake side I have the newer wire harness with the newer CDI I have a complete bottom end crank transmission everything is absolutely mint I have all kinds of carburetors you name it I got it

[@davidkettell1073]

Perfect lesson on how not to loosen a scew Joe . When in doubt drill it out,screws are cheap

[@Texas4x]

Oh my word!~ Joe has lost his marbles and is washing something before working on it! LOL. Jk, Joe!

[@TheDisorderly1]

The broken off part looks like a engagement dogs from one of the gears broken off.

[@robertcowie8230]

What happened to the 68 BSA?

[@SquidMissile1]

I've seen you strip the screws holding the shift drum a few times now... They are loctited from the factory. If you heat them with a heat gun they will come out easy.

[@Cloroxbleach-mp7hv]

Hey joe love the Ltz400 one of my favorite quad can’t wait for the breakdown love it man❤

So glad you clean the bikes first!!!

[@markkerin5699]

The greatest miracle of modern science is how you didn't break the drill bit for the ezy out. The bend you had on it would have definitely broken on me.

[@DunnMotors]

Learned alot, thank you

[@chrissinegra]

Piece you found is off one of the gears in the trans I found the same thing in mine when doing the timing chain

[@seansysig]

The piece is from a gear in the other side of the engine. I would try to straighten shift shaft in your press. Lay the shaft high side up in a piece of angle iron and press until under side of high side touches angle iron. Then turn shaft and press until it returns to original shape.

[@jackmundo4043]

excellent. Thank you.

[@hangfire5005]

If you're doing this at home, most japanese stuff uses JIS screws not Phillips head. It looks like a phillips but it's slightly different. This is why there's so many stripped screw heads on Japanese stuff

[@martymcmannis6581]

I have a drz400 I think it's exactly the same motor. That hunk of metal probably came off the transmission (sorry to say) I know that I love my 05 400. Had it 8 years added oil, tires, and batteries . Hope you have the same luck after you fix your issues. Thanks for sharing

[@jmendo2546]

Joe, I'm glad to see your better at negotiating. I think the guy before was riding and hit a tree or jumped on a rock with shifter shaft bent back and slamed gear back breaking it . I bought a Yamaha blaster the same way but my shift shaft is bent same way but case is broke were shaft goes into case, although my gear's are fine.

[@Nick-s-f]

The Maier USA sticker brings back some old trail memories.

[@marcdrolet7554]

Maybe you can check in repair manuel parts near the transmission look like the broken chunk. Always interesting

[@jessiej3991]

That broken off hunk of metal is one of the ears on one of the shift forks

[@thyreaper650]

That peice is one of the dog teeth on one of the gears of the transmission...it will prob stay in gear but it wont take much to break the others off now plus the gear it came from will be off balance, id go ahead and tear it down.... why wait cuz next time it may wedge and break alot more stuff and possibly the cases..

[@myguitaryourface5160]

I recommend using Allen bolts for the gearshift pawl lifter,I have been in the same boat before, except I drilled my bolts and extracted those first,I also think that piece is off a transmission gear

[@jacobmoore921]

I would love to see a video of what you look for when getting these a what you stay away from.

[@markymark5281]

If you watch Michael Sabo, he just finished restoring one of these. He just posted the final assembly video a couple of days ago.

[@brianmccullen9156]

Michael sabo just finished his up and it looks brand new

[@thomasjarosz7406]

My Guess is a Part of the Shift Fork. I hope you find it. God Bless

[@jamesholt2403]

Joe you know that's a shift dog.. you've taken these apart enough... save the time and pull it out split case and see which one it is and order it with the shift shaft and drum detent.... cause if one of the dogs are broke off... that whole peice is stressed and possible fractured and is gonna cause problems when you really get on it.

[@BONNIECLYDE-1934]

Happy Days Joe Has Posted 🔥🔥🔥

[@williamwonders9265]

Looks like an engagement dog from one of the transmission gears

[@porchonetwothreefour]

JIS bits are a must for these engines.

[@yoyoyoda1783]

Hey Joe. I hear a lot of traffic in the background. But when you ride around your yard. I see no highway. Mystery

[@franky1020]

Split the casings, you have to find where that metal chunk came from, it must be off gears or maybe a.folk tip

[@snowyowl7042]

Great video, nice quad. If not, parts, a planter, an anchore, play set for kids

[@frankalridge1797]

I think that piece of gear from inside the transmission,I would just take the engine apart from the get go,its not that difficult anyways but loving the video's ❤

[@zrkn1]

Nice work so far, I think I would split the case just to investigate further, and it also makes for great content and peace of mind. ps that broken piece didn't just appear from thin air it came from somewhere, Looking forward to your next video Thanks

[@amrc192]

That looks like a peace of the shift fork great vids