Suzuki DR-Z400 Project Bike - Episode 3 (Engine Assembly Part 1)

T2W Amazon Store: www.amazon.com...
Part 1 = Bearings / Crankshaft / Transmission
In this first part of the motor reassembly I will cover replacing the bearings in the bottom-end, installing a new crankshaft, and installing the transmission.
Tools used for this video:
Tusk Bearing Remover Set ($69.99) - www.rockymount...
Parts used in this video:
Hot Rods Complete Crankshaft Assembly ($368.96) - www.rockymount...
Hot Rods Main Bearing Set ($62.96) - www.rockymount...
Hot Rods Counter Balancer Bearing Kit ($35.96) - www.rockymount...
Hot Rods Transmission Bearing Kit ($89.96) - amzn.to/2KZFPkp
Tusk Engine Oil Seal Kit ($14.99) - www.rockymount...
For a list of other Tools, Equipment, and Supplies I use in my shop, visit: tim2wheels.com/...
Want to donate?
/ tim2wheels
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Video Sponsors:
Rocky Mountain ATV/MC - www.rockymount...
ToolVector.com: toolvector.com/
ToolVector 10% Discount Code for my viewers. Just enter “T2W” at checkout.
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Video Gear:
Canon EOS M50 - amzn.to/2PZMr2G
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GoPro Hero 5 Black - amzn.to/2PAAL5M
Music Credits:
Closing Song from Ampletunes.com - Nice work guys!
DISCLAIMER: The Information provided in this video IS NOT professional advice. It is simply a demonstration of how I performed this task and is for informational purposes only. If you are not comfortable performing this type of work, seek professional assistance. Always follow the manufacturer’s instructions when performing maintenance or installing parts and equipment.

[@narwhaljones4821]

Tim. I can't tell you how much I appreciate these videos. Truly. You sir. Are the man. Awesome videos and exactly, I mean EXACTLY what I was needing. You have me the confidence to take on this engine teardown and rebuild and I can't thank you enough sir.

[@ronanrogers4127]

I forgot to add, that’s a brilliant explanation of how to assemble a motorcycle transmission.

[@Tim2Wheels]

Thanks!

[@brs256ish]

Definitely giving me more confidence in putting this Drz back together, and I’m gonna go ahead and order all the bearings on your advice, thanks!

[@bigunitandmore]

I cant believe you got rocky mountain to sponser your channel.

[@Tim2Wheels]

Well to be clear, they are not a full sponsor of the channel (but that would be great!). They offered to help me out with some parts for this one project. I am VERY grateful for their help. I do these videos out of my own pocket and any support is very much appreciated.

[@fmtnic]

That was the best transmission install video Ive seen.

[@grandriver3152]

That was very pleasurable to watch sir.👍

[@mikebrown4429]

I ride a drz400, it has the ACT wide ratio trans gear set . Better than a six speed. I’m doing a big bore kit currently , but with only about 8000 miles on this bike ( it’s a 2017 that I bought new in June of 2018 ) I found the intake valve have severe carbon buildup 🤔 . I’m having to lap the valves and installing new valve seals . And I did some very minor port work , just to clean up the casting seams . Wish me luck !

[@zrkn1]

Nice to see you back in the garage working on a bike that us regular po folk own. Mechanics for the masses is the key to success in the youtube world. If you don't want to invest in another bike like your old one then doner bikes from friends works. Rework a DR650 or something I've seen a lot of bikes cheap on the facebook market in Arizona for the last few days. Save em, fix em, flip em it's a worthy cause with the current skyrocketing prices of bikes. Good luck from AZ.

[@Tim2Wheels]

Hey, thanks for the feedback. I do like working on the older bikes and keeping them running. I am on the lookout for a future project bike. Thanks for the comment and for watching.

[@fernandofernandez5719]

This Chanel is just amazing

[@denisb3559]

You are very accurate and professional service man. I was excited to see the rebuild. Cheers from Russia!

[@stevebrinkert8339]

👍 enjoying the series!

[@Tim2Wheels]

Thanks Steve. There's more coming soon.

[@geofox9484]

So glad I’m just doing the top end..

[@RoyKarny]

Great job, Sir! I find this inspiring to make things by myself. Thank you.

[@Tim2Wheels]

Hi Roy, Thanks for the comment and for watching.

[@j45acp69]

great great video, thank you for posting this!

[@s.y.b.1046]

placing the bearing in the cooler will help install it in the case as it will contract the metal :)

[@chance187]

Excellent video as usual Tim! I really appreciate all the details, your channel has helped me so much in understanding all the little things that people just don't show or explain. Thank you again for all the high quality content!

[@mrblaze8191]

Your making the best videos I seen on this atv very detailed

[@InTheGardenandTheBlessings]

Looks like new with all the polish and clean done on this.

[@GabrielAlmeidaSoares]

Very very good and easy to understand. Thanks very much for sharing the knowledge. I'm in Portugal so that you know your videos are spreading wide. As a suggestion for next videos, I would like know what to in case I decide to restore a dual-sport/dirt bike (how to choose and how to restore from scratch, logical steps, etc). This is probably too demanding and vague but I decided to ask anyway. Cheers!

[@artiexr222]

What an excellent educational video thank you for posting.

[@2001cusito]

Great video. Thank you.

[@Tim2Wheels]

Thanks for watching.

[@tougeattack123]

im going to build my 480 soon thanks for the video!

[@southernseclusion9525]

Great. Many thanks

[@PAULNAT]

Awesome video, thanks for sharing.

[@Blekk1989]

Thank you very much!

[@ronanrogers4127]

A timely video, and nice work, thank you. I’m considering installing the ACT wide ratio set into mine, which of course requires the cases to be split. Is there any reason why we should not apply a little heat around the case before removing every bearing, or heat the case and briefly freeze the bearings before installing them? Can you tell me what you used to get the cases internally clean?

[@Tim2Wheels]

Hi Ronan, There's no reason not to apply heat to the case and freeze the bearings. In fact doing so will make the job easier. To clean the cases i spray them with Brake parts cleaner, wipe them down, then dry well with compressed air. I''m working on a vapor/water blasting cabinet which will be ideal, but that is not finished yet. (too many projects). Best of luck with your project and thanks for watching.

[@johnboy2251]

When I bought my klr years ago I got a lot of enjoyment from you're videos. I bought a drz last November and here you are making videos about my new bike again. How did you know? I sure hope I don't have to do any of this for a long time.

[@Tim2Wheels]

Well, I'm looking for another project. Let me know what bike you are thinking of next! :) Thanks for watching.

[@difacilprojects6676]

Thanks for sharing!

[@bigunitandmore]

You could have put the new bearings in the freezer for an hour. they would have went in real easy.

[@Tim2Wheels]

Yes, absolutely. And if I were to do this again, I would do just that. Thanks for the comment.

[@Cloroxbleach-mp7hv]

Thanks

[@DailyerDoseOfInternet]

This makes me want to attempt to do mine Recently seized my bottem end in my drz and have a spare bottem end but the top end went in that motor so there is metal fragments in the bottem end so I thought it would be a great time to refresh the bottem end of the unseized motor I want to dive into this and try and get a understanding of the motors science breakdowns seems to be a regular for me

[@richardtschida2321]

Put the case in a oven at 250degrees and the bearings will call out with little or no effort. A!so a warm case with frozen bearings again little or no effort. Also a CLEAN case is beneficial!

[@Tim2Wheels]

Thanks for the tips Richard. I am now building a Vapor Blasting cabinet for cleaning engines and other parts. :) Thanks for watching.

[@bigunitandmore]

good work except you should of bought a bearing driver set. And why not clean the cases before you started assembly.

[@Tim2Wheels]

Yes, a bearing driver set would have been nice to have, but I had spent a lot already on this project. However that is on my wish list :) I did clean the cases thoroughly on the inside. I am working on a Vapor Basting cabinet, but it's not ready yet. When completed I'll be able to make parts like this look new. Thanks for the comment and for watching.

[@gregorymasincup7540]

Hey I agree, I would have cleaned every single part on the out side before even thinking about splitting the cases

[@mikaeljonsson2078]

Thank’s for doing this video series, I love it! I have one question as I’m in stage of putting the tranny together. There is this flanged bushing that the big second gear sprocket rides on. Is this bushing supposed to turn freely on the drive shaft?, because mine doesn’t..it will have to be pressed on to the shaft if I’m going to get it in place. However the second gear spins freely on the bushing without problems.

[@dandil]

protip: put the whole case half in the oven. Won't accidentally locally melt it, but you must wear oven gloves while removing the bearings lol

[@Syntax152]

You could have put new bearings inside a freezer or dry ice, also could remove old ones by just putting engine casing into a oven... most of the bearings would fall down also with a heat gun youre applying localized heat and risk warping the case

[@Syntax152]

great video series btw

[@gregorymasincup7540]

I'd like to know/see if a sixth gear could be installed? And add big bore kit and cams, and EFI install? I love you videos, could you help me do my drz 400s?

[@realpremier]

thanks alot for de detailed info! how is the quality of the hotrotsparts compared to the OEM stuff ? ty

[@Cuzzazbuzz]

Great videos Tim. One question. I assume the old bearings were thoroughly cleaned as using them to drive the new ones in surely risks debris falling out the old and into the new?

[@postalsnap]

How do you remove the clutch release camshaft lower needle bearing? There's no way to get a blind bearing puller on it or tap it out from the backside. I tried heating up the other side of the case from where it sits, but I guess it wasn't enough to let me pick out the bearing.

[@alfredosalazar526]

How much would this cost? “bottom end rebuild” and or “top end rebuild” for the drz?

[@drakonzebra]

Doing the same thing, you're just in time ;)

[@Tim2Wheels]

Good! I should have the other video up this week to show the complete assembly. Thanks for watching.

[@postmortemspasm]

Could anyone answer me a question... There is supposed to be two oil pumps on these engines, one to pressurize the oil for the engine, and one the send oil to the tank. I can only locate one in these videos; in the right case half. Where is the second one?

[@betaboybetaboy2606]

Hello iam from Germany and ich want to das that you have to heat up the Crank case a Bit More and cool down the Bearings with ice Spray so you dont Need a hammer Sorry for my bad englisch

[@husseinail3131]

شكرا لك على الترجمة الفيديو اتمنا منك عمل ترجمة لجميع الفيديوهات

[@brandongoesphotoxvideo]

Hey everyone!! I'm going through a bottom end rebuild and putting it all back together and it appears that I've lost the cover piece that Tim installs at 8:30. The cover for the gearshift cam bearing. I can't seem to find it available online anywhere and I've yet to find a DRZ parts diagram that has it labeled? Does anyone have a clue that could help me out? I've torn the shop apart and don't know how but it's virtually disappeared.

[@Angelrodriguez-w8w]

how do you close the engine caes without using the tool

[@jameshoffman8223]

I’m doing the transmission o a 07 ltz400 quad sport and the trans is a little different then that I can’t find anything on it and the book really don’t show u how it goes back together any help would be nice

[@keithparady2594]

Could you do one of the way the gears go I can’t find any information on a 05 kfx 400 trans

[@Tim2Wheels]

Sorry Keith, I don't have access to this bike any longer.

[@richardtschida2321]

Put the cases in the oven 300 for 15minutes the bearings will fall out w/little to no effort.

[@richardtschida2321]

Heat the case and freeze the bearings....then it won't be necessary to beat the ALUMINUM CASE,!

[@hotrodsather]

Yuo should use a piece of wood, you could be knocking debris into the new bearing.....

[@pupkorn7111]

To push in and take out the bearings?

[@hotrodsather]

Instead of the old bearing.

[@pupkorn7111]

hotrodsather I’ll keep that in mind

[@pupkorn7111]

Would this whole process apply to a 2009 drz 400sm?

[@Tim2Wheels]

Yes, the Engines are the same. The only difference that I am aware of is the E model has no thermostat, and your SM may,. But that is of no significance. Thanks for the comment and for watching.

[@pupkorn7111]

Tim2Wheels thanks a lot for the quick reply.

[@ShadowVonChadwick]

Sorry to say I was a bit disappoint you didn't spend the time in cleaning of cases and your work area, that work bench base towel should have been discarded and the cases externals should have been degreased and scrubbed to limit the contaminates from attaching to your hands and thus to internal components and new bearings......... After that money spent on parts and tools, you set a bad example for those who might attempt some basic works.

[@dandil]

tightening the puller with pliers made me cringe. very informative otherwise

[@Tim2Wheels]

I understand. Thanks for the comment and for watching.