This has got to be one of the best mechanic-ing videos I've seen so far. Good camera, very clear speech, good use of labels, informative. Very nice. I just wish it was for my motorcycle, haha.
I’ve been looking for this videos for months cuz I was looking for : Drz 400sm starter clutch tutorial and didn’t get anything and then I forgot there’s a 4 wheeler w the same engine so I looked it up and found you finally cuz I didn’t want to send it to a mechanic that’s gonna charge me 300 for it plus the starter clutch.. I just did mine w this video thanks a lot I appreciate it.. ps: I saved the video two so I won’t loose it just in case
Frank Camacho. I would recommend contacting a service center for your ATV. It sounds as though the ring gear on your flywheel could be missing teeth on it. I would recommend taking it to a shop though so they can verify what the issue is.
SORRY FOR MY ENGLISH AND THANKS FOR ANSWER MY FRIEND. EXTREMLY TECHNICAL. ENDURO ALL TIME WITH CRF 450 R. I ASK YOU FOR CRANK BEARING BECAUSE OTHER GUYS TELL ME ABUT THIS. I BUY Z400 17oz USED FOR 100 EURO. INSTALLED MY SELF. THE MOTO IS VERY BETTER !!!!!! THANK YOU AGAIN.
With the Trail Tech flywheels the crank bearing will not get damaged because Trail Tech balances their flywheels. This means that when you install a Trail Tech flywheel the added weight will not wear out your crank bearings because the flywheel has been balanced.
might as well upgrade to some 12.9 grade M6x1.0 bolts while in there. After upgrading to 12.9 grade, you can increase the clamping force by pushing the torque values up a bit..... and throw some blue medium locktite on there. Good luck boys!
I solved the problem it was the starter motor than was " stuck " i had to open it , clean all the parts like i saw here on youtube people explaning how to clean and service the starter motor , now its all good ! thanks anyways mate :)
Cool vid. Been hot min since Ive had that side of the motor apart. Just an fyi tho, that “bracket” under the chain guard is a “case saver”. If yiu havent already upgraded this bit now would be perfect time to swap. Either way DO NOT leave this bit off. If you break/derail a chain it very well may take your crank case with it if you delete this piece. I know this is prolly common knowledge but i really REALLY hate thousand dollar mistakes. Busted cases are bad juju. Esp if a 20$ part can eliminate it. Cheers!
The best thing to do in your case would be to contact an authorized Suzuki service center to see if they can point you in the right direction as to what could be causing your issue.
Ok for people wondering what the benefits are it had a better magnet for better charging and it's lighter than the stock one! Cool product guys you should advertise this for the Drz400 and make a supermoto version that's super lightweight alot guys use the drz400sm as a beginner gp bike.. you'll sell them I'm sure people are putting slipper clutches in the drz.. it's like a oversized grom there super popular
I wouldn't lump the grom in with a 400cc beast the drz is slightly more powerful thanks to its keihn carb and a more aggressive cdi box/rev limiter. I think they sell those in red tho with hi limters aftermarket
@@Kyle_gallegher I said "OVERSIZED" grom lol.. it's more powerful because it's a bigger engine obviously.. the ignition system on both bikes are almost identical just slightly different design and parameters..
@@snakevale198444 My boi ofcourse a drz is more powerful than a grom, a drz is more powerful than LTZ is what im getting at. And Ig tbh I just hate the grom. Aprilia small gp bike > grom. Its me I know
@@Kyle_gallegher the ltz400 is slightly more powerful than all of drz400 models it has fuel injection.. aside from that there almost the identical motor they pretty much are before 2009. Also you have to remember only the drz400e had the different carb and cams.. gas gas used the same engine in there 450mx quad it had a different bore but aside from that it was almost identical it had more power than all the bikes listed. one of the limiting factors back then was the cdi. Mickey Dunlap did all of the R&d on that quad he's a buddy of mine. He wrote a article about it and posts alot on Facebook if you really want to learn the history of this particular engine..
What do you mean by oil in the flywheel? There is no oil in the flywheel it's self but when you take the ignition cover off there is oil behind it. That is why it was on its side in the video. Just like what was posted below. If you do not want to put it on its side then you will need to drain the oil before removing the ignition cover.
My starter is just spinning when I push the start button but if I leave it in gear and push it, it will start. Would you say that it's the starter clutch?
HI DUDE FROM GREECE, I HAVE CRF 450 R 2009 AND I WONT TO CHANGE FLYWHEEL. WITH 17 OZ OR 11 OZ HAVY WEIGHT ? THE BETTER ? FOR ENDURO. WHAT ABUT CRANKSHAFT BEARING ? PROBLEM IN FEATURE ? THANKS
i have been searching all around the internet to figure out what that metal piece on the side of the stator cover is with the cables. i cannot figure out what that connects to so if anyone could tell me what those cables are too PLEASE reply.
One question , ive a Drz400E that is the same engine " at least i think so " , ive replaced the magneto cover , because it was cracked , and since i was having a hard time to remove it i had to open the starter motor , after i assemble all the parts again the starter motor wont start , it just clicks for eatch time i press the E- start , is there any special thing about assemble again the starter motor ?
so i had to replace my old starter clutch because it went out, and i got a new one that does the same thing as the one before. it just spins it dosnt turn the motor over what could it be?
What type of enduro riding are you doing? Is it extremely technical? Do you ride motocross at all? If it is technical then you will want to go with the +17oz flywheel. If you are going to ride motocross at all you will want to use the +11oz flywheel. Trail Tech Flywheels are balanced so there is not issue with crank bearing wearing out or going out at random.
There is no real way to check the flywheel other than visually inspecting it, but it is unlikely that is your issue. I would suggest checking the stator and CDI first.
I have an ATV that you here the starter spin but you don't hear the engine turning... If I move it a little bit in gear it will crank the engine when I push the starting button but the engine will turn for a little bit then it won't turn after that...
I'm installing a new starter clutch bearing on my Trail Tech flywheel [DRZ400] and I have it bolted to the back of the flywheel, just as you did, but it won't slide into place on the crank. It feels like the bearing won't fit over that part with the four grooves. A guy in the DRZ forums said I have to first install the bearing and then the Woodruff key and then the flywheel. Can you comment on this?
The key should be installed in the crankshaft before installing the flywheel on the crank. The bearing should be installed in the starter clutch and then the starter clutch bolted onto the back of the flywheel. The flywheel should then install onto the crank. Make sure to line the key on the crank up with the key way on the flywheel.
Well, I bolted the starter clutch back onto the flywheel and installed it on the crank and this time it just slid down into place. I have no idea why. I did the same thing 50 times yesterday and couldn't get it but this time it just worked. ¯\_(ツ)_/¯ Thanks for the reply.
So, now I'm trying to torque the flywheel nut to 72.5 ft lbs as per spec. I put it in 5th gear and wedged a socket between the front sprocket and the chain slider to stop the rear wheel but I was only able to torque the flywheel nut up to 50 ft lbs before the clutch started slipping. In the video, you use an impact wrench to install the nut but I don't have one and from what I've read, that can damage the crank. Since there's only one hole on the outer ring of my Trail Tech flywheel, what would you suggest is the best method or tool to hold the flywheel while I torque the nut?
I would recommend contacting your local Suzuki service center to see what they would recommend. There are flywheel holding tools that you can get to keep them from spinning. There are also piston stop tools that you can use as well.
So i replaced my starter clutch, now my bike wont start. Will a overtighten nut that holds THE Flywheel cuase my bike not to start? Cause its really tough to pop push while in gear. Of course holding the clutch down. Plz help
At this point without having the ATV here it is almost impossible for us to troubleshoot it. I would recommend contacting an authorized service center for your ATV.
Justin Yancy thanks for the reply. Well im thinking my flywheel key sheared? Will that cost it not to start? It just turns over like it wnats to catch. Need proper torque specs. Dont want to do this again
Francisco Ruiz If the flywheel key has sheared and the flywheel has spun on the crankshaft it can cause the motor not to start as it would be out of time. If this is what has happened I would recommend having your crankshaft checked also because the flywheel spinning on the crank can damage it. The proper torque spec is the stock spec. You can get this from an authorized service center for your ATV. The first thing you are going to need to do is to check to see if your key has actually sheared.
Justin Yancy thanks. So im just going to go ahead and install this flywheel key. Assuming i haven't damaged anything in the crankshaft. Doew the key need to fit all the way in you know. I cant. Find any image of an undamaged flywheel key
+Steelz Films Unfortunately we have never tried. You may be able to but it would be a very tight squeeze. More than likely the lever will need to be removed.
No red loctite? Should always use on these flywheel bolts the z has issues with them coming loose and breaking off tearing up the flywheel and stator. Good video otherwise.
![Facil🏍Como Sacar el MAGNETO sin Extractores [Secreto Revelado] forma Casera](/img/n.gif)
This has got to be one of the best mechanic-ing videos I've seen so far. Good camera, very clear speech, good use of labels, informative. Very nice. I just wish it was for my motorcycle, haha.
you sound young...I can't believe how professional you sound and this video is...kudos!
I’ve been looking for this videos for months cuz I was looking for : Drz 400sm starter clutch tutorial and didn’t get anything and then I forgot there’s a 4 wheeler w the same engine so I looked it up and found you finally cuz I didn’t want to send it to a mechanic that’s gonna charge me 300 for it plus the starter clutch.. I just did mine w this video thanks a lot I appreciate it.. ps: I saved the video two so I won’t loose it just in case
As many said... the best video tutorial on TH-cam. Great :)
Absolutely excellent video mang, keep up the killer work!
Thank you for talking about the PINS and BUSHINGS
Are you a robot, a manual reciter, a text to speech fanatic, an engine loving lawyer or all of the above?
Frank Camacho. I would recommend contacting a service center for your ATV. It sounds as though the ring gear on your flywheel could be missing teeth on it. I would recommend taking it to a shop though so they can verify what the issue is.
SORRY FOR MY ENGLISH AND THANKS FOR ANSWER MY FRIEND. EXTREMLY TECHNICAL. ENDURO ALL TIME WITH CRF 450 R. I ASK YOU FOR CRANK BEARING BECAUSE OTHER GUYS TELL ME ABUT THIS. I BUY Z400 17oz USED FOR 100 EURO. INSTALLED MY SELF. THE MOTO IS VERY BETTER !!!!!! THANK YOU AGAIN.
With the Trail Tech flywheels the crank bearing will not get damaged because Trail Tech balances their flywheels. This means that when you install a Trail Tech flywheel the added weight will not wear out your crank bearings because the flywheel has been balanced.
might as well upgrade to some 12.9 grade M6x1.0 bolts while in there. After upgrading to 12.9 grade, you can increase the clamping force by pushing the torque values up a bit..... and throw some blue medium locktite on there. Good luck boys!
dude... YOU MAKE GREAT VIDEOS ... THANK YOU!
+Troy mcconnell Glad we could help. We try to make it as easy as possible. If you have any questions please let us know.
I solved the problem it was the starter motor than was " stuck " i had to open it , clean all the parts like i saw here on youtube people explaning how to clean and service the starter motor , now its all good ! thanks anyways mate :)
Cool vid. Been hot min since Ive had that side of the motor apart. Just an fyi tho, that “bracket” under the chain guard is a “case saver”. If yiu havent already upgraded this bit now would be perfect time to swap. Either way DO NOT leave this bit off. If you break/derail a chain it very well may take your crank case with it if you delete this piece. I know this is prolly common knowledge but i really REALLY hate thousand dollar mistakes. Busted cases are bad juju. Esp if a 20$ part can eliminate it. Cheers!
your videos are legit bro....very well done!
The best thing to do in your case would be to contact an authorized Suzuki service center to see if they can point you in the right direction as to what could be causing your issue.
why i should do that? what is going to change??
Ok for people wondering what the benefits are it had a better magnet for better charging and it's lighter than the stock one! Cool product guys you should advertise this for the Drz400 and make a supermoto version that's super lightweight alot guys use the drz400sm as a beginner gp bike.. you'll sell them I'm sure people are putting slipper clutches in the drz.. it's like a oversized grom there super popular
I wouldn't lump the grom in with a 400cc beast the drz is slightly more powerful thanks to its keihn carb and a more aggressive cdi box/rev limiter. I think they sell those in red tho with hi limters aftermarket
@@Kyle_gallegher I said "OVERSIZED" grom lol.. it's more powerful because it's a bigger engine obviously.. the ignition system on both bikes are almost identical just slightly different design and parameters..
Reason I lump them together is also ride em back to back in stock form there the most popular bikes in my area besides Harleys and streetbikes...
@@snakevale198444 My boi ofcourse a drz is more powerful than a grom, a drz is more powerful than LTZ is what im getting at. And Ig tbh I just hate the grom. Aprilia small gp bike > grom. Its me I know
@@Kyle_gallegher the ltz400 is slightly more powerful than all of drz400 models it has fuel injection.. aside from that there almost the identical motor they pretty much are before 2009. Also you have to remember only the drz400e had the different carb and cams.. gas gas used the same engine in there 450mx quad it had a different bore but aside from that it was almost identical it had more power than all the bikes listed.
one of the limiting factors back then was the cdi. Mickey Dunlap did all of the R&d on that quad he's a buddy of mine. He wrote a article about it and posts alot on Facebook if you really want to learn the history of this particular engine..
Don't forget to locktight the bolts!
+Ride On Creations Thats very importent, many DRZ Engines are demaged by this reason!
Best advice ever I almost commented the same thing
The milky residue that you are seeing is not milky oil but the grease from the starter gear.
Yuck!!
after you have done this procedure, can you fire the motorcycle right away=???? or do you have to set it on time first???
When you took the fly wheel off the gear behind where you able to spin that by hand ?
What do you mean by oil in the flywheel? There is no oil in the flywheel it's self but when you take the ignition cover off there is oil behind it. That is why it was on its side in the video. Just like what was posted below. If you do not want to put it on its side then you will need to drain the oil before removing the ignition cover.
Clear your head and explain yourself again.
What size of the puller you used to pull out the flywheel..??
Coarse thread or fine thread
muy buena ilustración grasias
Great video man, finally found something lol
I think my gasket its leaking to under the motor , you think its cuz i reinstall the same one ? Small leak barely oil dropping
when you took the starter cover off, was there milky oil in by the starter gear?
Is this what trail tech made before becoming a digital guage company?
My starter is just spinning when I push the start button but if I leave it in gear and push it, it will start. Would you say that it's the starter clutch?
+RaShod Chatman We recommend taking it to your local dealer.
yes
anyone know the torque spec for that flywheel bolt
How can u tell if my flywheel is still good. Bike wont start. And buying a starter clutch. Should i also buy flywheel
HI DUDE FROM GREECE, I HAVE CRF 450 R 2009 AND I WONT TO CHANGE FLYWHEEL. WITH 17 OZ OR 11 OZ HAVY WEIGHT ? THE BETTER ? FOR ENDURO. WHAT ABUT CRANKSHAFT BEARING ? PROBLEM IN FEATURE ? THANKS
i have been searching all around the internet to figure out what that metal piece on the side of the stator cover is with the cables. i cannot figure out what that connects to so if anyone could tell me what those cables are too PLEASE reply.
How long did this take without time lapse?
One question , ive a Drz400E that is the same engine " at least i think so " , ive replaced the magneto cover , because it was cracked , and since i was having a hard time to remove it i had to open the starter motor , after i assemble all the parts again the starter motor wont start , it just clicks for eatch time i press the E- start , is there any special thing about assemble again the starter motor ?
Ask a shorter question.
@@jimmymcjimmyvich9052 hahaha 9 years Later
That rear gear assembly not sitting right I need help
What size puller did u use
so i had to replace my old starter clutch because it went out, and i got a new one that does the same thing as the one before. it just spins it dosnt turn the motor over what could it be?
reverse?
What type of enduro riding are you doing? Is it extremely technical? Do you ride motocross at all? If it is technical then you will want to go with the +17oz flywheel. If you are going to ride motocross at all you will want to use the +11oz flywheel. Trail Tech Flywheels are balanced so there is not issue with crank bearing wearing out or going out at random.
You don't half rabbit on)))
There is no real way to check the flywheel other than visually inspecting it, but it is unlikely that is your issue. I would suggest checking the stator and CDI first.
I have an ATV that you here the starter spin but you don't hear the engine turning... If I move it a little bit in gear it will crank the engine when I push the starting button but the engine will turn for a little bit then it won't turn after that...
I hear you bro))
Nothing like a new engine to work on lol they don't mention ita doesn't come apart that easy lol good vid bud thanks
I'm installing a new starter clutch bearing on my Trail Tech flywheel [DRZ400] and I have it bolted to the back of the flywheel, just as you did, but it won't slide into place on the crank. It feels like the bearing won't fit over that part with the four grooves. A guy in the DRZ forums said I have to first install the bearing and then the Woodruff key and then the flywheel. Can you comment on this?
The key should be installed in the crankshaft before installing the flywheel on the crank. The bearing should be installed in the starter clutch and then the starter clutch bolted onto the back of the flywheel. The flywheel should then install onto the crank. Make sure to line the key on the crank up with the key way on the flywheel.
Well, I bolted the starter clutch back onto the flywheel and installed it on the crank and this time it just slid down into place. I have no idea why. I did the same thing 50 times yesterday and couldn't get it but this time it just worked. ¯\_(ツ)_/¯ Thanks for the reply.
Glad you were able to get it on. Not sure what was causing the fitment issue before. Let us know if you have any other questions.
So, now I'm trying to torque the flywheel nut to 72.5 ft lbs as per spec. I put it in 5th gear and wedged a socket between the front sprocket and the chain slider to stop the rear wheel but I was only able to torque the flywheel nut up to 50 ft lbs before the clutch started slipping. In the video, you use an impact wrench to install the nut but I don't have one and from what I've read, that can damage the crank. Since there's only one hole on the outer ring of my Trail Tech flywheel, what would you suggest is the best method or tool to hold the flywheel while I torque the nut?
I would recommend contacting your local Suzuki service center to see what they would recommend. There are flywheel holding tools that you can get to keep them from spinning. There are also piston stop tools that you can use as well.
So i replaced my starter clutch, now my bike wont start. Will a overtighten nut that holds THE Flywheel cuase my bike not to start? Cause its really tough to pop push while in gear. Of course holding the clutch down. Plz help
At this point without having the ATV here it is almost impossible for us to troubleshoot it. I would recommend contacting an authorized service center for your ATV.
Justin Yancy thanks for the reply. Well im thinking my flywheel key sheared? Will that cost it not to start? It just turns over like it wnats to catch. Need proper torque specs. Dont want to do this again
Francisco Ruiz If the flywheel key has sheared and the flywheel has spun on the crankshaft it can cause the motor not to start as it would be out of time. If this is what has happened I would recommend having your crankshaft checked also because the flywheel spinning on the crank can damage it. The proper torque spec is the stock spec. You can get this from an authorized service center for your ATV. The first thing you are going to need to do is to check to see if your key has actually sheared.
Justin Yancy thanks. So im just going to go ahead and install this flywheel key. Assuming i haven't damaged anything in the crankshaft. Doew the key need to fit all the way in you know. I cant. Find any image of an undamaged flywheel key
hey dude is there engine oil in the flywheel area?
Yip))
Lock tight on the clutch bolts!!!! If you don't you will regret it!!!!
Can u get that cover off with out taking the shift lever off mines welded on
+Steelz Films Unfortunately we have never tried. You may be able to but it would be a very tight squeeze. More than likely the lever will need to be removed.
+Justin Yancy ok thanks I'm looking get mine lighten so went do it but didn't wanna take it apart then can get main cover off
Try semtex)) It will I promise))
Thanks!!!!!!!!
Very nice job on this video I must say, and I never say..
No red loctite? Should always use on these flywheel bolts the z has issues with them coming loose and breaking off tearing up the flywheel and stator. Good video otherwise.
No.. It is the same as a DVX 400 though...
Kinda))
2002 wtf I got the 1st year Ltz 400 and it’s a 2003
what about the middle bolt ? You didnt even touch it !
Do not touch it Ever!!!!
muy buena ilustración grasias
muy buena ilustración grasias
(Very good instructions, thank you)