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How to Build a Suzuki Quadzilla LT500R Engine | 1987 - 1990 Full Build Step by Step
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- čas přidán 15. 08. 2024
- How to Build a Suzuki Quadzilla LT500R Engine | 1987 - 1990 Full Build Step by Step
#2stroke #lt500r #quadzilla
CHAPTERS
0:00 - Intro
CENTER CASES
1:02 - Crank Installation
3:34 - Transmission Installation
4:32 - Shift Drum/Forks/Detent
8:02 - Center Case Assembly
10:40 - Shift Cam Bolt
11:23 - Sprocket/Countershaft
STATOR SIDE
12:02 - Counter Balancer
12:30 - Stator/Flywheel Assembly
CLUTCH SIDE
15:12 - Gearshift Cam/Shift Shaft
17:29 - Kick Start Assembly
18:41 - Power Valve Actuator
19:17 - Primary Drive Spacer/Gear
19:54 - Counter Balancer/Drive Gear
21:33 - Power Valve Governor
22:20 - Primary Drive and Counter Balancer Tightening
23:25 - Kicker Idler Gear
23:52 - Clutch Assembly
27:49 - Clutch Cover Installation
TOP END
29:27 - Piston Installation
31:22 - Power Valve Installation
33:53 - Cylinder Installation
36:44 - Head/Dome Installation
38:13 - Reeds/Intake Boot Installation
39:00 - Exhaust Flange Installation
39:31 - Power Valve Cover Installation
39:41 - Water Pump Impeller/Cover
SHOWCASE/CLOSING
40:45 - Showcasing/Running The Engine
42:18 - Closing
PARTS AND TOOLS IN THIS VIDEO - (These links may be affiliate links that I get a kick back for; there is no added cost to you)
Suzuki Service Manual - bit.ly/2ZqSDdw
Crank Installer - bit.ly/3j0mKjx
Assembly Lube - bit.ly/3qecHJt
Anti-Seize - bit.ly/2SP14vZ
Yamabond 6B - bit.ly/393wIdp
Milwaukee M12 Impact - amzn.to/3zIh5Vm
Milwaukee M18 Impact - amzn.to/3zImLi8
Blue Loctite - bit.ly/3h3CArh
Red Loctite - bit.ly/2SO2hDV
Large Torque Wrench - bit.ly/3zKjwa2
Dead Blow Hammer - amzn.to/3xxEQxt
T-Handle Allen Wrenches - bit.ly/3gPaSOM
Flywheel/Clutch Holding Tool - bit.ly/3cXqlej
Rekluse Oil - amzn.to/3gSYzBB
Assembly Grease - bit.ly/35FHiGk
Gasket Spray - amzn.to/3qe9iKy
Klotz Benol - amzn.to/2YqzNml
Clutch/Spring Kit - bit.ly/3pIIovX
Gasket/Seal Kit (87’) - ebay.us/tfzVoG
Gasket/Seal Kit (88’-90’) - ebay.us/T8mtqc
Cool Head - ebay.us/EPxNrR
COMPANIES I TRUST
Rocky Mountain ATV MC - bit.ly/3AkRaSS
Lion Parts - bit.ly/3jtEGSr
Rocket Ron - rocketronracin...
BPRacing - bpracingatv.com
Obor Tires - shop.obor-tire...
MERCH - michael-sabo.c...
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Oh man you had to take everything apart just for the little bracket that had to of sucked!!!
@@joshuajackson8142 it happens sometimes lol; luckily I was able to slip it under the gear and I didn't have to take everything off.
Your da making history with these videos man this shits awesome
@@krudlumpstv7854 I appreciate that man, thank you
🙏🏽🙏🏽🙏🏽🙏🏽👏🏽👏🏽👏🏽👏🏽
This video is INCREDIBLE! The Zilla community has needed this for years! So well done! Happy to help man!
Thank you for the feedback man and thank you for supplying some of the parts for the build 👊
I'm so glad I found this video I have my engine in pieces and a manual but this video is the perfect explanation 👍👍
Respect to you for saving that motor all that work you did prior to this assembling video..great video as always Mike👍🏻👍🏻
I appreciate that Andrew; thank you!
Great video! Very detailed and thorough. I'm glad to see people doing stuff like this for the lt500r community. Compared to other quads, lt500r content is in a drought. So this video is very appreciated!! Thank you!
Glad you enjoyed it man and I appreciate the feedback; hopefully this can help the community!
Older then dirt? Ouch. Good job kiddo! Also, you are correct, that is a 62cc cool head dome I sent. Glad someone could use it!
What's up Cy! I'm still regretting not taking a rip on your zilla! The oldies are the goodies and nothing but wisdom, experience and stories come with age so it's all good! Thank you for the dome, John didn't tell me where it came from.
@Michael Sabo Hey Mike! Had someone not exploded the chain and destroyed the drive sprocket! I blame John he rode it for all of 5 minutes 😁 lol. Also it's good to be reminded that I'm old from time to time, I easily forget lol. You're welcome on the dome, it was cool to donate to a worthy project!!
I am building a 1988 zilla and this video has been super helpful. Thank you for making this video.
This might be the perfect video for 2vintage lol. He just blew up his lt500. I think he vapor locked it because he burned through the fuel line
Nah, he just wrings it out in first gear, can't figure out second, and misses gears. He really has to start draining the fluids and add them himself so he knows what's going on, but many have told him and still machines he rides go up in smoke. We all know secretly he's watching Sabo's videos but won't comment. After blowing his wad on a 10 minute ride that comes out to around $400 per minute....that's all I'm saying about that ;) Hee, hee. The difference between Mike's videos/talent and Douche Vintage is night and day.
Oh gez, the hybrid one he got? I've toasted a fuel line before lol, unfortunate.
Outstanding overhaul video for the legendary Quadzilla LT500 engine. Judging by all the comments, your contribution to the Quadzuilla community was overdue. I think your commentary and video was outstanding, the best I've seen for any rebuild or any engine. Thank you!
Nice video 📹, I'm building a project Zilla now!
Thank you man, good luck on your build 👊
Good build sir! A great guide to anyone building a Zilla.
Also, I like to replace the impeller bolt and it's washers anyway. Insures it won't leak. I also use blue loctite on the impeller bolt, and I like it a little tighter than the manual says, to 9 ft-lbs, as I've seen MANY loosen.
Good call man, I cant remember if I put loctite on it but I most likely did.
@@MichaelSabo I'm sure you did. You put it on everything else that required it.
Just want to say thanks again. This video has helped me multiple times. It’s a great reference/guide. Much appreciated.
Man I just picked up a 1990 quadzilla and I’m so excited to see what’s wrong with it and take the things you teach and put them to work. Your a inspiration to me love the work you do and how clean you build bikes.
suzuki LT500R was my first quad over 20 years ago, my friends called it the 660 killer.
this video will help alot of people out when doing a rebuild
These are absolutely incredible videos dude, the time and effort you put into making these is insane. I don’t really think I’ll do my own motor work but I’m just truly entertained by all the detail you put into these builds. Keep it up! 👍🏼
Wow, awesome feedback and compliment man; I'm glad you enjoy these!
Love these kinda Builds..
Glad you like them. thank you Roy!
What's up Mike? Just wanted to commend you on your unscripted technical knowledge and mechanical abilities. So uncommon in the millennial age group it seems. Your hands tell the truth and 99% accurate when deciphering who's channel I am going to sub to. I'm 57 and have been wrenching as a professional in aviation, automotive, marine, and of course motorcycles since the age of 15. Its great to watch you work so fluidly through the inherent problems associated with dissimilar metal corrosion to general assembly on motorcycles. You have the gift brother, keep it up!
Keep coming back to this for my LT250R. Very very similar in design 😁
Heck yeah
Yes sir ,,SABO BUILT
Man you are good at talking in front of camera. Quality stuff, hope you make some money at it. I bought my 88 Zilla new in 87, still have it. Done a lot of zilla engine builds. Some advice. Base gasket likes to leak right below reed valve area, where the case halves meet (I dress mine with blue dye and large knife sharpening stone). You can buy rubberized steal "no-blow" base gaskets pretty cheap. Also I always do a 6 psi for 6 minutes pressure test before tear down, and especially after assembly. The exhaust drum valve will leak (normal), and the reeds love to leak, as well as base gasket. Duncan Racing did my porting (I bought the National Kit). The web page has incredible info (technical section) about building a 500 zilla engine, Kiehin jetting, and loads of useful info. I rode mine stock for 18 years, strong like a diesel. I got the national kit...holy crap, it became a flying carpet, rarely touching the ground....must have been double the hp.
I'm tearing down an '88 Zilla now. These videos are great! Very helpful and very well done. Keep it up!
On the Suzuki LT500 you should always have brass inserts machined into the cases. They are really hard on crank bearings. Also the crank should be put into the case that holds the crankshaft the crank from walking back and forth. Just my opinion.
Great video and very detailed.
Thank you for the feedback!
This video has been helping since posted. I’d love to see a complete resto/mod on a zilla from you!
I just picked up one of these and have to basically build it from the ground up. Your videos are extremely helpful thank you!
I don’t just mean for the Zilla all ur videos are extremely beneficial to watch I can’t tell you everything I’ve learned watching your channel man so thanks for them all
Omg Thank you for this. I totally needed this as a refresher course. I've had my zilla for a very long time and its time to break the cases for main bearings. Much appreciated!
She’s a beast
Zillas are a league if their own. Enjoyed watching the assembly.
Just a tip for u Mike after putting the crank in the freezer use wd40 or some type of oil to get rid of condensation, it’ll save it from rusting
That's a good idea man; thank you!
For those of you that don’t know it stands for water displacement down to -40° Fahrenheit
Awesome video Bro, best engine assembly video yet been waiting for this one. 🤙🏻
Thank you Dennis!
Stupid fast needs to make some content with this machine.
Good job bro way different when I build there is way more cussing lol
Lmao! That's what the editor is for; thank you as always for the feedback Dave!
Hell yeah brother!!! I have been waiting for this video!!!
Thank you for watching Ruben!
Great job on the build and video you don't know the memory's you brought back thanks. These are you best videos of you building something but great job.
Thank you for the kind words and feedback!
Finally ive been waiting years for a video like this
I hope it can help you 👊🤘
I would still love to see a complete zilla overhaul. And a top quad with all the big dogs.
A great addition for anyone that owns one of these machines, not a lot of this type of info on these rare machines
so sick ! Great addition to the channel !
Probally one of the best lt500r motor rebuild videos of all time. Your killing it mike cant wait to see the next build / quad wars. Sucks winters like here. Pennsylvania is pretty much winter now.
Love ur videos man they have helped so much cause u explain like ur ur talking to a beginner and do t assume we all kno everything.. thanks for them and keep making them man 🤙🏻
Such a thorough video with many links in the description. My wife is a school teacher and she has the same patience as you in explaining things; however, I don't know if you are also an educator for a living but you are damn good.
I have an 89 LT250 and it is wicked fast, especially when the power valve kicks in. I'd still like to get a 500 though. I think yours deserves a full restoration. If you have the engine completely apart, might as well give it a fresh coat of Champion Blue.
been watching all your videos the last couple months and i love them! these videos are so informative and are going to help so many people!
Just a fyi out of all the zillas I owned and as a fact, the 87 has a head gasket problem, well it’s actually not the head gasket due to the six stud configuration and the vibration from the engine and how the engine is held in the head stay will lift up on the head and cause it to blow the gasket, so don’t run the head stay
I appreciate the info man! I saw this in some other comments on a few of the build videos for this machine; have you heard about the stud mod? A lot of guys will upgrade to 10mm head studs which is supposed to help.
@@MichaelSabo yes I have but it’s easier to just not run the head stay in my opinion I’d be more worried about the ears on the jug, I did send you a private message on Instagram
@@fastmachines500r8 I appreciate it man, sorry I missed your message; I get bombarded.
That motor has all kinds of gadgets in it for an old school two stroke! I can only imagine how the new ones are with EFI
Mr... you are good at this! Amazing vid. Keep up, don't stop.
Phenomenal job Mike!
Should do a quad wars with jsr Suzuki vs Honda!!! Great work bro
Thank you Dave! We've actually been discussing this
I comment because youre simply a beast
loved the vid ! always fun watchin.. been buying tools as well
Best advice at 3:53… another solid build Mike! John is no dummy… if you were my friend I would coerce you into building my motors too! 😂
Great Video!!
Love this channel ❤️ ❤️
Killer video bro 🔥🔥🔥
Want to see some mad scientist engineer a 1000cc 2-stroke powerhouse using a couple of these engines.
This is an outstanding video! Great work and thank you!
I love your videos
This is great!
Hey man! I need some help. I just picked up a 88 LT 250 R quad racer. I need some input on coolant leaking out of the Weep hole at the bottom of the water pump.
Unfortunately, on the quadzilla video is the only thing you haven’t rebuild
As usual, you are always meticulous and it is a pleasure watching you build this incredible machines 🫡
Great video!!!!
🤩🤩🤩 Yeah i am waiting a long time to this video!!! Nice video!!!!!
Awesome work. Amazing how well you did. Def a complex engine and not much instruction on them
Awesomely put together
Nice video
That lower bearing clearance was huge, never seen any engine with thrust clearance specs of 1/4 inch before
That's because it has a Hot Rods rod kit. The big end bearing and big end of the rod is 2MM NARROWER than stock! Junk.
@@nunyabizzness5477 I figured something was wrong there. Thats crazy!
@@thatoneguy2756 Yeah, but they're the only ones made. Stock rods and components are discontinued. >
@@nunyabizzness5477 I would get custom thrust washers made similar to the ones he used on wrist pin then.
@@thatoneguy2756 That's how the Suzuki's were designed. The upper washers center the rod. The lower washers center the big end bearing. Not like usual, where the big end washers center the rod and bearing, and the wrist pin is left to float a little side to side. The Suzuki design improves fuel and oil flow to the big end, but puts a lot of stress on the wrist pin washers. Take into account that the 500 washers are a looser fit on the wrist pin than the later 250 washers, and that's why they break. Installing new, later 250 washers every time the cylinder is off is a cheap insurance policy.
Good job bro 🍺
That’s what she said 😂😂😂 . Never gets old.
Awesome video 👌 keep it up 3:56 dont want to go in dry that was funny lol
We need more zills motor videos! Thank you!
Good stuff!
Great video man ! You made that look easy
Thank you so much your trx250r video helped me alot and I just pick up a 87 Zilla there's not that many videos out there I subbed your channel keep making videos very nice work
Awesome! I'm glad my videos can help you out 👊
Great video not that I expected any less
Somebody's bound to make a head sooner or later.In Cota combustion chamber with chromium and call it a Chrome dome.I can't believe nobody's done that yet😊
"THIS QUAD IS OLDER THEN ME" glad to hear, because im as old as this quad and i have no hair left, had you been older than me with that much hair, I would of unsubbed(I'm joking obviously). nice watch man, this is my goto channel whem im eating. better than any TV channel keep them coming, and awesome work BTW! Cheers from Canada.
Great work 👏
Ya man, been wondering about this vid haha. Looks Lee's daunting then I thought. I've had a couple chances to trade off one of my shees for a zilla and I haven't pulled trigger. I may though. I'm subbed to jsr also. He's a quadracer gooroo big time. Builds super clean builds!!! Nice job on the motor bro!!!
Thank you man. Don't be scared to build one of these; they're really not that bad, especially if you leave it on the stock side; biggest thing is surfacing all of your mating surfaces on the Quad Racers. JSR and I may do a collab in the future 🤘
@@MichaelSabo yeah that would deff be whatsup!!! Dude I almost grabbed 2 for 1800. 3 hours from me. Texted pic of cash, got the address and was waiting to hear back on when to leave then he's like oh they sold bro. 2 basket cases but 3 motors, 2 chassis, almost everything there. Damn!!!! I surface all my cases after watching u do it. Deff works!!!!
Please do this on a 99-04 400ex I got one I have to rebuild
I really should do a 400ex; I'll put it on the list!
@@MichaelSabo you got the red one you could do it on
so thoworough in a rock n kind of way ITs ALL GOOOOD ! Luv wen u spurt out a little profantity ! Using the tha hand gester of rocknroll ! PEACE !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Thorough video, has anyone put one of these engines in a dirt bike chassis?
Awesome video. Is there a parts list for gaskets and Orings and miscellaneous parts replaced to do this rebuild on an 87 500? Thanks
You forgot about that shim guide plate for the that bearing inside of the case to still Michael sabo.
for next quad wars we need a honda trx300ex vs a Kawasaki lakota sport 300
Enjoyed the stock build of this lt500!! You gunna make any prlerformance builds for lt500s?
Hey bud have you ever tried Bel Ray H1R 2stroke oil? It’s also formulated for power valves and ester based. I have been using it in my Banshees for 20 years at 40:1 and have never lost a ring. It’s the best oil I’ve ever used. Also it smells way better then the Klotz. 👍 try it sometime. Also I enjoy your build series. I wish I had the time to do what your able to do. Keep it up
Countershaft cover lug smashed off should have tigg ed case
Bro you seriously need to do quadzilla vs 250r and definitely trx450r vs yfz450r
FYI, there is a gasket that goes between the reed cage and the cylinder
3rd love the content 🔥🔥🔥🙌🙌🙌
👊🤘
Nice Video, there are porting Templates for the 500 as well ill see what i can find for ya, ill shoot an email if i find them
Thank you bro; enjoyed what you sent me so far 🤘
Boss great videos like always brother but I have to point something out to you. Is that a crank on that crank seal behind the stator plate.
Will 1 if these smoke a 250r or banshee? Or r they all really close? I've only ever ridden built 250r an banshee. I must say 250r was most fun overall quad I've ever had the pleasure of riding. Great video man!! Wish I had ur skills
Is there any chance you can do a full bike rebuild and engine rebuild on a ktm 85 sx 2006
You should give 2Vintage some pointers
Any way I can direct message you, after so many years , I finally got my hands on a zilla, she's in good shape but been sitting . I've batled one small issue after the next. Now having clutch issues
Can I build a whole engine if I have that book or is it a service book? I am rebuilding a 87 zilla with a 90 engine but i need alot parts 🙈
How well do you think this engine will perform in a crosskart?