SUZUKI DRZ400E REBIRTHING || Broken carburetor damage and fix.
Vložit
- čas přidán 20. 09. 2023
- My DRZ400E suffered a major break down in the Australian outback. A piece of my carby broke off and went into the intake of the engine stopping the bike in it's tracks.
This video shows me pulling the engine apart, searching for the damage and what needs fixing to get the bike running again.
DISCLAIMER: I am not a mechanic and everything in this video is from a DIY approach. Please seek advice from a trained mechanic first.
Follow me INSTAGRAM:
the.apprent...
Follow me FACEBOOK:
/ theapprenticeadventurer
Thanks for the shout out mate,I’m glad I was able to help you in some way,and thanks for those flash stickers you gave me,up the Drz ☺️
No problems at all. Your engine saved me a fair few dollars. Once again I’m super appreciative about the whole thing. 👍
Awesome to see the moto community helping each other out. Jas you are the man!
You didn't mess around getting her going again. Well done, Lance. Now you've got me really interested in how much difference the big bore kit makes.
Thanks mate. I have a review video coming out soon. Hopefully some good advice pointers for you.
I'm not going to lie, I'm more excited over the big bore kit.
Lance a bit of advice mate never mix match bottom-end cases they are machined together from factory and shouldn’t be mixed especially not to mix with other bearings as they wear differently in their housing due to all cranks n bearings wearing differently if you have it that far apart just replace main bearings if no up n down on conrod but honestly id replace it all since its apart but use matching bottom end cases
Yeah i was thinking about all that and really just didn’t want to spend more money on it. That’s why it’s a dodgy DIY build that I can only blame myself if it goes to shit.
@@The_Apprentice_Adventurer Hopefully she holds up im sure it will you did the best with what you had and on budget main thing is she’s going again
$310 for a carb plate!!!! Man oh man that is daylight robbery! Anyway great to see it going again!
I know right. Even the store couldn’t believe it.
@@The_Apprentice_Adventurer
What carb do have on your bike ? Was it the stock carb or aftermarket one? TIA
@@johnmaciejewski4 just the stock one mate.
@@The_Apprentice_Adventurer
👍
Giddyup. Not a mechanic here.
Those moments where you hold your breath and it starts.
Yessssss.. Hopes n dreams.
It was a good moment. Even better that I’m 400kms into the new engine and it’s going great.
always use both crank case's ... they are made as a pair
Glad it all worked out, fantastic job Lance, thanks for sharing the autopsy, cheers mate
I rebuilt my motor, changed every bearing seal and hot rods crank and rod also used a cheaper ebay 434 big bore kit. It was the first time splitting a motor and learned a lot from some great youtube vids. Carb parts are definitely expensive as i replaced the slide and plate. The big bore definitely livens it up. You could have got a helicoil and new nut in your sump. Great job very satisfying doing it yourself.
Awesome work mate. I did have the helicoil but it also gave way over the years. I think it was installed poorly from the guy that did the job. Good old gasket maker kept it solid though. Haha.
Definitely done a number on the top end.
Looking forward to seeing Sally 2.0 back on the trails!
Talk about being unlucky. Good to see it wasn't an engine fault that caused it to let go.
Great to see it up & running again.
Great to see man, glad it all came back together.
Good job Lance, impressive, well done.
Yes, yes, yes... perfect words, and great to see and hear !
Awesome job
good stuff mate, keen to hear how it goes!
Love ya work. Good effort for not being a mechanic. You give me hope
Frankensally!! She's alive!! Well done on getting her going again Lance. :D
Glad to see you got her running again, can't wait to see the review vid on the big bore kit too...
Awesome Job lance getting Sally 2.0 Back up and running Big Bore kit was a great addition can’t wait for the Next EP to see the results
Well done Lance....Looking forward to "Sallys" first outing and performance evaluation. Nice effort on your rebuild mate. cheers
Hi from NZ Lance, well done on the rebuild mate, loving your content!!!
Well done Lance a proper job that Sally deserves looking forward to your review.
Great tip on the crankcase splitter that is useful to know.
Awesome👏🏻
Well Done lance,,,you have the patience of a saint my friend,,,Back on the Track brother 👍
Keep up the videos dude!
Good work.
Blessed
I've never watched an engine rebuild vid before let alone by someone who is not a mechanic but wow man you described what you were doing so well and it was brilliantly engaging. So very well done Lance and the best bit was firing her up in the end having done a cracking job. I could hear the slight nerves in your voice as you started her up and then it changed to the excitement of what's she like with a big bore?. Awesome stuff as always your dad is super proud to see he passed on all his knowledge and you used it well. Cant wait for more 🤙
Thanks for the kind words mate. These videos are actually real hard to make for me and not that enjoyable to be honest. Just hard with always stopping and starting. Grease going everywhere. Kids run in and out of the garage and so on. I know that they are helpful for others though so I’ll always try my best to get something out.
The excitement when she fired up, mate I could feel that lol, no better feeling
Yeah it was a good moment that’s for sure. Especially knowing I did all the work.
Bit behind the 8 ball here after just watching jbs vids.
Moto mechanic here.
Props on how you split the cases and paid attention to the dowel at the front engine mount.
We don't tend to use the pullers for that reason tho.
A good soft blow hammer like the 38mm Thor hammer or a snapon dead blow is the go too.
Working generally on 1 side of the engine between the crank and the countershaft they always come apart, you don't have to hit them hard at all.
The only thing that would concern me about the rebuild (and you may have done it of camera) is the head defo needed a good look at.
I would've had the valves removed and checked.
Guides checked/replaced, seats checked/reground.
Anything low on compression is either piston/cylinder damage or head damage.
On another note I've seen that same carby issue and it was from a fellow mechanic trying to remove the slide by rotating the carb and getting the slide out for a new needle, instead of removing the seat and lower subframe bolts to lift the subframe and airbox away.
Anyway bud just my 2 cents, hope she runs like a dream from now on.
Thanks for the info mate. It’s always good to hear what a qualified person would do and or say. I did check everything you mentioned but certainly didn’t measure or test if everything was within spec, it looked good and I knew it had low kilometres, so fingers crossed it will be a solid fix 🤙
Legendary
This is dead set one of the best youtube videos I've watched. I've been so invested in your journey with Josh, such great closure to see Sally spark back to life - loved seeing the detailed explanation of what you're doing mechanically. This time next year my goal is to be licensed and a proud owner of a DRZ, you blokes have inspired me. Those adventures won't happen unless I do something about them. Thanks for the videos Lance.
Thanks mate. I’m glad you liked it. I was in two minds about making the video. It’s turned out alright though.
Absolutely mate. Josh and I can do all the adventures for you to watch but nothing beats getting out there yourself. You’ll love it 👍
It would be interesting to hear if anyone else has experienced carburettor fatigue. Love the case splitter.
Had it happen to a DR400 back in 05, 2000 model that had done 200hrs.
Seen it happen to other Enduro Carby bikes over the years.
Carby slide is 2 pieces, change the rear / small slide now end again. Shit happens
Lance, well done mate. 👍👍👍👍👍👍👍(HOKITIKA West Coast, Sth Island NZ) 😎
This was a great video. Thank you!
Great job. Breaking down in the middle of nowhere is not the end of the world but pretty close. Happy to see you have been able to find the cause and rebuild. Prices were scary though.
May you have good luck from now.
Safety first, fun second.
Thanks mate. I had a good run until that point. Hopefully I get another good stint out of her.
Its Alive!
Hopefully Sally will survive im crossing my fingers
I have had exactly the same happen at 26k. mine went straight out exhaust with seemingly no ongoing troubles just the bike was idling very high but rideable. I have installed an aftermarket vacuum plate in the carb that is from poland. It has slight differences which eliminates the breaking problem with the standard one. Early days but so far so good for me.
That’s lucky mate. How much did the Poland one cost?
jeeezus lance great job, ive been riding45 yeras and no way would i have atempted what you just did. that carby part was a rip. might have been netter off putting a new one on and keeping the old one for spares. i have a 2009 drz 400e only done 600ks. safe riding mate. your videos are great.
Your not wrong. It was a rubbish break down.
Great work Lance. I had a similar situation and rebuilt my 2005 recently. Managed to kill 3rd gear riding through a rock garden so had to do the full case split too. Keen to hear your thoughts on the big bore kit. I didn't do it this time because my 05 only had 9k on it when 3rd broke so my top end all measured in spec. Definitely worth opening up the airbox and throwing a jet kit at the carby now you have a big bore. Made a decent difference on my stock build. Awesome to see Sally 2.0 up and running. Excellent work by you and Josh on the whole series too!
Thanks mate. I’m trying to put together a big bore kit review. Hopefully I can do it some justice.
Good on ya you did very well, you may have a new trade DRZ boys will be dropping their bikes off one after the other, but I think you need a bigger work bench first. Great comments on what you found and what you fixed all the best glad she is running. Can't wait to see what you reckon of her now.
Haha maybe it can be my side hustle. I agree though I definitely need a better work area. It’s coming soon.
Well done lance! One way to get to know your bike well!
I think 434cc is a really great cost effective upgrade I see some go out to 470cc which would most likely require oversized intake and exhaust valves I think!
All of us U Tube supporters should pitch in and buy you a wide ratio gear set to throw in with that big bore kit to get you on your way!
Haha I would love that. Fund all the upgrades as a collective and I’ll go test them. Sounds like a deal to me 😉
So far the new power is great.
Great video Lance. Next time you make a video however think about your lighting. For the most part your shadow was covering your work making it harder to see.
Haha I know. That’s my old man cave which sucked. My Next man cave video will be on point and lighting improved. 👍
I mentioned on Josh's channel about a week ago. I was pretty sure a new slide would have got the bike running again to get you home. Once back I would have done a strip down to check it all out. Any how.. nicely done
Good luck with that, with the availability of EFI in later models there is no way I would use a carbie model for what you do.
You can fit a helicoil insert to your stripped drain bolt hole very easily to repair the thread. I’ve used them many times.
They can be shortened by cutting with side cutters to the correct length.
I’m led to believe that the carburettor slide vacuum plate is made from plastic, although I don’t know for sure.
I’ve just bought two new aluminium vacuum plates from a guy who makes them in Poland.
They’re very well made & are meant to be a lot more robust & last a lot longer.
I found out a lot of very good information from the ThumperTalk forums regarding DRZ carbs, etc.
Mine’s a SM model thatI’m fitting the E type Keihin FCR carb to.
If you’ve been getting dust in the top of the carb, check for wear on the carb internally, where the slide rollers run.
There may be grooves worn by the rollers in the body.
I’ve bought a couple of repair kits from a guy in the Netherlands, which are meant for the later FCR carbs.
The kit takes out all of the play from the grooves worn in the carb body.
Apparently, the play can cause more pressure on the vacuum plate, causing it to fail faster.
I’m hoping I can make the repair kit work on my OEM Suzuki DRZ400E slant FCR carb. I haven’t tried it yet.
Thanks for the info mate. I did have a helicoil but the guy who installed it butchered it and it only lasted a year. The hole was just stuffed.
Responding early, but it looks like the metal may have made it skip a couple of teeth in the timing chain and the exhaust valves have been smashing into the cylinder … eventually causing a loss of compression.
Mate I actually didn’t even think to check the timing before hand properly. Very possible indeed.
Did u ever find metal shard in ur exhust looks like she spat it out through the exhust could be a few bits still in ur baffle and have watched both ur view and Josh on Cape York and loved it keep up the good videos.❤
There could be. Certainly nothing fell out when I removed the exhaust and tipped it upside down.
Thanks for tuning in.
Great work mate. Congrats on getting it up and running. It’s a little reassuring to know that I am not the only one that mangled their DRZ oil drain. I have a replacement case ready to go and now I just got to bite the bullet and get stuck in. Can I ask, was that giant torque wrench the murder weapon? I have the same one haha.
Haha mate I did mine due to being in a hurry and upside down. Had a little wrench and thinking to myself why is this so tight not paying attention that I was tightening it.
My big wrench has stripped others bolts though, I really need a smaller bike specific one.
In future If you need parts, there is a guy in Winston Hills that has plenty of DRZ spares.
Good Video Lance, great outcome .Did you reco your head or use the one off the donor engine ?
Mate a mechanic would die in their grave if they knew. I used the other engines head. But used one valve from my engine and kept three valves from the other engine. It’s a total miss match. Lol
@@The_Apprentice_Adventurer,I would of done the same as long as it all looks serviceable and in spec ,Sounded nice and crisp on first start up . .👍
Awesome video and explanation Lance, and Sally lives 👍👍ps, how do you get your audio from body mic to your gopro ? to match up with the video, something I struggle with. Cheers mate 🍻🍻
Thanks mate. On the GoPro there is a receiver that plugs into the audio input. So I wear the transmitter and the GoPro has the receiver attached to it.
Hey mate - I've just brought a 2009 DRZ400E and loving your content. Question, what gearing do you use on your bike. I plan on doing similar trip with a lot of KM's at 100km/hrs.
Congrats mate.
For those sort of speeds I’d run a 15-44 setup. That’s what I have always used for my long distance trips.
Hey Lance, great content mate. Was curious to know if you ever considered injection?
Thanks mate, not really, I’m just so use to the carby setup and haven’t really given It much thought.
Will be interesting to see what your fuel consumption will be after the big bore kit.
Have an e with athena bigbore kit, fuel consumption is crazy low, 2 passengers, lot of slow singletrack, under 5 liters. Maybe i should check the jetting 😅
Yep I can confirm it’s better.
great work...I also do my own wrenching...but, I have an automotive background...good Idea going for the big bore kit....what size did you go to....some sizes require jetting and exhaust...others go extreme and do valves and port work....???
Just did the Cylinder Works 434. Zero tuning required for it. Literally just bolt it on and ride away. Pretty happy with it as a result.
Nice job, why didn't you clean the engine before disassembly 😮
Mate I did. That’s my engine in its clean mode. 🤔
Lance I'm really struggling to find a clear windscreen for the drz400e.... Have you got any tips or links?? There's plenty of drz400s screens out there, but been told they're different 🤷♂️
Mate go onto adventure bike Australia website.
They have mine in stock the Bajaworx in tint and clear. Expensive but a good screen.
I just bought an 07 DRZ400s. I know these engines are reliable but anything mechanical will eventually have some kind of problem. How many KM's were on this engine when this happened? Edit: I see it was 30K KM's. I was also wondering if a Mikuni carb can be matched up to this engine. Thanks for the informative videos!
Yeah everything will eventually wear out sadly. I know plenty of DRZ with heaps more km with zero carby issues. Just one of those things I guess.
Perhaps the timing is too early, the exhaust valves are still partially closed at detonation?
Sounds like a piece of metal stuck in the intake valve kept it open as per your description of the bike revving out, as a non mechanic lol
Don't mix engine cases from two different engines, the cases are a matched pair, line bored for bearings and shafts. Although it may initially work, the minor misalignment will cause failures later down the road.
Edit. Wrote this as soon as you mentioned it, hopefully you didn't do so.
What year is the bike and how many km’s? Is the carby slide failure a common issue?
2017, 29000km. Turns out it is a common thing for higher mileage ones. I have since been recommended to replace the slide every 20000 from several people.
Pretty sure it’s bad practice to use a torque wrench like a ratchet to undo bolts makes them less accurate 👍
Efi may end up being more reliable in this case
How many kilometres on it?
Only 29000km.
I don’t know why you persist with that bike…? I’m not knocking the DR, but with the riding trips you do, you’ll have such a better time on something better.
Mate your breaking my heart. I love me little DRZ though. It’s going to be a family heirloom.
when a better bike exists i'll buy one.
Let me say if anyone I know reads this they know you wouldn't catch me dead on a Suzuki. But I think he is on one of only 2 bikes worth considering. So what bike do you think he should be on then .. asking for a friend 😂😂
When they make one with fuel injection and a 6th gear I'll buy it.....till then I'll keep my 2001 DRZ Weezer purring right along.
P.S. I just pulled out the Gen 1 acct and finally put in a mcct at drum roll please 24,000 miles😁🥃🛵☁️☁️☁️☁️☁️
Love ya videos but never use your tension wrench to undo nuts and bolts. Your dear old Dad would kick you up the arse!
Hahaha I never learn.
Maybe spend less time shaving you body and more time actually understanding how engine's work would be a good idea!!!