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Author Topic: DRZ400E Engine rebuild due to seized camshaft  (Read 7270 times)

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Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #20 on: August 28, 2012, 10:07:18 pm »
R10.500 is not too bad as you'll have a new motor then?

As I understand a LTZ 400 motor also fits.

I check all over e-bay for LTZ, KFX, CCM, Arctic Cat heads. They use the DRZ motor but not the 400E cam specs, more like 400S cams on most of the quads and only slightly cheaper than new. I'll order all parts in one go to save on shipping. New = peace of mind.
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Offline Heddles

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Re: DRZ400E seized camshaft
« Reply #21 on: August 28, 2012, 11:14:44 pm »
It looks as if only the one camshaft is damaged.. I have seen worse repaired.. I will try and contact a mate of mine in JHB for a name of someone who can repair them... I know of a few guys in the Western Cape who can fix... Now just to find a head..
 

Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #22 on: August 29, 2012, 08:38:07 am »
It looks as if only the one camshaft is damaged.. I have seen worse repaired.. I will try and contact a mate of mine in JHB for a name of someone who can repair them... I know of a few guys in the Western Cape who can fix... Now just to find a head..

Thanks Hedley. I also found a complete head, barrel and piston in the UK, just waiting to hear if its 400E spec cams. Will appreciate any info you can find about fixing my inlet camshaft.
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Offline Heddles

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Re: DRZ400E seized camshaft
« Reply #23 on: August 29, 2012, 11:01:31 am »
Place in CT. I think are called Goch and Cooper.. Very good and enthusiasts.. Helped me with a head on a Polo.. Worked a treat and their prices were reasonable. Service was good, polite and professional.. Got my mate on it, like snot on a retard for info about places in Gautengaleng...
 

Offline Heddles

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Re: DRZ400E seized camshaft
« Reply #24 on: August 30, 2012, 01:31:13 pm »
My mate has suggested a place in East London..

The guys name is Gary Miles.. Able to do the cam and will be able to help with the head as well.. Contact details hopefully to follow...
 

Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #25 on: August 30, 2012, 05:25:35 pm »
I've been to busy in the garage to even post here for 24h. I cleaned the cams up, took about 3 hours on a centre lathe with 800- and 1200 grit wet & dry paper. I measured the journals after cleaning and they're all within 0.05mm of each other and well within spec. Pics to follow.

I found a cam cap of another model Suzuki which can be machined to fit the DRZ. Tim Basson Performance Engineering in Melkbosstrand is going to bore out the cam caps and insert half-shells for me.

So by saving the cams and repairing the head I'm saving between R6k and R7K.

« Last Edit: August 30, 2012, 06:03:45 pm by Torque Curve »
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Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #26 on: August 30, 2012, 06:13:50 pm »
Davies' Motors in PE has a large supply of stripped bikes, mostly 80's and 90's Japanese bikes. I found this cap on a shelf with a load of GSXR heads. Its a little longer than stock and the location point for the tappet cover bolt needs to be moved, but all that's easily done in a decent machine shop.
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Offline Heddles

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Re: DRZ400E seized camshaft
« Reply #27 on: August 30, 2012, 06:42:50 pm »
Well done bud..

This is what it is all about.. Making a reliable plan... I have heard about Tim.. He has a really good reputation.. Keep us all in the loop..
 

Offline the_BOBNOB

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Re: DRZ400E seized camshaft
« Reply #28 on: August 30, 2012, 07:29:48 pm »
good luck with the rebuild

if i'm not mistaken Go Girl had some pitting on her cams ans she had the cams redone - dont know how they do it but they redo the lobes etc back to spec  :thumleft:

years ago my dad had a crank redone for a 11 special - not sure how they do it but they can rebuild cranks and cams

do you know why this happened ???

whats preventing it from happening again ???
 

Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #29 on: August 30, 2012, 08:06:15 pm »
good luck with the rebuild


do you know why this happened ???

whats preventing it from happening again ???

Someone in the past removed the inlet cam cap and it was then not torqued correctly. Several mangled nuts and bolts in motor points to total lack of mechanical ability by whoever worked on it. That's all going to be repaired/replaced. This motor will be as good as the day it left that fantastic SUZUKI factory in Japan!
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Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #30 on: August 30, 2012, 09:15:48 pm »
Two mangled nuts and a few stripped heads all hidden under the clutch cover. I'm guessing this guy owned a hammer, chisel and maybe a leatherman?
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Offline Etienne2T

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Re: DRZ400E seized camshaft
« Reply #31 on: August 30, 2012, 09:20:43 pm »
Ouch thats painful to see.
 

Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #32 on: August 30, 2012, 09:49:28 pm »
I'm deglazing the cylinder tomorrow. Hoping to remove a slight alu deposit where the piston rubbed after off. Then this goes onto my list. If rebore is required +2mm piston will do nicely.

Its a Wiseco forged piston with Teflon skirts.
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Offline Heddles

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Re: DRZ400E seized camshaft
« Reply #33 on: August 31, 2012, 01:17:17 am »
I would check the bottom end, just to make sure that the same crude workmanship was not used in there as well.. So not cool to do that to nuts and bolts.. they never torque down properly again after abuse like that...
 

Offline Kenzogs

Re: DRZ400E seized camshaft
« Reply #34 on: August 31, 2012, 06:43:26 pm »
Hannes,

Head all packed. Will get it to Time Freight on Monday.

ken
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Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #35 on: August 31, 2012, 11:19:26 pm »
Hannes,

Head all packed. Will get it to Time Freight on Monday.

ken

Thanks again, Ken. I'm so excited about this head you're sending me. As soon as its here I can finalise my parts shopping list and properly get this rebuild started!

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Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #36 on: September 01, 2012, 05:16:04 pm »
I spent the most of the afternoon cleaning parts and flushing more shavings from the casings. The crank and bearings will need to be pressed out. Again, someone in the past installed bearings and the crank by hammer only, which took also took a chunk out of the side bearing. I'll be replacing all bearings in this motor as well as the conrod. Don't plan to open this motor again, so I'll be doing the job right.
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Offline Torque Curve

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Re: DRZ400E seized camshaft
« Reply #37 on: September 01, 2012, 05:24:59 pm »
The piston and cylinder has some vertical scrapes and slight aluminium rub-off can be seen. As said before, I'm doing this motor once so NS2-Stroke will have to say if it can be repaired to standard or if they have to go over-size.
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Offline Skipskop

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Re: DRZ400E seized camshaft
« Reply #38 on: September 01, 2012, 05:56:56 pm »
That`s disgusting workmanship ( actually disgusting even for a butcher-backjard job). please name and shame so we can know who to stay away from . I must say it looks like you are doing a good job of it.
This scares the hell out of me to buy second hand .
This bike was obviously butchered buy the then owner just to get rid of it ,hope it was not the previous owner, otherwise I would let him dock up for the costs.
Sorry for the negative rant ,this is just so wrong .
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Offline Heddles

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Re: DRZ400E seized camshaft
« Reply #39 on: September 01, 2012, 06:20:22 pm »
That`s disgusting workmanship ( actually disgusting even for a butcher-backjard job). please name and shame so we can know who to stay away from . I must say it looks like you are doing a good job of it.
This scares the hell out of me to buy second hand .
This bike was obviously butchered buy the then owner just to get rid of it ,hope it was not the previous owner, otherwise I would let him dock up for the costs.
Sorry for the negative rant ,this is just so wrong .


I fully agree.... Name and shame....!!