How to split the Z400 engine case

Ok our goal here is to split the cases of a LTZ400 to help the many people out that are going to install an aftermarket crank like the HotRods. I'm going to start this at the point that the top end is removed already and bottom end removed from the frame. Side note: If you doing this I'm going to assume you know how to do normal thinks like remove side covers and such

To start we need to discuss tools that are needed for the job.
    1.    Sockets 8mm-17mm
    2.    Socket 27mm
    3.    Assorted Screw drivers
    4.    Extended Magnet
    5.    Torque Wrench(s) Capable of 7ft/lbs to 120+ ft/lbs
    6.    Impact Screwdriver
    7.    SUZUKI LTZ400 MANUAL
    8.    Snap ring tool
    9.    Allen sockets 4mm-10mm
    10.  LTZ400 Flywheel puller
    11.  LocTite Blue color
    12.  Suzuki Bond 1207B #99104-31140
    13.  Good Impact gun
    14.  Rubber Mallet

Optional tools not used but recommended for the job and it's not my fault if you break something because you didn't use them.
    1.    Off set 27mm wrench (Bent mine up myself)
    2.    Clutch Sleeve Hub Holder #09920-53740
    3.    Crank Case Separating Tool #09920-13120
    4.    Crankshaft Installer #09910-32812
    5.    Spacer #09910-32820
    6.    Attachment #09911-11310

Now let’s get to work:
First start with a clean work area and set out your tools for easy access. I also use small boxes or zip locks to store parts as they come off to keep things together.



Now remove the side covers for both the Flywheel side and Clutch side. Don't forget the bolt behind the started reducer gear on the Flywheel side. You need to remover the stator too BTW.



Once their out turn to the Flywheel side 1st. The small gear will remove by hand and you can pull out the rod it's on but is not needed. This is the point where I zip of the flywheel nut with a 17mm socket and the impact gun. I usually hold the rod in my finger to keep it from flying around but you the right way to do it is to put a 27mm wrench on the opposite side of the crank.




Now we are going to remove the reverse sensor. There are 2 4mm Allen bolts that hold in the sensor. Notice which way is up because if you install it upside down all your forward gears will have a rev limit on them like the reverse gear. Once you remove the sensor you will see this...




As you can see there is an o-ring and two pins that are in the shift drum. Pull the pins out with the magnet and they will come with two small springs. Keep all that together and spin the motor around we are done on this side for now.

We need to pull off the whole clutch assembly. I'm assuming again that you have changed you clutch so remove the cover and all the plates. Now you need to flatten down the Hub washer and zip off the retaining nut with the Impact and 27mm socket. Here is where the Hub Sleeve tool thingy is used but I just put a large screwdriver to hold the hub and the impact zips it off so fast it's really not that bad.



Pull everything off and keep it together. There is a washer between the Hub and the basket, also there is a collar that usually on the back of the basket but sometimes it sticks to the shaft. Now it should look like this...



First I pull off the Oil pipe. Next if the cam chain guide and there is a washer behind the guide you don't want to lose. Then the chain should just snake right off. Next using the snap ring tool we are going to remove the Oil Pump Idle gear and the Oil Pump Drive Gear. Watch the Drive gear because it has an indexing rod that you can see in the pic. Now the Oil pump assembly needs to be removed and this is where you MUST use the impact screwdriver or else you are going to strip the heads of the bolts and will be drilling them out. Once the screws are removed you can pull the assembly off and it should look like this...



I highlighted that shaft because it has a snap ring on it and it looks like it should come off but DON'T REMOVE IT OR IT WILL FALL OUT WHEN YOU SPLIT THE CASES.

Now we are going to get the shifter shaft out of the way. There is a Snap ring on the Flywheel side that needs to be removed and the shaft just pushes through the cases. There is a washer behind the snap ring and also behind the assembly that you’re pushing out. See pics below...







BTW: This shaft should come out real easy. If it doesn't you will have to give it some persuasion and when it's out check it for damage. These bend a lot on Z400's.