Big's 2004 Z400 Project

bigbambizzle · 11-16-2011, 12:49 PM

When I started this build a month ago I had no idea how fun and challenging this project would be until I picked up a set of 09 Z reservoir shocks from ltz-rum off the Suzuki Central classifieds. I'm hooked and want to customize my Z to my liking. Here's what I've done in the past month-

Installed 09 Z400 reservoirs

20redfrogs · 11-16-2011, 12:53 PM

Rub it in Bigbambizzle.... lol

bigbambizzle · 11-16-2011, 12:56 PM

Installed an Alba Pro Elite stick style rebuildable steering stabilizer. I like how its high over the shroud, and sticks out of the left fender so you don't have to dismount to adjust. It also allows you to keep your radiator shroud intact. I did have it so it sticks out the front but I didn't like it.

bigbambizzle · 11-16-2011, 01:04 PM

Relocated the key and idiot lights

TuckerHardRide · 11-16-2011, 01:10 PM

Whats next?

bigbambizzle · 11-16-2011, 01:14 PM

I'm currently working on replacing the air box with new. Here's what I had to work with... yep that's ductape, epoxy, and spraypaint.... it wasn't till I bought a k&n powerlid, and a new secondary MAF filter that then I realized 75% of the box was epoxy and ductape lol

I'm also in the process of decal removal, fender sanding, and plastic shining...

bigbambizzle · 11-16-2011, 01:19 PM

I got big plans to do engine mods in the spring, which is why I redid the suspension and intake now. Im picking up Ferrea valves, DRZe kit, kibblewhite springs, and a CW 434 and CDI.

bigbambizzle · 11-16-2011, 01:41 PM

Some mods by next fall would include a bullhorn bumper, 1" grab bar, custom bolt on LED taillight, New custom graphics, powdercoated a-arms and frame, and I was thinkin about blacking my rims w/ new holeshots F&R.

bigbambizzle · 11-16-2011, 04:13 PM

Lol 20redfrogs and thanks tucker for the interest... I'm open to ideas to make the z better or if anyone has gone through this in the past and can give me a heads up on potential problems with what I want to do with the Z. Thanks people, this site has been an awesome reference point for me.

TuckerHardRide · 11-16-2011, 04:49 PM

My advice is don't strip any bolts!

sd1 · 11-16-2011, 05:53 PM

Quote:

Originally Posted by bigbambizzle

Lol 20redfrogs and thanks tucker for the interest... I'm open to ideas to make the z better or if anyone has gone through this in the past and can give me a heads up on potential problems with what I want to do with the Z. Thanks people, this site has been an awesome reference point for me.

id go for a velocity intake next...my 2 cents

bigbambizzle · 11-16-2011, 07:07 PM

Quote:

Originally Posted by TuckerHardRide

My advice is don't strip any bolts!

Too late. The bottom rear fender mounts were stripped when I got to em.

bigbambizzle · 11-19-2011, 01:52 PM

I got the airbox off today... finally got my hands on an 8mm socket. The box is junk, but on the side of the stock air box was halfassed riveted with a heat shield type material currently burned to the middle... if I get a new stock box I'm betting it would melt there again, right? Also took the rear and side plastics off and in the process of complete restoration. Paint thinner is working great on the sticky crap, and I'm applying sandpaper 220/120, and 5 clear coats. It's not taking the boot scrapes completely out but it looks 90% better than it did. Got a lot of suggested ways to go about it from the forum. And I was thinkin about making a custom box out of tin but I dunno how to make the powerlid fit after... I might buy a stock box today if I thought it wouldn't melt.

TuckerHardRide · 11-19-2011, 02:55 PM

Well if your saying it melted where there wasn't any heat shield then of course it would melt but it it did have a functional heat shield it wouldn't melt. Talk to spize about the tin.

bigbambizzle · 11-19-2011, 05:04 PM

There's a shield riveted to the airbox. Maybe I should heatwrap the headpipe?

11-16-2011, 12:49 PM	#1 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	Big's 2004 Z400 Project When I started this build a month ago I had no idea how fun and challenging this project would be until I picked up a set of 09 Z reservoir shocks from ltz-rum off the Suzuki Central classifieds. I'm hooked and want to customize my Z to my liking. Here's what I've done in the past month- Installed 09 Z400 reservoirs __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-16-2011, 12:53 PM	#2 (permalink)
20redfrogs :::DVX 400 Rider::: Join Date: Jul 2011 Location: Missouri/Afghanistan Posts: 963	Rub it in Bigbambizzle.... lol __________________ 06 LTR 450 Mine 03 LTZ400 Wife's 04 LTZ400 Son's 04 Ozark 250 Daughter's 09 LTZ400 None of these quads are stock.

11-16-2011, 12:56 PM	#3 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	Installed an Alba Pro Elite stick style rebuildable steering stabilizer. I like how its high over the shroud, and sticks out of the left fender so you don't have to dismount to adjust. It also allows you to keep your radiator shroud intact. I did have it so it sticks out the front but I didn't like it. __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-16-2011, 01:04 PM	#4 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	Relocated the key and idiot lights __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-16-2011, 01:10 PM	#5 (permalink)
TuckerHardRide :::Official Spammer::: Join Date: Feb 2008 Location: PA Posts: 3,247	Whats next? __________________ 2006 LTR450 Engine Mods: Yoshimira Cherry Bomb - RS-5 Full Exhaust - Inspection Plug Choke B/O Nut - Start Button JE Piston Suspension, Steering & Chassis: Flexx Bars w Turner Clamps - Precision Damper - Tag Skid Plate Powermadds - LT Fox Evol w FuelATV A-Arms - Fox Podium Rear Pro Armor Grab Bar - IMS Roll Nerf + Heel + Bumper Misc: DID X-Ring Chain - Sprocket Guard - Frame Guards - ProDesign K/S Hiper Tec 3 - ITP Beadlock Rear Rims Parted Out: 2004 LTZ400 - September 2011 QOTM

11-16-2011, 01:14 PM	#6 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	I'm currently working on replacing the air box with new. Here's what I had to work with... yep that's ductape, epoxy, and spraypaint.... it wasn't till I bought a k&n powerlid, and a new secondary MAF filter that then I realized 75% of the box was epoxy and ductape lol I'm also in the process of decal removal, fender sanding, and plastic shining... __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-16-2011, 01:19 PM	#7 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	I got big plans to do engine mods in the spring, which is why I redid the suspension and intake now. Im picking up Ferrea valves, DRZe kit, kibblewhite springs, and a CW 434 and CDI. __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-16-2011, 01:41 PM	#8 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	Some mods by next fall would include a bullhorn bumper, 1" grab bar, custom bolt on LED taillight, New custom graphics, powdercoated a-arms and frame, and I was thinkin about blacking my rims w/ new holeshots F&R. __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-16-2011, 04:13 PM	#9 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	Lol 20redfrogs and thanks tucker for the interest... I'm open to ideas to make the z better or if anyone has gone through this in the past and can give me a heads up on potential problems with what I want to do with the Z. Thanks people, this site has been an awesome reference point for me. __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-16-2011, 04:49 PM	#10 (permalink)
TuckerHardRide :::Official Spammer::: Join Date: Feb 2008 Location: PA Posts: 3,247	My advice is don't strip any bolts! __________________ 2006 LTR450 Engine Mods: Yoshimira Cherry Bomb - RS-5 Full Exhaust - Inspection Plug Choke B/O Nut - Start Button JE Piston Suspension, Steering & Chassis: Flexx Bars w Turner Clamps - Precision Damper - Tag Skid Plate Powermadds - LT Fox Evol w FuelATV A-Arms - Fox Podium Rear Pro Armor Grab Bar - IMS Roll Nerf + Heel + Bumper Misc: DID X-Ring Chain - Sprocket Guard - Frame Guards - ProDesign K/S Hiper Tec 3 - ITP Beadlock Rear Rims Parted Out: 2004 LTZ400 - September 2011 QOTM

11-19-2011, 01:52 PM	#13 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	I got the airbox off today... finally got my hands on an 8mm socket. The box is junk, but on the side of the stock air box was halfassed riveted with a heat shield type material currently burned to the middle... if I get a new stock box I'm betting it would melt there again, right? Also took the rear and side plastics off and in the process of complete restoration. Paint thinner is working great on the sticky crap, and I'm applying sandpaper 220/120, and 5 clear coats. It's not taking the boot scrapes completely out but it looks 90% better than it did. Got a lot of suggested ways to go about it from the forum. And I was thinkin about making a custom box out of tin but I dunno how to make the powerlid fit after... I might buy a stock box today if I thought it wouldn't melt. __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

11-19-2011, 02:55 PM	#14 (permalink)
TuckerHardRide :::Official Spammer::: Join Date: Feb 2008 Location: PA Posts: 3,247	Well if your saying it melted where there wasn't any heat shield then of course it would melt but it it did have a functional heat shield it wouldn't melt. Talk to spize about the tin. __________________ 2006 LTR450 Engine Mods: Yoshimira Cherry Bomb - RS-5 Full Exhaust - Inspection Plug Choke B/O Nut - Start Button JE Piston Suspension, Steering & Chassis: Flexx Bars w Turner Clamps - Precision Damper - Tag Skid Plate Powermadds - LT Fox Evol w FuelATV A-Arms - Fox Podium Rear Pro Armor Grab Bar - IMS Roll Nerf + Heel + Bumper Misc: DID X-Ring Chain - Sprocket Guard - Frame Guards - ProDesign K/S Hiper Tec 3 - ITP Beadlock Rear Rims Parted Out: 2004 LTZ400 - September 2011 QOTM

11-19-2011, 05:04 PM	#15 (permalink)
bigbambizzle :::Mini LT80 Rider::: Join Date: Sep 2011 Location: Harbor Beach, MI Posts: 167	There's a shield riveted to the airbox. Maybe I should heatwrap the headpipe? __________________ 2004 jetted, DMC Alien full exhaust, Regina chain and sprockets, ITP Holeshots, 09 reservoir shocks front & rear, K&N Powerlid and outerwear, Tusk case saver and hanguards, ALBA Pro Elite steering stabilizer, EBC brakes, smoked out headlight cover, shaved front fenders, modquad oilstick, skull handgrips, full armor, DG front bumper and Nerf bars, heel guards, relocated lights/key Also riding an 03 Bombardier Rally Fitting a 300ex with a 1970s CB500 motor.

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