Many Z400 owners have found that one of the first things to go has been the stock axle. The axle has been noted to be soft and fragile. Suzuki did update this in later Z400 models but the stock axle is just not going to cut it for the type of use that our project Quadsport Z400 will experience. To solve this problem we ordered a Dura Blue Eliminator X-33. Not only does this axle solve the strength problem but it also solves the problem with hubs that keep coming loose. The X-33 axle does not neck-down like most axles but instead retains its 1 3/8" diameter all the way out. The hub is then clamped and driven by a pin. You can adjust the axle width by using the desired pin hole in the axle. To save weight, the axle is rifted. The Z400 model also features the patented Posi•Lock system which removes threaded sections from the flexing area of the shaft.

The Posi•Lock system tightens up against the snap ring on one side and the sprocket hub on the other, then the set screw clamps the nut to the threads. On the axle end there are two holes for the pin-driven hubs.

Installation The toughest part of the installation is actually the disassembly. On the Z400 you need to start on the left side and loosen the double lock nuts. It is easiest to do this while your ATV is still sitting on the ground on wheels and tires with chain attached. You will either need to acquire the special tool or some humungus crescent wrenches. The 18" one is the smallest that will adjust large enough.

Locking nut unthreaded on the sprocket side.	Removing the emergency brake and rear caliper.

With the nuts removed we put the Z400 up on our Pro ATV Stand and removed the wheels. Next was removing the brake caliper and emergency brake. With that done we then removed the left side wheel hub. The sprocket hub was a little more difficult. It resides on a splined section of the axle and takes some convincing to get off. The splines have something called "Suzuki bond" to keep the sprocket tight on the splines. The large hammer and drive pin finally convinced it to come off. With the sprocket removed you can then draw the axle out the right side of the quad.

We kept rotating the axle and using this drive pin to knock the sprocket off.	Slide the axle out from the right side. The brake hub remains on the axle.

Next is to move the brake rotor to the new Dura Blue Eliminator axle and to remove the old sprocket off the sprocket hub and replace it with the new Patriot sprocket. You will also want to check your axle bearings and seals. We found that the left side bearing was no longer rolling smoothly. We ordered a new bearing and seal set from Pivot Works and will be installing that as soon as it arrives.

The left side axle bearing was shot. (Maybe from the bent axle?)	New Patriot Sprocket and old Z400 sprocket.

Installing the new X-33 axle from the right side.	The sprocket hub is followed by the Dura Blue Posi-Lock.

The installation goes very quickly with the disassembly. out of the way. Slide the new axle in then install the sprocket hub and follow that with the Dura Blue Posi-Lock. The Posi-Lock slides on then you install the snap ring in place on the axle. With the snap ring in place you can tighten the Posi-Lock between the sprocket hub and the snap ring. After this is tight then you will need to install the allen screw which will pinch the threads and lock the nut in place.

The hub slides on the axle very snugly then is lined up with the outside hole in the axle and pin inserted.	A nut and lock washer is installed on the other side to lock the hub in place.

After the axle is in place we installed our new pin drive hubs. We used the outside hole for the full width The allen bolt / pin is then installed and then lock washer and nut. (Make sure to use locktite on this nut!) Install your wheels and you are ready to ride again. Summary In the October issue we will report on the durability of the axle after some testing, but we expect nothing but the best of reports. The axle looks awesome and should not have to be replaced again. As long as we keep the pin tight the hubs look like they should stay tight unlike the hubs on other axles we have used. At $400 with hubs it is not an inexpensive item, but one that may almost be a necessity if you ride your Z400 very aggressively.

Send us your comments on Project Z400

Dura Blue Inc.
20521 Crescent Bay Dr.
Lake Forest, CA 92630
(949) 770-5533 • FAX: (949) 768-4273
www.durablue.com

Patriot Racing
PO Box 3132
St. Charles, IL 60174
info@patriotsprockets.com
630-443-9250
Fax: 630-443-2849
www.patriotsprockets.com

Pivot Works
3025 Justin Drive
Urbandale, IA 50322
Phone: 515-402-8000
Fax: 515-402-8002
www.pivotworks.com