Suzuki LT-Z400 Repair Manual 2003-2008

The 2003-2008 Suzuki LT-Z400 ATV repair manual by Clymer, covers models indicated.
Book Excerpt: 2003-2008 Suzuki LT-Z400 Repair Manual ENGINE TOP END

The LT-Z400 engine features dual overhead cam shafts. The camshafts are mounted in the cylinder head and driven off the crankshaft by the timing chain. All cylinder head components can be serviced with the engine in the frame. This chapter describes service procedures for the following top end components:

1. Valve cover.
2. Camshafts.
3. Cam chain and guides.
4. Valves.
5. Exhaust system.
6. Cylinder head.
7. Pistons and piston rings.

Always clean the engine before starting repairs. If the engine will remain in the frame, clean the surrounding framework, cables and harnesses. Keep the work environment as clean as possible. Store parts and assemblies in well-marked plastic bags and containers. Keep reconditioned parts wrapped until they will be installed. When inspecting components, compare measurements to the specifications in Table 2. Replace any component that is damaged, worn to the service limit or out of specification. During assembly, tighten fasteners to the provided torque specifications. Tables 1-3 are located at the end of the chapter.

BREAK-IN PERIOD

On new and reconditioned engines, the performance and service life of the engine depends greatly on a careful and sensible break-in. Observe the following when breaking in an engine.

1. Check the oil frequently. Make sure the engine is filled with the correct amount and weight of engine oil.
2. Make sure the air filter is clean.
3. For the first 10 hours of operation, use no more than 1/2 throttle. Vary the speed as much as possible within this throttle range. Avoid running the machine at a steady speed. Avoid hard acceleration. The speed limiter screw can be adjusted to restrict throttle opening. Refer to Control Cables in Chapter Three.

Subject: 2003, 2004, 2005, 2006, 2007, 2008 Suzuki LT-Z400 service, maintenance, repair. ISBN-10: 1599692953 | ISBN-13: 9781599692951 | Clymer M270-2