Suzuki LT-Z400 2003 - ENGINE

ENGINE 3·1
ENGINE
r------------- -- ------ CONTENTS
ENGINE COMPONENTS
REMOVABLE WITH ENGINE IN PLACE ... 3- 2
ENGINE LEFT SIDE ..................................................................... 3- 2
ENGINE RIGHT SIDE .................................................................. 3- 2
ENGINE CENTER .... .............. .. .................................................... 3- 2
ENGINE REMOVAL AND REMOUNTING . .. ............................ .. .......... 3- 3
ENGINE REMOVAL ................ .. ............................. .. ............... .. ... 3- 3
ENGINE REMOUNTING .. ....................... .... .......... .. .......... .. ..... ... . 3- 7
ENGINE DISASSEMBL Y ............ .. . .. .................................................... 3- 9
ENGINE COMPONENTS INSPECTION AND SERVICE .. ......... .. ........ 3-19
CYLINDER HEAD
..................................... .. . ... ............................. 3-19
CAMSHAFT IAUTOMA TIC DECOMPRESSION ASSEMBL Y .. ... 3·28
CAM CHAIN TENSION ADJUSTER AND TENSIONER ............. 3-30
CYLINDER ........................ .. .... .. ................................................... 3-30
PISTON
AND PISTON RING ................. .. .. .................................. 3-31
CONROD ....................... .. ............................................................. 3-33
CRANKSHAFT ................. .. ... ... .. .... .. ............................................ 3-33
BALANCER SHAFT AND BALANCER DRIVEN GEAR .. ........... 3-34
STARTER
CLUTCH ........... .. .. .. .................................................... 3- 35
STARTER TORQUE LIMITER ........ .. ........................................... 3-36
OIL PUMP ......................... ... .. ................................. .. ................... 3-36
CLUTCH ........................................ .. ............................................. 3-37
GEARSHIFT FORK AND GEAR ........................ .... ................ ... ... 3-38
TRANSMISSION ........... .. ............................................................. 3-39
CRANKCASE ............ .. .. . .. . .. . .. ...... .. .................................... .. . .. ..... 3-42
CLUTCH COVER ... .. . .... ............... .. ................ ... ........................... 3-46
ENGINE REASSEMBL Y ................. .. .. .. ........................................ .. ... .. 3-47
CRANKSHAFT ....... .. ....... .. . .. ......... .. .. ......................................... .. 3-47
GEARSHIFT CAM , FORK AND REVERSE LOCK SHAFT ...... .. 3-48
CRANKCASE ......................... .... ........................... .. .. . .. ................ 3-49
STARTER CLUTCH AND GENERA TOR ROTOR ...................... 3-50
PRIMARY DRIVE GEAR AND BALANCER GEAR ............... .. ... 3-51
GEARSHIFT CAM DRIVEN GEAR ................................... .. ...... .. . 3-52
OIL PUMP ...... J. •... ••.• .•••••••.... ......... .•............• ••• • ••••• • ••••••••••• •• •• • •• •• •• 3-53
CAM CHAIN ................................ .. .. .... . .. .................................... .. 3-53
OIL PIPE ............... .. ..................... .. ....................... .. ............. .. ...... 3-53
CLUTCH . .. ............. .. ........... .. ........................................................ 3-54
NEUTRAL SWITCH ..................................................................... 3- 56
GENERATOR ROTOR COVER ........................................... .. ...... 3-56
PISTON RING ............................................................. ... .............. 3- 57
PISTON AND CYLINDER ............ ... . .... . .. ..... .. .. .......................... .. 3-58
CYLINDER HEAD ........... .. ........... .. ............................................ .. 3-59
CAMSHAFTIAUTOMA TIC DECOMPRESSION ASSEMBL Y ..... 3-60
CYLINDER HEAD COVER ......... .. ...................... ... ...................... 3-62
CAM CHAIN TENSION ADJUSTER ............................. .. ...... .. ..... 3-63