Suzuki LT-Z400 2003 User manual

FOREWORD
This manual contains an introductory description on
t he SUZUKI LT-Z400 and procedures for its inspec-
tion, service, and overhaul of its main components .
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its main te-
nance. Use this sec tion as well as ot her sections as
a guide for proper inspecti on and service.
This
manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.
* This manual has been prepared on the basis
of the latest specifications at the time of publi -
cation. If modifications have been made si nce
then, differences may exist be t ween the con-
tent of this manual and the actual vehicle.
" fl/ustrations in this manual are used to show
the basic principles of operation and work
procedures.
They may not represent the
actual vehicle exactly
in detail.
• This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for seIVicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcy·
cle dealer
to help you.
A WARNING
Inexperienced mechanics or mechanics
without the proper tools and equipment
may
not be able to properly perform the
services described in
this manual.
Improper repair may result In injury to the
mechanic and may render the vehicle
unsafe
for the rider.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
IFUEL SYSTEM
COOLING AND
LUBRICATION SYSTEM
CHASSIS
ELECTRICAL SYSTEM
ISERVICING INFORMATION

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section tlttes are listed in the
GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
th e first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit there is an exploded view which provides work instructions and other
service information (e.g.: tightening torque, lubricating points, and locking agent points).
Example: Front and rear wheels
CD Disc cover
t%I Front disc
I3J ..,.".,
@Dustseal
(5) Hub bearing
$ Bearing spacer
!!l Front wheel hub
iJ) Hub bearing
(9) Dust seal
ilII ..,.".,
®Washer
@Cotterpin
@Tirevalve
® Fronllire
($l Front wheel rim
t§I Sprodo;et flange
<I1J Sp"",",t
ill Washer
~ Rearwheel hub
~ Washer
@Reartire
@ Rear wheel rim
@Tirevalve
®Washer
®Cotter pin
I3l Hub plate
® Disc bolt
<Bl Wheel set nut
tel Front hub nut
(() Rear axle nut
rtl Sprocket mounting bolt
® Rear hub nut
[!l
ITEM
N,m kgf-m
®
23 2.3
iI!l
50 5.0
©
65 6.5
ill
180 18.0
IE>
54
5.4
iI'l
100 10.0
Ib-O
16.5
36 .0
47.0
130.0
39.0
72.5
---'
(2)
~ @ ~'~~
® @ @
~ ~
----='
®
IE>

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing . The meaning of each symbol is also included in the table .
SYMBOL DEFINITION SYMBOL DEFINITION
(!J
Torque control required.
..
Apply THREAD LOCK "1342",
Data beside it indicates specified
99000-32050
torque.
-
Ind icates service data. • Apply THREAD LOCK SUPER "1360
",
99000-32130
~
Apply oil. Use engine oil unless
~
Apply or use brake flui d.
otherwise specified .
-m
Apply molybdenum oil solution.
~
(mix ture of engine oil and SUZUKI Measure in voltage range.
MOLY PASTE in a rati o of 1 : 1)
~
Apply SUZUKI SUPER GREASE "A ",
~
99000-25030 (USA) Measure in resistance range.
99000-25010 (Others)
J0t
Apply SUZUKI SILICONE GREASE,
~
Measure in current range.
99000-25t 00
~
Apply SUZUKI MOLY PASTE.
99000-25140
~
Measure in diode test range.
~
Apply SUZUKI BOND "1207B"
~
99104-31140 (USA) Measure
in continuity test range.
99000-31140 (Others)
a Apply SUZUKI BOND "1215",
99000-31110 (Except USA)
.footl
Use special too l.
• Apply THREAD LOCK SUPER "1303",
eJ
Use engine coolant.
99000-32030 99000-99032-11X (Except USA)
..
Apply THREAD LOCK SUPER "1322",
99000-32110 (Except USA)

GENERALINFORMATION 1-1
GENERAL INFORMATION
,-------------------- CONTENTS
WARNINGICAUTIONINOTE ............................
.. .. .. ............................ 1- 2
GENERAL PRECAUTIONS ................................................... .. ........... 1- 2
SUZUKI LT-Z400 ... .. ...................... .. . .. ............. .. ... .. ............ .. ................ 1- 4
SERIAL NUMBER LOCATION ........................................................... 1- 4
FUEL AND OIL RECOMMENDATION .. ............. .. .......................... .. .. 1- 4
FUEL ........................................................ .. . .. ........ .. ..................... 1- 4
ENGINE OIL...................... .. .......................................................... 1- 5
BRAKE FLUID .. ........................................................................... 1- 5
ENGINE COOLANT ..................................................................... 1- 5
BREAK-IN PROCEDURES ................................................................ 1- 6
INFORMATION LABELS ... .... .................. .. ......................................... 1- 7
SPECIFICATIONS .... .. . .. ............. .. .. ......... .. ................... .. .................... 1- 8
COUNTRY AND AREA CODES ......................................................... 1-10

1- 2 GE N ERALINFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
A WARNING
Indicates a potential hazard that could result in death or inj ury .
ICAUTIONI
Indicates a potential hazard that could result In vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazar ds re lating to the servici ng . or lack of servicing, of the vehicl e. In addition to the WARNINGS
and CAU T IO NS stated, you must u se good judgement and basic mechanical safety principles. If you are
unsure about how to perform a pa
rt icular service operation, ask a more experienced mechanic fo r advice.
GENERALPRECAunONS
A WARNING
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the vehicle.
* When two or more pe rs ons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors , make sure that exhaust gas is forced out-
doors.
* When working with toxic or flammable materials, make sure that the area you work in is well
ventilated and that you follow all of the manufacturer 's Instructions .
* Never use gasoline as a cleaning solvent .
* To avoid getting burned, do not touch the engine, engine oil, radiator , and exhaust system
until they have cooled.
* After servicing the fuel, oil, exhaust or brake systems , check all of the lines, and fi tt i ngs
related to the system for leaks.

GENERAL INFORMATION 1-3
ICAUTIONI
• If parts replacement Is necessary, replace the parts with SUZUKI Genuine Parts or their equiv-
alent.
• When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order.
* Be sure to use special tools when Instructed.
• Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricants , bonds , or sealants.
* When removing the battery, disconnect the e battery lead wire first , then the (£J battery lead
wire.
• When reconnecting the battery, connect the ® battery lead wire first , then the e battery lead
wire. Finally,
cover the ® battery terminal with the terminal cover.
* When performing service to electrical parts , disconnect the 8 battery lead wire , unless the
service
procedure requires the battery power .
" When tightening cylinder head and crankcase nuts and bolts, tighten the larger sizes first.
Always tighten the nuts and bolts from the inside working out , diagnoally and to the specified
torque .
* Whenever you remove oil seals, gaskets, packing , O-rings, self - locking nuts, locking wash-
ers, cotter pins, circlips , snap rings and other specified parts, be sure to replace them with
new ones . Also , before installing these new parts , be sure to remove any left over material
from the mating surfaces.
* Never reuse a circlip and snap ring. When Installing a new snap ring , take care not to expand
the end gap larger than required to slip the snap ring over the shaft. After installing a snap
ring, always ensure it Is completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread Is smeared
with them.
• After reassembling, check parts for tightness and proper operation.
• To protect the environment , do not unlawfully dispose of used motor oil , all other fluids , bat-
teries, and tires.
• To protect the earth's natural resources , properly dispose of used vehicles and parts.

1 -4 GENERAL INFORMATION
SUZUKI LT-Z400
RIGHT SIDE lEFT SIDE
• Difference between photographs and actual ~hicles depends on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V. I. N. (Vehicle Identification Number) CD is stamped on the left side of the frame
pipe. The engine serial number (2J is located on the right side of the crankcase. These numbers are required
especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATION
FUEL (For CANADA and USA)
• Use only unleaded gasoline of at least 87 pump octane ( R ~ M ) method or 91 octane or higher rated by
the Research Method.
• SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible.
• Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.
• Use of blended gasoline/alcohol fuel is permined, provided that the fuel contains not more than 10% etha-
nol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibi-
tors are present in it.
• If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should
switch to alcohol-free unleaded gasoline.
• Failure to follow these guidelines could possibly vo id applicable warranty coverage. Check with your fuel
supplier to make sure that the fuel you intend to use meets the requirements listed above.

GENERAL INFORMATION Hi
FUEL (For the other countries)
Use unleaded gasoline that is graded 91 octane or higher by the Research Method.
ENGINE OIL (For USA)
SUZUKI recommends the use of SUZUKI PER FORMANCE 4
MOTOR OI L or oils that meet API service classifications SF or
SG and that have a viscosity rating of SAE 10W-40. If engine oil
with a rating of SAE 10W-40 is not available, select an alter-
native according to the chart.
M UL TIGRAD E
ENGINE OIL (For the other countries)
Use a premium quality 4-stroke motor o il to ensure longer ser-
vice life of your veh ic l e. Use only oils that mee t API service cl as-
sifications SF or SG and thaI have a viscosity rating of SAE
10W-40. If engine oil with a rating of SAE 1 0W-40 is not avail-
able, select an altemative according to the chart.
BRAKE FLUID
fJ Specification and classification : DOT 4
A WARNING
!OW 30
·c - 30 - 20 _ 10 0 10 20 30 40
TEM'. ." -
22 _4 14 32 50 61 16 104
This vehicle uses a glycol-based brake fluid . 00 not use or mix different types of brake fluid
such as silicone-based and petroleum-ba s ed fluids for refilling the system , otherwise serious
damage will result to the brake system .
Never
use any brake fluid taken from old , us ed , or unsealed containers .
Never reuse brake fluid left over from th e last servicing or which has been stored for a long
period of time.
ENGINE COOLANT
Since antifreeze also has corrosion- and rust-inhibiting properties, always use engine coolant containing
antifreeze, even if the atmospheric temperature does
not go below the freezing point.
Use an antifreeze designed f
or aluminum radiator. SUZUKI recommends the use of SUZUK I COOLANT
antifreeze. if this is not available, use an equivalent antifreeze for aluminum radiators.
Mix only distilled
water with the antifreeze. Other types of water can corrode and clog the aluminum radiator.
Mix distilled water and antifreeze at a ratio of 50:50 -40:60.
For more information, ref er to page 5-3 in the Cooling System section.
I CAUTION I
The percentage of antifreeze in the coolant should be between 50 to 60%. If the percentage of
antifreeze is above or below this range the coo l ant's frost protection and rust - inhibiting capa-
bilities will be reduced . Always keep the antifreeze content above 50 % even if the atmospher ic
temperature does not go below the freezing point.

H GENERAL INFORMATION
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a very
high standard. It is still necessary to allow the moving parts to "BREAK·IW before subjecting the engine to
maximum stresses. The future periormance and reliability of the engine depends on the care and restraint
exercised during its early life. Refer to the following break-in engine speed recommendations.
• Keep to these breake-in engine speed limits.
Break·ln engine speeds
Initial 10 hours : Less than Y2 throttle
• After the engine has been operated for 10 hours the engine to full throttle operation, for short periods of
time.

INFORMATION LABELS
NO LABEL or PLATE NAME
(j)
Certification pla te e
12>
Information label i£l
ill
nre air pressure labele
Ii)
T ire air pressure label and warning no--passenger label ®
<Sl
General warning label 'El
(I) Genel3J warning label ®
(1J Warning no-passenger label i£I
@ Age, 16 label e
@ Age,
16 label ®
~
Manual notice label i£>
® Gearshift label
i£>
@ Gearshift label
<£l
@ ICES canada label
~
® Compliance label
<t>
$ Chain adjustment label
El
~ Chain adjustment label ®
®
EC approval marl<
i£l: English <£>: French
W ® @
=
=~
=
GENERALINFORMAnON 1-7
APPLIED SPEC IFICATION
E-03 E-28 E-33
0 0
--0
0 0 0
-0 -
0 0 0
0 -
0 0 0
0 0 0
-0 -
0 -0
0 0 0
-0 -
-0 -
-0 -
0 0 0
0 -
0
1 .®
Left side of frame

1·8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length.......................................................1 830 mm (72.0 in)
Overall width ........................................................1 165 mm (45.9 in)
Overall height....................................................... 1 160 mm (45.7 in)
Wheelbase. .. ........................................................ 1 245 mm (49.0 in)
Front
track ............................................................ 935 mm (36.S in)
Rear track ............................................................
910 mm (35.8 in)
Ground clearance ................................................
265 mm (10.4 in)
Seat height........................................................... 810 mm (31.9 in)
Dry mass.............................................................. 169 kg (373Ibs)
ENGINE
Type.....................................................................Four·stroke, liquid-cooled , DOHC
Number of cylinders .............................................1
Bore .....................................................................90.0 mm (3.543 in)
Stroke...................................................................62.6 mm (2.465 in)
Pi s ton displacement............................................. 398 cm:! (24.3 cu.in)
Compression ratio................................................ 11 .3: 1
Carburetor......................................................... ... MIKUNI BSR36 SS, single
Air cleaner............................................................ Polyurethane foam element
Starter system ...................................................... Electric
Lubrication sys tem ............................................... Dry sump
Idle speed ......................................................... ... 1500 ± 100 r/ min
DRIVE TRAIN
Clutch................................................................... Wet multi-plate type
Transmission........................................................5-forward and l-reverse
Gearshift pattern , forward .......................... .... ......1 down 4 up , foot operated
reverse ............... ... ................ .. Foot/hand operated
Primary reduction ratio.........................................2.960 (74/25)
Gear ratios, Low ..................................................2.538 (33/13)
2nd...................................................1.666 (30/18)
3rd....................................................1.238 (26121)
4th....................................................1.000 (23123)
Top...................................................0.846 (22126)
Reverse ...........................................2.153 (28/13)
Final reduction ratio .............................................2.857 (40114)
Drive chain ....................... ... ................................. RK 520KZO 96 Links

GENERAL INFORMATION 1 -9
CHASSIS
Front suspension................................................. Independent, double wishbone, coil spring, oil damped
Rear suspension
.. ... .. ........................... .. . .. .......... Swingarm type, coil spring, oil damped
Front wheel travel................................................ 215
mm (8 .5 in)
Rear
wheellra v el ................................................ 225 mm (8 .9 in)
Caster........................
.. ... ..................................... 8.50
Trail .. .. ........... .. .................................... .. . .. ........... 36 mm (1.42 in)
Toe-in ........................................... .. ..................... 5 mm (0.20 in)
Camber ...............................................................
-0 .90
Steering angle ..... .. ............................................. 41
0
Turning radius ..... .. . .. ................. . .. ............... 3.1 m (10.2 ft)
Front brake .. ................ ... ...................... .. .. ........... Disk brake, twin
Rear brake .......................................
... ............... Disk brake
Front tire size ......
.. .............................................. AT22 x 7 Rl0 ~* tubeless
Rear tire size .........
.. ... ....................... .. ............... AT20 x 10 R9 *'tr tubeless ,
ELECTRICAL
Ignition type .. ... .. .... ............................................. Electronic ignition (COl)
Ignition timing .... ......................
.. .. .. .. .................. 100 B.T.D. C. at 1 500 rpm
Spark plug ................................. .. . .. ... ... ............... NGK GA7E or DENSO U22ESA-N
Battery................................................................. 12 V
28 .8 kG (8 Ah )/ 10 HA
Generator .......... .. .................................... .. ......... Three-phase A.C. generator
Main fuse............... ............................................. 20 A
Headlight ............................................................. 12 V 30/30 W x 2
Brake lightfTaillight.............................................. 12 V
21 /5 W
Neutral indicator light
.... ...................................... 12 V 3 W
Reverse indicator light......................................... 12 V 3 W
Coolant tempereture warning light ...................... 12 V 3 W
CAPACITIES
Fuel tank, including reserve................ .. ............... 10.0 L (2 .6/2.2 USlimp gal)
reserve
.. .............................................. 2.6 L (0.7/0.6 US/Imp gal)
Engine oil, oil change .......................................... 2 000 ml (2. 1/1.8 US /Imp qt )
li~er change ....................................... 2 100 ml (2. 21 1.8 US /Imp ql )
overhaul ........................ .. ..... ....... 2 200 ml (2 .31 1.9 US /Imp ql )
Goolant.. .......................................
... .. .. . .. ... 1.15 L (1 .2/1.0 US/Imp ql)

1-10 G ENERALINFOR MA TION
COUNTRY AND AREA CODES
The following codes stand for the applicable countries and areas.
CODE COUNTRY OR
AREA
E-03 USA
E-28 Canada
E-33 California (USA)

PERIODIC MAINTENANCE 2·'
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCESCHEDULE ..........................................
.. 2- 2
PERIODIC MAINTENANCE CHART ........................................... 2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ............................... 2- 3
AIR CLEANER .............................................................................2- 3
EXHAUSTPIPE NUTS AND MUFFLER BOLTS ........................2- 4
VALVE CLEARANCE ..................................................................2- 5
SPARK PLUG .................................... .. .................•.................... .. 2-10
FUEL HOSE .................................................................................2-11
THROTTLE CABLE PLAY ......................... .... . .. ......................... .. 2-11
ENGINE IDLE SPEED ...... .. ..........................................................2-11
ENGINE OIL AND OIL FILTER ....................................................2-12
ENGINE OIL HOSES ............................................................ .. ... .. 2-13
ENGINE COOLANT .... .. ................... .. ..........................................2-14
RADIATOR HOSES ............................... .. .................................... 2-15
SPARK ARRESTER .... .. . .. ......................................................... .. 2-15
CLUTCH ....................................... .. ..............................................2-16
BRAKES .... .. ............. .. ................................................... .... ......... .. 2-16
BRAKE FLUID .............................................................................2-18
BRAKE HOSES ....................... .. ..................................................2-20
TIRES ................................................................................
.. .........2-20
STEERING ..
.. ........ .. .............................. ... ....................................2-21
DRIVE CHAIN ..............................................................................2- 22
SUSPENSIONS ............................................................................2-24
CHASSIS BOLTS AND NUTS ..................................................... 2-25
GENERAL LUBRICATION ................................... .. .....................2-28
COMPRESSION PRESSURE CHECK .................................................2-29
COMPRESSION TESTPROCEDURE ....................................... .. 2-29
OIL PRESSURE CHECK ....... ...... ............ .. ........................... .. ..... .. ..... .. 2-30
OIL PRESSURE TEST PROCEDURE ......
.. .................................2-30

2·2 PERIOOIC MAINTENA NC E
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the vehicle operating at peak performance and economy . Ma intenance intervals are expressed in terms of
kilometers, miles and months, and are dependent on whichever comes first.
NOTE:
More frequent servicing may be performed on vehicles that are use under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
In it ial Every Every
Item 1
month
3 months 6
months
Air cleaner -C C
Exhaust pipe nuts and muffler bolt T T T
Valve clearance
I I
- - I
Spark plug Replace every 18
months .
Spark arrester --C
Idle speed I I I
ThroHle cable I I I
Fuel line I
Replace every 4 years. I
Engine oil and oil filler R -R
Engine oil hoses I I I
Clutch I -I
Coolant Replace
every 2 years.
Radiator hose I
Replace every 4 years. I
Drive chain Inspect every time before riding.
Brakes I
-
Brakes fluid
Brake hose
Wheels and tires -
Suspension -
Steering I
Chassis bolts and nuts
T
General lubrications L
I =Inspect and adjust, clean. lubricate, or replace as necessary.
R = Rep/ace
T =Tighten
C =Clean
L = Lubricate
I I
I I
Replace every 2 years.
I I
Replace every 4 years.
I I
-I
I I
T T
L L

MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item
mentioned
in the Periodic Maintenance chart.
AIR CLEANER
I Clean every 3 months .
If the air cleaner is clogged with dust, intake resistance will be
increased. with a resultant decrease in power output and an
increase in fuel consumption. Check and clean the air cleaner
element in the following manner.
• Remove the seat.
• Remove the air cleaner case cover (1).
• Remove the air cleaner element ~.
• Separate the polyurethane foam element @. element frame
@ and element holder.
• Fill a wash pan of a proper size with a non·flammable clean-
ing solvent. Immerse the air cleaner element in the cleaning
solvent and wash
it.
• Press the air cleaner element between the palms of both
hands to remove the excess
solvent do not twist or wring the
element or it will tear_
• Immerse the element in motor oil, and then squeeze oul the
excess oil leaving the element slightly wet.
® Non-flammable cleaning solvent
@ Motor oil SAE 130 or SAE 10W- 40
PERIODIC MAINTENANCE 2,'3

2-4 PERI ODIC MAINTENANCE
ICAUTIONI
* Inspect the air cleaner element for tears. A torn ele-
ment must be replaced.
• If driving under dusty conditions , clean the air
cleaner element more frequently. The surest way to
accelerate engine wear is to operate the engine wlth ~
out the element or with torn element. Make sure that
the air cleaner element Is in good condition at all
times. Life of the engine depends largely on this
component!
• Remove the drain cap CD of t he ai r cleaner box to all ow any
water to drain out.
EXHAUST PIPE NUTS AND MUFFLER
BOLTS
Tighten Initially at 1 month and every 3 mont hs there·
after .
• Tighten the exhaust pipe nuts (1), muffler connectton bolt ~,
and muffler mounting bolt @ to the specified tor que .
~ Exhaust pipe nut : 23 N·m (2.3 kgf-m, 16.5 Ib-ft)
Muffler connection
bolt : 23 N·m (2.3 kgf -m, 16.5 Ib-tt)
MuHler mount ing bolt : 23 N·m (2.3 kgf-m, 16.5 Ib-ft)

VALVE CLEARANCE
Inspect Initially at 1 month and every 6 months there-
after.
Excessive valve cl earance results In valve noise and insuffICient
valve clearance results in valve
damage and reduced power .
Check the intake and exhaust valve clearances at the distances
indicated above and adjust the valve clearances to specification,
if necessary.
• Remove the seat. ( c:::r 6-4)
• Remove the fuel tank top cover <D and fuel t ank covers ~.
(L&R)
• Turn the fuel valve to the " ON" position and remove the fuel
tank.
• Remove the spark plug.
• Disconnect the engine oil hose @ and engine oil breather
hose @.
• Remove the cylinder head cover.
The tappet clearance specification is different for both intake
and exhaust valves.
Tappet clearance adjustment must be checked and adjusted: 1)
at the time of periodic inspection, 2) when the valve mechanism
is serviced, and 3) when the camshafts are removed for servic-
ing.
PERIOOIC MAINTENANCE 2-5

2-6 PERIODIC MAINTENANCE
• Remove the valve timing inspection plug G) and generator
cover cap (l).
NOTE:
• The piston must
be at top dead center (TDC) on the compres-
sion stroke in order to check
or adjust the tappet clearance.
• The tappet clearance should only be checked when the engine
js cold.
• Rotate the crankshaft with a box wrench to set the piston at
TOe on the compression stroke. (Rotate the crankshaft until
the "T" line
on the generator rotor is aligned with the triangle
mark on the generator cover.)
• Insert a thickness gauge between the tappet and the cam. If
the clearance is out of specification, adjust it to the specifica-
tion
as follows.
c!liI 09900-20803: Thickness gauge
~ Tappet clearance (when cold)
NOTE:
IN : 0.10 - 0. 20 mm (0.0039 - 0.0079 In)
EX: 0.20 -0.30 mm (0. 0079- 0.0118 in)
The cam must be at position ® in order to check and adjust
valve clearance. Clearance readings should not be taken with
the cam in any otherposition than this position.