Suzuki LT-Z50, LT80, LT-Z90, LT-F250, LT250R, LT-Z250, LT-F300F, LT-A400, LT-F400, LT-Z400, LT-R450, LT500R, LT-A500F, LT-A700, LT-A750 ATV Repair Service Manuals
Catalog:
Model:
Complete service repair manual with Electrical Wiring Diagrams for Suzuki LT-Z50, LT80, LT-Z90, LT-F250, LT250R, LT-Z250, LT-F300F, LT-A400, LT-F400, LT-Z400, LT-R450, LT500R, LT-A500F, LT-A700, LT-A750 ATV, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki LT-Z50, LT80, LT-Z90, LT-F250, LT250R, LT-Z250, LT-F300F, LT-A400, LT-F400, LT-Z400, LT-R450, LT500R, LT-A500F, LT-A700, LT-A750 ATV workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Suzuki LT250R Quadracer ATV (LT250RG, LT250RH, LT250RI, LT250RJ, LT250RK, LT250RL, LT250RM, LT250RN) '85-'92 Service Manual.pdf
Suzuki LT500R QuadZilla (LT500RH, LT500RJ, LT500RK, LT500RL) '87-'90 Service Manual.pdf
Suzuki LT-80 Parts Catalog.pdf
Suzuki LT-80 Quadsport (LT-80H, LT-80J, LT-80K, LT-80L, LT-80M, LT-80N, LT-80P, LT-80R, LT-80S, LT-80T, LT-80V, LT-80W, LT-80X, LT-80Y, LT-80K1, LT-80K2, LT-80K3, LT-80K4, LT-80K5, LT-80K6) Service Manual.pdf
Suzuki LT-A400(F), LT-F400(F) '08-'09 Service Manual.pdf
Suzuki LT-A500F '02-'07 Service Manual.pdf
Suzuki LT-A700 '05 Service Manual.pdf
Suzuki LT-A750(P)(XP) '08-'09 Service Manual.pdf
Suzuki LT-F250 (LT-F250K2, LT-F250K3, LT-F250K4, LT-F250K5, LT-F250K6, LT-F250K7, LT-F250K8, LT-F250K9) Service Manual 2002-2009.pdf
Suzuki LT-F300, LT-F300F KingQuad 300 (LT-F300X, LT-F300X, LT-F300Y, LT-F300FY, LT-F300K1, LT-F300FK1, LT-F300K2, LT-F300FK2) Service Manual '99-'02.pdf
Suzuki LT-R450 Service Manual '06.pdf
Suzuki LT-Z50K6, LT-Z50K7, LT-Z50K8, LT-Z50K9 Service Manual '06-'09.pdf
Suzuki LT-Z90K7, LT-Z90K8, LT-Z90K9 Service Manual '07-'09.pdf
Suzuki LT-Z250K4, LT-Z250K5, LT-Z250K6, LT-Z250K7, LT-Z90K8, LT-Z90K9 Service Manual '04-'09.pdf
Suzuki LT-Z400K3 Parts Catalog.pdf
Suzuki LT-Z400K3 Service Manual '03.pdf
Suzuki LT-Z400 Service Manual '09.pdf
Suzuki Porting instruction.pdf
Suzuki Tuning Guide Instruction.pdf
PRODUCT DETAILS:
Total Pages: 5,822 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Suzuki LT-80 Parts Catalog...2
80cc (LT80 1988-1995)...3
80cc (LT80 1996-2001)...44
80cc (LT80 2002-2006)...83
kfx80...125
Suzuki LT-80 Quadsport (LT-80H, LT-80J, LT-80K, LT-80L, LT-80M, LT-80N, LT-80P, LT-80R, LT-80S, LT-80T, LT-80V, LT-80W, LT-80X, LT-80Y, LT-80K1, LT-80K2, LT-80K3, LT-80K4, LT-80K5, LT-80K6) Service Manual...128
Cover...128
Service Manual Index...133
Chapter 1 - General Information...135
Chapter 2 - Maintenance and Tune-Up Procedures...147
Chapter 3 - Engine Servicing...163
Chapter 4 - Fuel and Lubrication Systems...217
Chapter 5 - Electrical System...226
Chapter 6 - Chassis...238
Chapter 7 - Troubleshooting ...281
Chapter 8 - 1988 Model Supplement...302
Chapter 9 - 1989 Model Supplement...307
Chapter 10 - 1990 Model Supplement...324
Chapter 11 - 1991-2001 Model Supplement...332
Chapter 12 - 2002-2005 Model Supplement...341
Chapter 13 - 2006 Model Supplement...347
Suzuki LT-A400(F), LT-F400(F) '08-'09 Service Manual...355
FOREWORD...355
TABLE OF CONTENTS...357
00 PRECAUTIONS...361
PRECAUTIONS...362
PRECAUTIONS...362
WARNING / CAUTION / NOTE...362
GENERAL PRECAUTIONS...362
PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE...363
0 GENERAL INFORMATION...369
GENERAL INFORMATION...370
GENERAL DESCRIPTION...370
SYMBOLS...370
ABBREVIATIONS...370
SAE-TO-FORMER SUZUKI TERM...371
VEHICLE SIDE VIEW...371
VEHICLE IDENTIFICATION NUMBER...372
FUEL AND OIL RECOMMENDATION...372
BREAK-IN PROCEDURES...373
COUNTRY AND AREA CODES...373
WIRE COLOR SYMBOLS...373
WARNING, CAUTION AND INFORMATION LABELS LOCATION...374
COMPONENT LOCATION...375
ELECTRICAL COMPONENTS LOCATION...375
SPECIFICATIONS...379
SPECIFICATIONS...379
SPECIAL TOOLS AND EQUIPMENT...383
SPECIAL TOOL...383
MAINTENANCE AND LUBRICATION...386
PRECAUTIONS...386
PRECAUTIONS FOR MAINTENANCE...386
GENERAL DESCRIPTION...386
RECOMMENDED FLUIDS AND LUBRICANTS...386
SCHEDULED MAINTENANCE...386
PERIODIC MAINTENANCE SCHEDULE CHART...386
LUBRICATION POINTS...387
REPAIR INSTRUCTIONS...388
AIR CLEANER ELEMENT INSPECTION AND CLEANING...388
EXHAUST PIPE BOLT AND MUFFLER BOLT INSPECTION...389
VALVE CLEARANCE INSPECTION AND ADJUSTMENT...389
SPARK PLUG REPLACEMENT...390
SPARK PLUG INSPECTION AND CLEANING...391
SPARK ARRESTER CLEANING...392
FUEL LINE INSPECTION...392
ENGINE OIL AND FILTER REPLACEMENT...392
FRONT DIFFERENTIAL GEAR OIL INSPECTION (LT-A400F, LT-F400F)...394
FRONT DIFFERENTIAL GEAR OIL REPLACEMENT (LT- A400F, LT-F400F)...395
FINAL GEAR OIL INSPECTION...396
FINAL GEAR OIL REPLACEMENT...396
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...398
ENGINE IDLE SPEED ADJUSTMENT...398
DRIVE V-BELT INSPECTION (LT-A400/F)...398
CLUTCH INSPECTION (LT-F400/F)...399
DRIVE SHAFT BOOTS INSPECTION (LT-A400F, LT- F400F)...399
FRONT BRAKE SYSTEM INSPECTION...400
REAR BRAKE PEDAL / REAR BRAKE (PARKING BRAKE) LEVER INSPECTION AND ADJUSTMENT...401
TIRE INSPECTION...402
STEERING SYSTEM INSPECTION...403
TOE-IN ADJUSTMENT...403
SUSPENSION INSPECTION...404
CHASSIS BOLT AND NUT INSPECTION...404
COMPRESSION PRESSURE CHECK...406
OIL PRESSURE CHECK...406
AUTOMATIC CLUTCH INSPECTION (LT-A400/F)...406
SPECIFICATIONS...407
TIGHTENING TORQUE SPECIFICATIONS...407
SPECIAL TOOLS AND EQUIPMENT...407
RECOMMENDED SERVICE MATERIAL...407
SPECIAL TOOL...407
SERVICE DATA...409
SPECIFICATIONS...409
SERVICE DATA (LT-A400/F)...409
SERVICE DATA (LT-F400/F)...413
TIGHTENING TORQUE LIST (LT-A400/F)...417
TIGHTENING TORQUE LIST (LT-F400/F)...419
01 ENGINE...423
PRECAUTIONS...426
PRECAUTIONS...426
PRECAUTIONS FOR ENGINE...426
ENGINE GENERAL INFORMATION AND DIAGNOSIS...427
DIAGNOSTIC INFORMATION AND PROCEDURES...427
ENGINE SYMPTOM DIAGNOSIS...427
EMISSION CONTROL DEVICES...429
PRECAUTIONS...429
PRECAUTIONS FOR EMISSION CONTROL DEVICES...429
GENERAL DESCRIPTION...429
CARBURETOR SYSTEM DESCRIPTION...429
REPAIR INSTRUCTIONS...430
CRANKCASE BREATHER (PCV) HOSE INSPECTION...430
CRANKCASE BREATHER (PCV) HOSE REMOVAL AND INSTALLATION...430
ENGINE MECHANICAL...431
SCHEMATIC AND ROUTING DIAGRAM...431
THROTTLE CABLE ROUTING DIAGRAM...431
DIAGNOSTIC INFORMATION AND PROCEDURES...432
ENGINE MECHANICAL SYMPTOM DIAGNOSIS...432
COMPRESSION PRESSURE CHECK...432
REPAIR INSTRUCTIONS...433
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE...433
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION...435
AIR CLEANER ELEMENT INSPECTION AND CLEANING...435
AIR CLEANER BOX REMOVAL AND INSTALLATION...435
ENGINE ASSEMBLY REMOVAL...436
ENGINE ASSEMBLY INSTALLATION...439
ENGINE TOP SIDE DISASSEMBLY...440
ENGINE TOP SIDE ASSEMBLY...443
CYLINDER HEAD COVER DISASSEMBLY AND ASSEMBLY...450
CYLINDER HEAD COVER RELATE PARTS INSPECTION...451
CYLINDER HEAD DISASSEMBLY AND ASSEMBLY...452
CYLINDER HEAD RELATED PARTS INSPECTION...453
VALVE GUIDE REPLACEMENT...456
VALVE SEAT REPAIR...458
CAMSHAFT INSPECTION...458
CAM CHAIN TENSION ADJUSTER INSPECTION...460
CAM CHAIN TENSIONER INSPECTION...460
CAM CHAIN GUIDE INSPECTION...460
CYLINDER INSPECTION...460
PISTON RING REMOVAL AND INSTALLATION...461
PISTON AND PISTON RING INSPECTION...462
ENGINE BOTTOM SIDE DISASSEMBLY...464
ENGINE BOTTOM SIDE ASSEMBLY...473
CONROD AND CRANKSHAFT INSPECTION...488
WIDTH BETWEEN CRANKSHAFT WEBS...489
CRANKSHAFT OIL SEAL INSPECTION...489
BEARING INSPECTION...489
BEARING REMOVAL AND INSTALLATION...490
SPECIFICATIONS...497
SERVICE DATA (LT-A400/F, LT-F400/F)...497
TIGHTENING TORQUE SPECIFICATIONS...499
SPECIAL TOOLS AND EQUIPMENT...499
RECOMMENDED SERVICE MATERIAL...499
SPECIAL TOOL...500
ENGINE LUBRICATION SYSTEM...504
PRECAUTIONS...504
PRECAUTIONS FOR ENGINE OIL...504
SCHEMATIC AND ROUTING DIAGRAM...504
ENGINE LUBRICATION SYSTEM CHART DIAGRAM...504
CYLINDER HEAD COOLING SYSTEM CHART DIAGRAM...506
DIAGNOSTIC INFORMATION AND PROCEDURES...507
ENGINE LUBRICATION SYMPTOM DIAGNOSIS...507
OIL PRESSURE CHECK...507
REPAIR INSTRUCTIONS...508
ENGINE OIL AND FILTER REPLACEMENT...508
ENGINE OIL LEVEL INSPECTION...508
OIL SUMP FILTER REMOVAL AND INSTALLATION...508
OIL SUMP FILTER INSPECTION AND CLEANING...509
OIL JET REMOVAL AND INSTALLATION (LT-F400/F)...509
OIL JET INSPECTION (LT-F400/F)...509
OIL PUMP DRIVE GEAR / OIL PUMP REMOVAL AND INSTALLATION...509
OIL PUMP INSPECTION...511
OIL COOLER AND OIL HOSE COMPONENTS...512
OIL COOLER / OIL COOLER HOSE INSPECTION AND CLEANING...512
OIL COOLER / OIL COOLER HOSE REMOVAL AND INSTALLATION...513
OIL COOLER CLEANING...514
COOLING FAN COMPONENTS...515
COOLING FAN INSPECTION...515
COOLING FAN REMOVAL AND INSTALLATION...516
COOLING FAN THERMO-SWITCH REMOVAL AND INSTALLATION...516
COOLING FAN THERMO-SWITCH INSPECTION...517
ENGINE OIL TEMPERATURE SWITCH REMOVAL AND INSTALLATION...517
ENGINE OIL TEMPERATURE SWITCH INSPECTION...518
OIL PRESSURE REGULATOR REMOVAL AND INSTALLATION...518
OIL PRESSURE REGULATOR INSPECTION...519
SPECIFICATIONS...519
SERVICE DATA (LT-A400/F)...519
SERVICE DATA (LT-F400/F)...519
TIGHTENING TORQUE SPECIFICATIONS...520
SPECIAL TOOLS AND EQUIPMENT...520
RECOMMENDED SERVICE MATERIAL...520
SPECIAL TOOL...520
FUEL SYSTEM...522
PRECAUTIONS...522
PRECAUTIONS FOR FUEL SYSTEM...522
GENERAL DESCRIPTION...522
I.D. NO. LOCATION...522
FUEL SYSTEM DESCRIPTION...523
SCHEMATIC AND ROUTING DIAGRAM...531
CARBURETOR HOSE ROUTING DIAGRAM...531
DIAGNOSTIC INFORMATION AND PROCEDURES...532
CARBURETOR SYMPTOM DIAGNOSIS...532
REPAIR INSTRUCTIONS...533
FUEL TANK CONSTRUCTION...533
FUEL TANK REMOVAL AND INSTALLATION...534
FUEL VALVE REMOVAL AND INSTALLATION...534
FUEL FILTER INSPECTION AND CLEANING...535
FUEL LEVEL GAUGE REMOVAL AND INSTALLATION...535
FUEL LEVEL GAUGE INSPECTION...536
THROTTLE CABLE REMOVAL AND INSTALLATION...536
THROTTLE CABLE INSPECTION...536
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...536
STARTER CABLE REMOVAL AND INSTALLATION...536
STARTER CABLE INSPECTION...536
STARTER CABLE PLAY INSPECTION AND ADJUSTMENT...536
CARBURETOR COMPONENTS...537
CARBURETOR ASSEMBLY REMOVAL AND INSTALLATION...538
CARBURETOR DISASSEMBLY...538
CARBURETOR ASSEMBLY...541
FLOAT HEIGHT INSPECTION AND ADJUSTMENT...542
CARBURETOR INSPECTION AND CLEANING...542
ENGINE IDLE SPEED INSPECTION...543
FUEL LINE INSPECTION...543
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION...543
AIR CLEANER ELEMENT INSPECTION AND CLEANING...543
SPECIFICATIONS...543
SERVICE DATA (LT-A400/F, LT-F400/F)...543
TIGHTENING TORQUE SPECIFICATIONS...544
SPECIAL TOOLS AND EQUIPMENT...544
RECOMMENDED SERVICE MATERIAL...544
SPECIAL TOOL...544
IGNITION SYSTEM...545
SCHEMATIC AND ROUTING DIAGRAM...545
IGNITION SYSTEM DIAGRAM...545
IGNITION SYSTEM COMPONENTS LOCATION...545
DIAGNOSTIC INFORMATION AND PROCEDURES...545
IGNITION SYSTEM SYMPTOM DIAGNOSIS...545
NO SPARK OR POOR SPARK...546
REPAIR INSTRUCTIONS...547
SPARK PLUG REMOVAL AND INSTALLATION...547
SPARK PLUG INSPECTION AND CLEANING...547
IGNITION COIL AND PLUG CAP INSPECTION...547
IGNITION COIL REMOVAL AND INSTALLATION...549
CKP SENSOR INSPECTION...549
CKP SENSOR REMOVAL AND INSTALLATION...550
ENGINE STOP SWITCH INSPECTION...550
IGNITION SWITCH INSPECTION...550
IGNITION SWITCH REMOVAL AND INSTALLATION...550
SPECIFICATIONS...551
SERVICE DATA (LT-A400/F, LT-F400/F)...551
TIGHTENING TORQUE SPECIFICATIONS...551
SPECIAL TOOLS AND EQUIPMENT...551
SPECIAL TOOL...551
STARTING SYSTEM...552
SCHEMATIC AND ROUTING DIAGRAM...552
STARTING SYSTEM DIAGRAM...552
COMPONENT LOCATION...552
STARTING SYSTEM COMPONENTS LOCATION...552
DIAGNOSTIC INFORMATION AND PROCEDURES...552
STARTING SYSTEM SYMPTOM DIAGNOSIS...552
STARTER MOTOR WILL NOT RUN...553
STARTER MOTOR RUNS BUT DOES NOT CRANK THE ENGINE...553
ENGINE DOES NOT TURN THOUGH THE STARTER MOTOR RUNS...553
REPAIR INSTRUCTIONS...554
STARTER MOTOR COMPONENTS...554
STARTER MOTOR REMOVAL AND INSTALLATION...554
STARTER MOTOR DISASSEMBLY AND ASSEMBLY...555
STARTER MOTOR INSPECTION...555
STARTER RELAY REMOVAL AND INSTALLATION...556
STARTER RELAY INSPECTION...557
NEUTRAL RELAY REMOVAL AND INSTALLATION...557
NEUTRAL RELAY INSPECTION...558
NEUTRAL SWITCH DIODE INSPECTION...558
IGNITION / STARTER CONTROL RELAY REMOVAL AND INSTALLATION...559
IGNITION / STARTER CONTROL RELAY INSPECTION...559
PARKING BRAKE SWITCH INSPECTION...559
GEAR POSITION SWITCH INSPECTION...559
STARTER CLUTCH REMOVAL AND INSTALLATION...560
STARTER DRIVEN GEAR BEARING REMOVAL AND INSTALLATION...562
STARTER RELATED PARTS INSPECTION...562
STARTER BUTTON INSPECTION...563
RECOIL STARTER COMPONENTS...563
RECOIL STARTER ASSEMBLY REMOVAL AND INSTALLATION...564
RECOIL STARTER DISASSEMBLY AND ASSEMBLY...564
RECOIL STARTER INSPECTION...566
SPECIFICATIONS...567
SERVICE DATA (LT-A400/F, LT-F400/F)...567
TIGHTENING TORQUE SPECIFICATIONS...567
SPECIAL TOOLS AND EQUIPMENT...567
RECOMMENDED SERVICE MATERIAL...567
SPECIAL TOOL...568
CHARGING SYSTEM...569
SCHEMATIC AND ROUTING DIAGRAM...569
CHARGING SYSTEM DIAGRAM...569
COMPONENT LOCATION...569
CHARGING SYSTEM COMPONENTS LOCATION...569
DIAGNOSTIC INFORMATION AND PROCEDURES...569
CHARGING SYSTEM SYMPTOM DIAGNOSIS...569
BATTERY RUNS DOWN QUICKLY...570
REPAIR INSTRUCTIONS...571
BATTERY CURRENT LEAKAGE INSPECTION...571
REGULATED VOLTAGE INSPECTION...571
GENERATOR INSPECTION...572
GENERATOR REMOVAL AND INSTALLATION...573
REGULATOR / RECTIFIER INSPECTION...578
BATTERY COMPONENTS...579
BATTERY CHARGING...579
BATTERY REMOVAL AND INSTALLATION...581
BATTERY VISUAL INSPECTION...581
SPECIFICATIONS...582
SERVICE DATA (LT-A400/F, LT-F400/F)...582
TIGHTENING TORQUE SPECIFICATIONS...582
SPECIAL TOOLS AND EQUIPMENT...582
RECOMMENDED SERVICE MATERIAL...582
SPECIAL TOOL...582
EXHAUST SYSTEM...584
PRECAUTIONS...584
PRECAUTIONS FOR EXHAUST SYSTEM...584
REPAIR INSTRUCTIONS...584
EXHAUST SYSTEM COMPONENTS...584
MUFFLER / EXHAUST PIPE REMOVAL AND INSTALLATION...585
EXHAUST SYSTEM INSPECTION...586
SPARK ARRESTER INSPECTION...586
SPECIFICATIONS...587
TIGHTENING TORQUE SPECIFICATIONS...587
02 SUSPENSION...589
PRECAUTIONS...590
PRECAUTIONS...590
PRECAUTIONS FOR SUSPENSION...590
SUSPENSION GENERAL DIAGNOSIS...591
DIAGNOSTIC INFORMATION AND PROCEDURES...591
SUSPENSION AND WHEEL SYMPTOM DIAGNOSIS...591
FRONT SUSPENSION...592
REPAIR INSTRUCTIONS...592
FRONT SUSPENSION COMPONENTS...592
FRONT SUSPENSION ASSEMBLY CONSTRUCTION...593
FRONT SUSPENSION INSPECTION...594
FRONT SHOCK ABSORBER INSPECTION...594
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATION...594
FRONT WHEEL HUB / STEERING KNUCKLE REMOVAL AND INSTALLATION...594
FRONT WHEEL HUB / STEERING KNUCKLE RELATED PARTS INSPECTION...597
STEERING KNUCKLE DUST SEAL / FRONT WHEEL HUB BEARING REMOVAL AND INSTALLATION...597
FRONT SUSPENSION UPPER / LOWER ARM REMOVAL AND INSTALLATION...599
FRONT SUSPENSION ARM RELATED PARTS INSPECTION...600
STEERING KNUCKLE END REMOVAL AND INSTALLATION...601
FRONT SUSPENSION UPPER / LOWER ARM BUSHING REMOVAL AND INSTALLATION...602
SPECIFICATIONS...603
TIGHTENING TORQUE SPECIFICATIONS...603
SPECIAL TOOLS AND EQUIPMENT...603
RECOMMENDED SERVICE MATERIAL...603
SPECIAL TOOL...604
REAR SUSPENSION...605
REPAIR INSTRUCTIONS...605
REAR SUSPENSION COMPONENTS...605
REAR SHOCK ABSORBER REMOVAL AND INSTALLATION...606
REAR SUSPENSION INSPECTION...606
REAR SHOCK ABSORBER INSPECTION...606
SWINGARM REMOVAL AND INSTALLATION...606
SWINGARM INSPECTION...607
SWINGARM BUSHING REMOVAL AND INSTALLATION...608
SPECIFICATIONS...608
TIGHTENING TORQUE SPECIFICATIONS...608
SPECIAL TOOLS AND EQUIPMENT...608
RECOMMENDED SERVICE MATERIAL...608
WHEELS AND TIRES...609
PRECAUTIONS...609
PRECAUTIONS FOR WHEEL AND TIRE...609
REPAIR INSTRUCTIONS...610
FRONT AND REAR WHEEL COMPONENTS...610
FRONT / REAR WHEEL REMOVAL AND INSTALLATION...611
TIRE REMOVAL AND INSTALLATION...611
SPECIFICATIONS...613
SERVICE DATA (LT-A400/F, LT-F400/F)...613
TIGHTENING TORQUE SPECIFICATIONS...613
03 DRIVELINE / AXLE...615
PRECAUTIONS...617
PRECAUTIONS...617
PRECAUTIONS FOR DRIVELINE / AXLE...617
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT...618
DIAGNOSTIC INFORMATION AND PROCEDURES...618
DRIVE SHAFT SYMPTOM DIAGNOSIS...618
REPAIR INSTRUCTIONS...618
FRONT DRIVE SHAFT COMPONENTS (LT-A400F, LT-F400F)...618
FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION (LT-A400F, LT-F400F)...619
FRONT DRIVE SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400F, LT-F400F)...619
FRONT DRIVE SHAFT INSPECTION (LT-A400F, LT- F400F)...622
REAR AXLE COMPONENTS...623
REAR AXLE CONSTRUCTION...624
REAR AXLE / AXLE HOUSING REMOVAL AND INSTALLATION...624
REAR AXLE / AXLE HOUSING INSPECTION...626
REAR AXLE HOUSING DISASSEMBLY AND ASSEMBLY...627
SPECIFICATIONS...628
TIGHTENING TORQUE SPECIFICATIONS...628
SPECIAL TOOLS AND EQUIPMENT...628
RECOMMENDED SERVICE MATERIAL...628
SPECIAL TOOL...628
DIFFERENTIAL...630
DIAGNOSTIC INFORMATION AND PROCEDURES...630
DRIVE TRAIN SYMPTOM DIAGNOSIS...630
REPAIR INSTRUCTIONS...631
FRONT DRIVE (DIFFERENTIAL) COMPONENTS (LT-A400F, LT-F400F)...631
FRONT DRIVE (DIFFERENTIAL) CONSTRUCTION (LT-A400F, LT-F400F)...632
FRONT DRIVE (DIFFERENTIAL) GEAR OIL LEVEL INSPECTION (LT-A400F, LT-F400F)...633
FRONT DRIVE (DIFFERENTIAL) GEAR OIL REPLACEMENT (LT-A400F, LT-F400F)...633
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY REMOVAL AND INSTALLATION (LT-A400F, LT-F400F)...633
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY DISASSEMBLY AND ASSEMBLY (LT-A400F, LT- F400F)...634
FRONT DRIVE (DIFFERENTIAL) RELATED PARTS INSPECTION (LT-A400F, LT-F400F)...642
UNIVERSAL JOINT BEARING / PINION GEAR PILOT BEARING INSPECTION...643
FRONT DRIVE (DIFFERENTIAL) GEAR SHIM INSPECTION AND SELECTION (LT-A400F, LT-F400F)...644
FINAL GEAR COMPONENTS...648
FINAL GEAR CONSTRUCTION...649
FINAL GEAR OIL LEVEL INSPECTION...650
FINAL GEAR OIL REPLACEMENT...650
FINAL GEAR ASSEMBLY REMOVAL AND INSTALLATION...650
FINAL GEAR ASSEMBLY DISASSEMBLY AND ASSEMBLY...652
FINAL GEAR RELATED PARTS INSPECTION...657
FINAL GEAR BACKLASH INSPECTION AND SHIM ADJUSTMENT...659
TRANSFER CABLE INSPECTION AND ADJUSTMENT (LT- A400F, LT-F400F)...662
TRANSFER CABLE REMOVAL AND INSTALLATION (LT- A400F, LT-F400F)...662
SPECIFICATIONS...663
SERVICE DATA (LT-A400/F, LT-F400/F)...663
TIGHTENING TORQUE SPECIFICATIONS...663
SPECIAL TOOLS AND EQUIPMENT...664
RECOMMENDED SERVICE MATERIAL...664
SPECIAL TOOL...664
TRANSFER...666
DIAGNOSTIC INFORMATION AND PROCEDURES...666
TRANSFER SYMPTOM DIAGNOSIS (LT-A400/F)...666
TRANSFER SYMPTOM DIAGNOSIS (LT-F400/F)...666
REPAIR INSTRUCTIONS...667
TRANSFER COMPONENTS (LT-A400/F)...667
TRANSFER COMPONENTS (LT-F400/F)...668
TRANSFER REMOVAL AND INSTALLATION (LT-A400/F)...669
TRANSFER REMOVAL AND INSTALLATION (LT-F400/F)...672
TRANSFER CONSTRUCTION (LT-A400/F)...673
TRANSFER DISASSEMBLY AND ASSEMBLY (LT-A400/ F)...674
TRANSFER IDLE GEAR BEARING REMOVAL AND INSTALLATION (LT-F400/F)...674
TRANSFER GEARSHIFT CAM COMPONENTS (LT-A400/F)...675
TRANSFER GEARSHIFT CAM COMPONENTS (LT-F400/F)...676
GEARSHIFT SYSTEM CONSTRUCTION (LT-A400/F)...677
GEARSHIFT SYSTEM CONSTRUCTION (LT-F400/F)...677
TRANSFER GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-A400/F)...678
TRANSFER GEARSHIFT SHAFT NO.1 BEARING INSPECTION (LT-A400/F)...678
TRANSFER GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-F400/F)...679
TRANSFER RELATED PARTS INSPECTION (LT-A400/F)...680
TRANSFER RELATED PARTS INSPECTION (LT-F400/F)...680
GEAR POSITION (GP) SWITCH INSPECTION...681
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-A400/F)...681
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-F400/F)...682
TRANSFER GEARSHIFT SHAFT NO. 2 / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION (LT-A400/F)...682
GEARSHIFT LINKAGE INSPECTION (LT-A400/F)...684
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION (LT-A400/F)...684
TRANSFER RANGE LEVER COMPONENTS (LT-A400/F)...685
TRANSFER RANGE LEVER COMPONENTS (LT-F400/F)...685
TRANSFER RANGE LEVER REMOVAL AND INSTALLATION...685
TRANSFER RANGE LEVER DISASSEMBLY AND ASSEMBLY...686
SHIFT ROD LENGTH ADJUSTMENT...686
REVERSE SWITCH INSPECTION (LT-F400/F)...686
SPECIFICATIONS...687
SERVICE DATA (LT-A400/F)...687
SERVICE DATA (LT-F400/F)...687
TIGHTENING TORQUE SPECIFICATIONS...688
SPECIAL TOOLS AND EQUIPMENT...688
RECOMMENDED SERVICE MATERIAL...688
SPECIAL TOOL...688
PROPELLER SHAFTS...689
REPAIR INSTRUCTIONS...689
FRONT OUTPUT SHAFT COMPONENTS...689
OUTPUT SHAFT REMOVAL AND INSTALLATION...691
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400/F)...692
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-F400/F)...695
FRONT OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400F, LT-F400F)...698
REAR OUTPUT SHAFT RELATED PARTS INSPECTION...699
FRONT OUTPUT SHAFT RELATED PARTS INSPECTION (LT- A400F, LT-F400F)...701
DRIVE BEVEL GEAR REMOVAL AND INSTALLATION (LT- A400/F)...701
DRIVE BEVEL GEAR REMOVAL AND INSTALLATION (LT- F400/F)...703
DRIVEN AND DRIVE BEVEL GEAR SHIM INSPECTION AND ADJUSTMENT...704
DRIVEN AND DRIVE BEVEL GEAR SHIM ADJUSTMENT INFORMATION...708
SPECIFICATIONS...710
SERVICE DATA (LT-A400/F, LT-F400/F)...710
TIGHTENING TORQUE SPECIFICATIONS...710
SPECIAL TOOLS AND EQUIPMENT...710
RECOMMENDED SERVICE MATERIAL...710
SPECIAL TOOL...710
04 BRAKE...713
PRECAUTIONS...715
PRECAUTIONS...715
PRECAUTIONS FOR BRAKE SYSTEM...715
BRAKE FLUID INFORMATION...715
BRAKE CONTROL SYSTEM AND DIAGNOSIS...716
SCHEMATIC AND ROUTING DIAGRAM...716
FRONT BRAKE HOSE ROUTING DIAGRAM...716
BRAKE CABLE ROUTING DIAGRAM...717
DIAGNOSTIC INFORMATION AND PROCEDURES...718
BRAKE SYMPTOM DIAGNOSIS...718
REPAIR INSTRUCTIONS...718
BRAKE PEDAL ADJUSTMENT...718
FRONT BRAKE LIGHT SWITCH INSPECTION...718
REAR BRAKE LIGHT SWITCH INSPECTION...719
REAR BRAKE LIGHT SWITCH INSPECTION AND ADJUSTMENT...719
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION...720
PARKING BRAKE SWITCH INSPECTION...720
BRAKE FLUID LEVEL CHECK...720
FRONT BRAKE HOSE INSPECTION...720
AIR BLEEDING FROM FRONT BRAKE FLUID CIRCUIT...720
BRAKE FLUID REPLACEMENT...721
FRONT BRAKE HOSE REMOVAL AND INSTALLATION...722
REAR BRAKE CABLE REMOVAL AND INSTALLATION...722
FRONT BRAKE MASTER CYLINDER COMPONENTS...723
FRONT BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION...723
FRONT BRAKE MASTER CYLINDER / BRAKE LEVER DISASSEMBLY AND ASSEMBLY...725
FRONT BRAKE MASTER CYLINDER PARTS INSPECTION...726
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATION...726
REAR BRAKE PEDAL CONSTRUCTION...727
REAR BRAKE PEDAL REMOVAL AND INSTALLATION...727
SPECIFICATIONS...728
SERVICE DATA (LT-A400/F, LT-F400/F)...728
TIGHTENING TORQUE SPECIFICATIONS...729
SPECIAL TOOLS AND EQUIPMENT...729
RECOMMENDED SERVICE MATERIAL...729
SPECIAL TOOL...729
FRONT BRAKES...730
PRECAUTIONS...730
PRECAUTIONS FOR FRONT BRAKES...730
REPAIR INSTRUCTIONS...730
FRONT BRAKE COMPONENTS...730
FRONT BRAKE PAD INSPECTION...731
FRONT BRAKE PAD REPLACEMENT...731
FRONT BRAKE CALIPER REMOVAL AND INSTALLATION...732
FRONT BRAKE CALIPER DISASSEMBLY AND ASSEMBLY...733
FRONT BRAKE CALIPER PARTS INSPECTION...735
FRONT BRAKE DISC REMOVAL AND INSTALLATION...736
FRONT BRAKE DISC INSPECTION...737
SPECIFICATIONS...737
SERVICE DATA (LT-A400/F, LT-F400/F)...737
TIGHTENING TORQUE SPECIFICATIONS...738
SPECIAL TOOLS AND EQUIPMENT...738
RECOMMENDED SERVICE MATERIAL...738
SPECIAL TOOL...738
REAR BRAKES...739
PRECAUTIONS...739
PRECAUTIONS FOR REAR BRAKE...739
SCHEMATIC AND ROUTING DIAGRAM...739
REAR BRAKE BREATHER HOSE ROUTING DIAGRAM...739
REPAIR INSTRUCTIONS...740
REAR BRAKE COMPONENTS...740
REAR BRAKE CONSTRUCTION...741
REAR BRAKE SHOE INSPECTION...741
REAR BRAKE DISASSEMBLY AND ASSEMBLY...741
REAR BRAKE RELATED PARTS INSPECTION...746
SPECIFICATIONS...747
SERVICE DATA (LT-A400/F, LT-F400/F)...747
TIGHTENING TORQUE SPECIFICATIONS...747
SPECIAL TOOLS AND EQUIPMENT...748
RECOMMENDED SERVICE MATERIAL...748
PARKING BRAKE...749
SCHEMATIC AND ROUTING DIAGRAM...749
PARKING / REAR BRAKE CABLE ROUTING DIAGRAM...749
REPAIR INSTRUCTIONS...749
PARKING / REAR BRAKE LEVER COMPONENTS...749
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION...749
PARKING BRAKE SWITCH INSPECTION...749
IGNITION / STARTER CONTROL RELAY (PARKING BRAKE RELAY) INSPECTION...749
PARKING / REAR BRAKE LEVER INSPECTION AND ADJUSTMENT...749
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATION...750
PARKING / REAR BRAKE CABLE REMOVAL AND INSTALLATION...751
SPECIFICATIONS...751
TIGHTENING TORQUE SPECIFICATIONS...751
SPECIAL TOOLS AND EQUIPMENT...751
RECOMMENDED SERVICE MATERIAL...751
05 TRANSMISSION / TRANSAXLE...753
PRECAUTIONS...755
PRECAUTIONS...755
PRECAUTIONS FOR TRANSMISSION / TRANSAXLE...755
AUTOMATIC TRANSMISSION...756
SCHEMATIC AND ROUTING DIAGRAM...756
DRIVE TRAIN OPERATION (LT-A400/F)...756
DIAGNOSTIC INFORMATION AND PROCEDURES...759
AUTOMATIC TRANSMISSION SYMPTOM DIAGNOSIS...759
REPAIR INSTRUCTIONS...760
AUTOMATIC TRANSMISSION COMPONENTS...760
V-BELT COOLING DUCT CONSTRUCTION...761
V-BELT COOLING DUCT REMOVAL AND INSTALLATION (LT-A400/F)...761
CLUTCH ENGAGEMENT AND LOCK-UP SPEED INSPECTION...762
V-BELT TYPE CONTINUOUSLY VARIABLE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION...762
MOVABLE DRIVE FACE DISASSEMBLY AND ASSEMBLY...765
MOVABLE DRIVEN FACE DISASSEMBLY AND ASSEMBLY...766
DRIVE V-BELT INSPECTION...770
MOVABLE / FIXED DRIVE FACE PARTS INSPECTION...770
MOVABLE / FIXED DRIVEN FACE PARTS INSPECTION...771
CLUTCH SHOE REMOVAL AND INSTALLATION...771
V-BELT OUTER COVER BEARING REMOVAL AND INSTALLATION...773
V-BELT INNER COVER DISASSEMBLY AND ASSEMBLY...774
CLUTCH RELATED PARTS INSPECTION...776
SPECIFICATIONS...777
SERVICE DATA (LT-A400/F)...777
TIGHTENING TORQUE SPECIFICATIONS...778
SPECIAL TOOLS AND EQUIPMENT...778
RECOMMENDED SERVICE MATERIAL...778
SPECIAL TOOL...779
MANUAL TRANSMISSION...780
DIAGNOSTIC INFORMATION AND PROCEDURES...780
MANUAL TRANSMISSION SYMPTOM DIAGNOSIS (LT-F400/F)...780
REPAIR INSTRUCTIONS...781
TRANSMISSION COMPONENTS (LT-F400/F)...781
TRANSMISSION REMOVAL AND INSTALLATION (LT- F400/F)...782
TRANSMISSION CONSTRUCTION...783
COUNTERSHAFT GEAR / DRIVESHAFT GEAR DISASSEMBLY AND ASSEMBLY (LT-F400/F)...784
TRANSMISSION REVERSE GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-F400/F)...785
TRANSMISSION RELATED PARTS INSPECTION (LT- F400/F)...786
GEAR POSITION (GP) SWITCH INSPECTION (LT-F400/ F)...786
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-F400/F)...786
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-A400/F)...787
GEARSHIFT LEVER REMOVAL AND INSTALLATION (LT- F400/F)...787
GEARSHIFT LEVER HEIGHT INSPECTION AND ADJUSTMENT (LT-F400/F)...788
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE COMPONENTS (LT-F400/F)...789
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION (LT-F400/F)...790
GEARSHIFT LINKAGE INSPECTION (LT-F400/F)...791
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION (LT-A400/F)...792
SPECIFICATIONS...792
SERVICE DATA (LT-F400/F)...792
TIGHTENING TORQUE SPECIFICATIONS...793
SPECIAL TOOLS AND EQUIPMENT...793
RECOMMENDED SERVICE MATERIAL...793
SPECIAL TOOL...793
CLUTCH...794
PRECAUTIONS...794
PRECAUTIONS FOR CLUTCH SYSTEM...794
DIAGNOSTIC INFORMATION AND PROCEDURES...794
CLUTCH SYSTEM SYMPTOM DIAGNOSIS...794
REPAIR INSTRUCTIONS...795
CLUTCH COMPONENTS (LT-F400/F)...795
CLUTCH REMOVAL AND INSTALLATION (LT-F400/F)...796
CLUTCH RELATED PARTS INSPECTION (LT-F400/F)...799
CLUTCH COVER DISASSEMBLY AND ASSEMBLY (LT- F400/F)...801
CLUTCH RELEASE ROLLER INSPECTION (LT-F400/F)...803
SPECIFICATIONS...803
SERVICE DATA (LT-F400/F)...803
TIGHTENING TORQUE SPECIFICATIONS...803
SPECIAL TOOLS AND EQUIPMENT...804
RECOMMENDED SERVICE MATERIAL...804
SPECIAL TOOL...804
06 STEERING...805
PRECAUTIONS...806
PRECAUTIONS...806
PRECAUTIONS FOR STEERING...806
STEERING GENERAL DIAGNOSIS...807
DIAGNOSTIC INFORMATION AND PROCEDURES...807
STEERING SYMPTOM DIAGNOSIS...807
STEERING / HANDLEBAR...808
REPAIR INSTRUCTIONS...808
STEERING / HANDLEBARS COMPONENTS...808
STEERING ASSEMBLY CONSTRUCTION...809
HANDLEBARS REMOVAL AND INSTALLATION...810
HANDLEBARS INSPECTION...812
STEERING SHAFT / TIE-ROD REMOVAL AND INSTALLATION...812
STEERING PARTS INSPECTION...817
SPECIFICATIONS...818
SERVICE DATA (LT-A400/F, LT-F400/F)...818
TIGHTENING TORQUE SPECIFICATIONS...818
SPECIAL TOOLS AND EQUIPMENT...819
RECOMMENDED SERVICE MATERIAL...819
SPECIAL TOOL...819
09 BODY AND ACCESSORIES...821
PRECAUTIONS...822
PRECAUTIONS...822
PRECAUTIONS FOR ELECTRICAL SYSTEM...822
COMPONENT LOCATION...822
ELECTRICAL COMPONENTS LOCATION...822
WIRING SYSTEMS...823
SCHEMATIC AND ROUTING DIAGRAM...823
WIRING DIAGRAM...823
WIRING HARNESS ROUTING DIAGRAM...830
SPECIFICATIONS...832
SERVICE DATA (LT-A400/F, LT-F400/F)...832
TIGHTENING TORQUE SPECIFICATIONS...832
LIGHTING SYSTEMS...833
REPAIR INSTRUCTIONS...833
HEADLIGHT CONSTRUCTION...833
FRONT SIDE REFLECTOR CONSTRUCTION...834
HEADLIGHT COMPONENTS...835
HEADLIGHT REMOVAL AND INSTALLATION...835
HEADLIGHT BULB REPLACEMENT...836
HEADLIGHT BEAM ADJUSTMENT...836
REAR COMBINATION LIGHT COMPONENTS...837
REAR COMBINATION LIGHT REMOVAL AND INSTALLATION...837
REAR COMBINATION LIGHT BULB REPLACEMENT...838
REVERSING LIGHT BULB REPLACEMENT (FOR P-17)...838
REVERSING LIGHT RELAY INSPECTION (FOR P-17)...838
DIMMER SWITCH INSPECTION...839
SPECIFICATIONS...839
SERVICE DATA (LT-A400/F, LT-F400/F)...839
TIGHTENING TORQUE SPECIFICATIONS...839
SPECIAL TOOLS AND EQUIPMENT...839
SPECIAL TOOL...839
COMBINATION METER / FUEL METER / HORN...840
REPAIR INSTRUCTIONS...840
SPEEDOMETER COMPONENTS...840
SPEEDOMETER REMOVAL AND INSTALLATION...841
SPEEDOMETER DISASSEMBLY AND ASSEMBLY...842
SPEEDOMETER LIGHT BULB / INDICATOR LIGHT BULB REPLACEMENT...842
IGNITION SWITCH INSPECTION...842
IGNITION SWITCH REMOVAL AND INSTALLATION...842
HORN INSPECTION (FOR P-17, 24)...843
HORN REMOVAL AND INSTALLATION (FOR P-17, 24)...843
SPECIFICATIONS...843
SERVICE DATA (LT-A400/F, LT-F400/F)...843
SPECIAL TOOLS AND EQUIPMENT...843
SPECIAL TOOL...843
EXTERIOR PARTS...844
REPAIR INSTRUCTIONS...844
REAR FENDER HEAT SHIELD CONSTRUCTION...844
FASTENER REMOVAL AND INSTALLATION...845
EXTERIOR PARTS REMOVAL AND INSTALLATION...846
BODY STRUCTURE...850
REPAIR INSTRUCTIONS...850
BODY FRAME CONSTRUCTION...850
FOOTREST CONSTRUCTION...850
FOOTREST REMOVAL AND INSTALLATION...851
CARRIER CONSTRUCTION...852
FRONT CARRIER REMOVAL AND INSTALLATION...853
REAR CARRIER REMOVAL AND INSTALLATION...853
FRONT GRIP BAR CONSTRUCTION...854
FRONT GRIP BAR REMOVAL AND INSTALLATION...854
TRAILER TOWING REMOVAL AND INSTRUCTION...855
SPECIFICATIONS...856
TIGHTENING TORQUE SPECIFICATIONS...856
SPECIAL TOOLS AND EQUIPMENT...856
RECOMMENDED SERVICE MATERIAL...856
10 LT-A400F / LT-F400F K9 ('09 MODELS)...857
SPECIFICATIONS (FOR LT-A400/F)...859
SPECIFICATIONS (FOR LT-F400/F)...858
SERVICE DATA (FOR LT-A400/F)...860
SERVICE DATA (FOR LT-F400/F)...865
FRONT SUSPENSION...870
Suzuki LT-A500F '02-'07 Service Manual...873
FOREWORD...873
HOW TO USE THIS MANUAL ...876
TO LOCATE WHAT YOU ARE LOOKING FOR: ...876
COMPONENT PARTS AND WORK TO BE DONE ...876
SYMBOL ...877
01 GENERAL INFORMATION ...879
WARNING/CAUTION/NOTE ...880
GENERAL PRECAUTIONS ...880
SUZUKI LT-A500FK2 (2002-MODEL) ...882
SERIAL NUMBER LOCATION ...882
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ...882
FUEL...883
ENGINE OIL...883
FRONT AND REAR DRIVE GEAR OIL ...883
BRAKE FLUID ...883
ENGINE COOLANT ...883
BREAK-lN PROCEDURES...884
INFORMATION LABELS ...885
SPECIFICATIONS ...886
COUNTRY AND AREA CODES ...888
02 PERIODIC MAINTENANCE ...889
PERIODIC MAINTENANCE SCHEDULE ...890
PERIODIC MAINTENANCE CHART ...890
MAINTENANCE AND TUNE-UP PROCEDURES ...891
AIR CLEANER ...891
EXHAUST PIPE NUTS AND MUFFLER BOLTS ...893
VALVE CLEARANCE ...893
SPARK PLUG ...895
FUEL HOSE ...896
THROTTLE CABLE PLAY ...896
ENGINE IDLE SPEED ...896
ENGINE OIL AND OIL FILTER ...897
DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL ...899
ENGINE COOLANT ...900
RADIATOR HOSES ...901
DRIVE BELT ...901
SPARK ARRESTER ...904
BRAKES ...905
BRAKE FLUID ...906
BRAKE HOSES ...908
TIRES ...908
STEERING ...909
SUSPENSIONS ...910
CHASSIS NUTS AND BOLTS ...911
GENERAL LUBRICATION ...913
COMPRESSION PRESSURE CHECK ...914
COMPRESSION TEST PROCEDURE ...914
OIL PRESSURE CHECK ...915
OIL PRESSURE TEST PROCEDURE ...915
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION ...916
INITIAL ENGAGEMENT INSPECTION ...916
CLUTCH LOCK-UP INSPECTION ...917
03 ENGINE ...919
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...920
ENGINE LEFT SIDE ...920
ENGINE RIGHT SIDE ...920
ENGINE CENTER ...920
ENGINE REMOVAL AND INSTALLATION ...921
ENGINE REMOVAL ...921
ENGINE INSTALLATION ...927
ENGINE DISASSEMBLY ...930
ENGINE TOP SIDE ...930
ENGINE BOTTOM SIDE ...933
ENGINE COMPONENTS INSPECTION AND SERVICING ...942
CYLINDER HEAD COVER ...942
CYLINDER HEAD ...943
CAMSHAFT ...953
CAM CHAIN TENSION ADJUSTER ...955
CYLINDER ...955
PISTON ...956
CONROD/CRANKSHAFT ...958
CLUTCH ...959
MOVABLE DRIVE FACE AND DRIVEN FACE ...961
DRIVE BELT ...968
OIL PUMP ...968
TRANSFER ...969
SHIFT FORK ...971
GEARSHIFT CAM ...972
CRANKSHAFT ...973
DRIVE TRAIN (INBOARD SIDE) ...974
SHIM ADJUSTMENT ...983
CRANKCASE ...987
DRIVE BELT COVER ...993
GENERATOR COVER ...995
RECOIL STARTER ...997
ENGINE REASSEMBLY ...999
ENGINE BOTTOM SIDE ...999
ENGINE TOP SIDE ...1011
04 DRIVE TRAIN ...1021
FRONT DRIVING SYSTEM ...1022
FRONT DRIVE (DIFFERENTIAL) REMOVAL ...1023
FRONT DRIVE (DIFFERENTIAL) DISASSEMBLY ...1023
FRONT DRIVE (DIFFERENTIAL) INSPECTION ...1027
FRONT DRIVE (DIFFERENTIAL) REASSEMBLY ...1030
FRONT DRIVE (DIFFERENTIAL) INSTALLATION ...1036
SHIM ADJUSTMENT ...1037
REASSEMBLY INFORMATION ...1040
REAR DRIVING SYSTEM ...1041
REAR DRIVE REMOVAL ...1042
REAR DRIVE DISASSEMBLY ...1043
REAR DRIVE INSPECTION ...1048
REAR DRIVE REASSEMBLY ...1051
REAR DRIVE INSTALLATION ...1056
SHIM ADJUSTMENT ...1057
REASSEMBLY INFORMATION ...1060
05 FUEL SYSTEM ...1063
FUEL TANK ...1064
CONSTRUCTION ...1064
FUEL LINE INSPECTION ...1065
REMOVAL ...1065
REMOUNTING ...1065
FUEL VALVE ...1066
REMOVAL AND INSPECTION ...1066
FUEL STRAINER ...1066
REMOUNTING ...1066
FUEL LEVEL GAUGE ...1067
REMOVAL ...1067
INSPECTION ...1067
REMOUNTING ...1067
CARBURETOR ...1068
CONSTRUCTION ...1068
SPECIFICATIONS ...1069
I.D. NO. LOCATION ...1069
REMOVAL ...1070
DISASSEMBLY ...1071
CLEANING ...1074
INSPECTION ...1074
REASSEMBLY ...1075
REMOUNTING ...1076
06 COOLING AND LUBRICATION SYSTEM ...1077
ENGINE COOLANT ...1078
COOLING CIRCUIT ...1079
COOLING CIRCUIT INSPECTION ...1079
RADIATOR AND HOSES ...1080
RADIATOR REMOVAL ...1080
RADIATOR REMOUNTING ...1080
RADIATOR RESERVOIR TANK ...1080
RADIATOR CAP INSPECTION ...1081
RADIATOR INSPECTION AND CLEANING ...1081
RADIATOR HOSE INSPECTION ...1082
COOLING FAN ...1082
REMOVAL ...1082
INSPECTION ...1083
INSTALLATION ...1083
COOLING FAN THERMO-SWITCH ...1084
REMOVAL ...1084
INSPECTION ...1084
INSTALLATION ...1084
ENGINE COOLANT TEMPERATURE SWITCH ...1085
REMOVAL ...1085
INSPECTION ...1085
INSTALLATION ...1085
THERMOSTAT ...1086
REMOVAL ...1086
INSPECTION ...1086
INSTALLATION ...1086
WATER PUMP ...1087
REMOVAL AND DISASSEMBLY ...1087
INSPECTION ...1088
REASSEMBLY AND INSTALLATION ...1089
LUBRICATION SYSTEM ...1092
OIL PRESSURE ...1092
OIL FILTER ...1092
OIL PRESSURE REGULATOR ...1092
OIL STRAINER ...1092
OIL PUMP ...1092
ENGINE LUBRICATION SYSTEM CHART ...1093
ENGINE LUBRICATION SYSTEM ...1094
07 CHASSIS ...1097
EXTERIOR PARTS ...1098
CONSTRUCTION ...1098
REMOVAL ...1100
REMOUNTING ...1105
FRONT AND REAR WHEELS ...1106
CONSTRUCTION ...1106
REMOVAL ...1106
REMOUNTING ...1106
TIRES ...1107
TIRE REPLACEMENT ...1107
FRONT DRIVE SHAFT ...1109
CONSTRUCTION ...1109
REMOVAL ...1109
INSPECTION AND REASSEMBLY ...1111
REMOUNTING ...1113
FRONT BRAKE ...1114
CONSTRUCTION ...1114
BRAKE PAD REPLACEMENT ...1115
BRAKE FLUID REPLACEMENT ...1116
BRAKE CALIPER REMOVAL AND DISASSEMBLY ...1116
BRAKE CALIPER INSPECTION ...1118
BRAKE CALIPER REASSEMBLY AND REMOUNTING ...1119
BRAKE DISC REMOVAL AND DISASSEMBLY ...1121
BRAKE DISC INSPECTION ...1122
BRAKE DISC REASSEMBLY AND REMOUNTING ...1122
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...1123
MASTER CYLINDER INSPECTION ...1125
MASTER CYLINDER REASSEMBLY AND REMOUNTING ...1125
FRONT SUSPENSION ...1127
CONSTRUCTION ...1127
REMOVAL AND DISASSEMBLY ...1128
INSPECTION ...1130
REASSEMBLY AND REMOUNTING ...1133
STEERING ...1136
CONSTRUCTION ...1136
REMOVAL AND DISASSEMBLY ...1137
INSPECTION ...1139
REASSEMBLY AND REMOUNTING ...1141
TOE-IN ADJUSTMENT ...1143
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION ...1144
REAR BRAKE ...1145
CONSTRUCTION ...1145
BRAKE PAD REPLACEMENT ...1146
BRAKE FLUID REPLACEMENT ...1147
BRAKE CALIPER REMOVAL AND DISASSEMBLY ...1147
BRAKE CALIPER INSPECTION ...1149
BRAKE CALIPER REASSEMBLY AND REMOUNTING ...1150
BRAKE DISC REMOVAL AND DISASSEMBLY ...1152
BRAKE DISC INSPECTION ...1152
BRAKE DISC REASSEMBLY AND REMOUNTING ...1153
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...1154
MASTER CYLINDER INSPECTION ...1155
MASTER CYLINDER REASSEMBLY AND REMOUNTING ...1156
REAR SUSPENSION ...1158
CONSTRUCTION ...1158
REMOVAL ...1159
INSPECTION AND DISASSEMBLY ...1160
REASSEMBLY AND REMOUNTING ...1161
REAR AXLE ...1163
CONSTRUCTION ...1163
REMOVAL ...1164
INSPECTION AND DISASSEMBLY ...1164
REASSEMBLY AND REMOUNTING ...1166
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION ...1168
GEARSHIFT LEVER ...1169
CONSTRUCTION ...1169
REMOVAL AND DISASSEMBLY ...1170
INSPECTION ...1171
REASSEMBLY AND REMOUNTING ...1172
CABLES ...1174
INSTALLATION ...1174
CABLE PLAY ADJUSTMENT ...1176
08 ELECTRICAL SYSTEM ...1177
CAUTIONS IN SERVICING ...1178
CONNECTORS ...1178
COUPLERS ...1178
CLAMPS ...1178
FUSES ...1178
SEMI-CONDUCTOR EQUIPPED PARTS ...1178
BATTERY ...1179
CONNECTING THE BATTERY ...1179
WIRING PROCEDURE ...1179
USING THE MULTI CIRCUIT TESTER ...1179
LOCATION OF ELECTRICAL COMPONENTS ...1180
CHARGING SYSTEM ...1182
TROUBLESHOOTING ...1182
INSPECTION ...1184
STARTER SYSTEM ...1187
TROUBLESHOOTING ...1187
STARTER MOTOR REMOVAL AND DISASSEMBLY ...1188
STARTER MOTOR INSPECTION ...1189
STARTER MOTOR REASSEMBLY AND REMOUNTING ...1190
STARTER RELAY INSPECTION ...1191
NEUTRAL RELAY INSPECTION ...1192
IGNITION/STARTER CONTROL RELAY ...1192
PARKING BRAKE SWITCH ...1192
IGNITION SYSTEM ...1193
TROUBLESHOOTING ...1193
INSPECTION ...1195
2WD/4WD SELECTING SYSTEM ...1199
DESCRIPTION ...1199
TROUBLESHOOTING ...1200
INSPECTION ...1201
SPEEDOMETER ...1203
PARTS NAMES ...1203
OPERATING PROCEDURE ...1204
INSPECTION ...1206
LAMPS ...1208
HEADLIGHT AND AUXILIARY LIGHT ...1208
BRAKE LIGHT/TAILLIGHT ...1209
DIODE ...1211
SWITCHES ...1212
BATTERY ...1213
SPECIFICATIONS ...1213
INITIAL CHARGING ...1213
SERVICING ...1215
RECHARGING OPERATION...1215
09 SERVICING INFORMATION ...1217
TROUBLESHOOTING ...1218
ENGINE ...1218
DRIVE TRAIN ...1221
CARBURETOR ...1221
CHASSIS ...1222
BRAKES ...1223
RADIATOR (COOLING SYSTEM) ...1223
ELECTRICAL ...1224
BATTERY ...1225
WIRING DIAGRAM ...1226
WIRING HARNESS, CABLE, AND HOSE ROUTING ...1227
WIRING HARNESS ROUTING ...1227
CABLE ROUTING ...1230
CARBURETOR HOSE ROUTING ...1232
COOLING SYSTEM HOSE ROUTING ...1233
FRONT BRAKE HOSE ROUTING ...1234
REAR BRAKE HOSE ROUTING ...1235
SPECIAL TOOLS ...1236
TIGHTENING TORQUE ...1239
ENGINE ...1239
DIFFERENTIAL ...1240
CHASSIS ...1240
TIGHTENING TORQUE CHART ...1241
SERVICE DATA ...1242
10 LT-A500FK3 (’03-MODEL) ...1249
SPECIFICATIONS ...1250
ENGINE ...1252
TRANSFER ...1252
GEARSHIFT CAM ...1254
DRIVE BEVEL GEAR BEARING ...1256
PROPELLER SHAFT INSTALLATION ...1256
CHASSIS ...1257
PARKING INTERLOCK CABLE ADJUSTMENT ...1257
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION ...1258
REAR BRAKE ...1259
WIRING DIAGRAM ...1265
REAR BRAKE HOSE ROUTING ...1266
SERVICE DATA ...1267
11 LT-A500FK4 (’04-MODEL) ...1275
SPECIFICATIONS ...1276
SERVICE DATA ...1278
TIGHTENING TORQUE ...1285
FRONT WHEEL, FRONT SUSPENSION AND STEERING ASSEMBLY ...1286
HANDLEBAR GRIP INSTALLATION ...1287
FUEL METER INSPECTION ...1288
FUEL LEVEL GAUGE INSPECTION ...1289
FUEL LEVEL GAUGE INSTALLATION ...1289
WIRING DIAGRAM ...1290
WIRE HARNESS ROUTING ...1292
CABLE ROUTING ...1294
12 LT-A500FK5 (’05-MODEL) ...1295
SPECIFICATIONS ...1296
SERVICE DATA ...1297
TIGHTENING TORQUE ...1305
FRONT AND REAR BRAKE CALIPER MOUNTING BOLTS ...1305
WIRING HARNESS ROUTING ...1306
13 LT-A500FK6 (’06-MODEL) ...1307
SPECIFICATIONS ...1308
SERVICE DATA ...1309
TIGHTENING TORQUE ...1317
WIRING DIAGRAM ...1318
14 LT-A500FK7 ('07-MODEL) ...1320
SPECIFICATIONS ...1321
SERVICE DATA ...1322
FRONT BRAKE HOSE ROUTING...1330
REAR BRAKE HOSE ROUTING...1331
Suzuki LT-A700 '05 Service Manual...1332
Suzuki LT-A750(P)(XP) '08-'09 Service Manual...1809
FOREWORD...1809
TABLE OF CONTENTS...1811
00. PRECAUTIONS...1814
PRECAUTIONS...1815
PRECAUTIONS...1815
WARNING / CAUTION / NOTE...1815
GENERAL PRECAUTIONS...1815
PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE...1816
0. GENERAL INFORMATION...1822
GENERAL INFORMATION...1823
GENERAL DESCRIPTION...1823
SYMBOLS...1823
ABBREVIATIONS...1823
SAE-TO-FORMER SUZUKI TERM...1824
VEHICLE SIDE VIEW...1825
VEHICLE IDENTIFICATION NUMBER...1825
FUEL AND OIL RECOMMENDATION...1825
ENGINE COOLANT RECOMMENDATION...1826
BREAK-IN PROCEDURES...1826
COUNTRY AND AREA CODES...1827
WIRE COLOR SYMBOLS...1827
WARNING, CAUTION AND INFORMATION LABELS LOCATION...1828
COMPONENT LOCATION...1829
ELECTRICAL COMPONENTS LOCATION...1829
SPECIFICATIONS...1831
SPECIFICATIONS...1831
SPECIAL TOOLS AND EQUIPMENT...1833
SPECIAL TOOL...1833
MAINTENANCE AND LUBRICATION...1838
PRECAUTIONS...1838
PRECAUTIONS FOR MAINTENANCE...1838
GENERAL DESCRIPTION...1838
RECOMMENDED FLUIDS AND LUBRICANTS...1838
SCHEDULED MAINTENANCE...1838
PERIODIC MAINTENANCE SCHEDULE CHART...1838
LUBRICATION POINTS...1839
REPAIR INSTRUCTIONS...1840
AIR CLEANER ELEMENT INSPECTION AND CLEANING...1840
EXHAUST PIPE BOLT AND MUFFLER BOLT INSPECTION...1841
VALVE CLEARANCE INSPECTION AND ADJUSTMENT...1841
SPARK PLUG REPLACEMENT...1846
SPARK PLUG INSPECTION AND CLEANING...1846
SPARK ARRESTER CLEANING...1847
FUEL LINE INSPECTION...1847
ENGINE OIL AND FILTER REPLACEMENT...1847
FRONT DIFFERENTIAL GEAR OIL INSPECTION...1849
FRONT DIFFERENTIAL GEAR OIL REPLACEMENT...1850
FINAL GEAR OIL INSPECTION...1851
FINAL GEAR OIL REPLACEMENT...1851
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...1852
THROTTLE BODY INSPECTION...1852
COOLING SYSTEM INSPECTION...1852
DRIVE V-BELT INSPECTION AND REPLACEMENT...1854
DRIVE SHAFT BOOTS INSPECTION...1854
FRONT BRAKE SYSTEM INSPECTION...1854
REAR BRAKE PEDAL / REAR BRAKE (PARKING BRAKE) LEVER INSPECTION AND ADJUSTMENT...1856
REAR BRAKE FRICTION PLATE WEAR LIMIT INSPECTION...1857
TIRE INSPECTION...1858
STEERING SYSTEM INSPECTION...1858
TOE ADJUSTMENT...1859
SUSPENSIONS INSPECTION...1859
CHASSIS BOLT AND NUT INSPECTION...1860
COMPRESSION PRESSURE CHECK...1863
OIL PRESSURE CHECK...1863
SDS CHECK...1863
AUTOMATIC CLUTCH INSPECTION...1863
SPECIFICATIONS...1864
TIGHTENING TORQUE SPECIFICATIONS...1864
SPECIAL TOOLS AND EQUIPMENT...1864
RECOMMENDED SERVICE MATERIAL...1864
SPECIAL TOOL...1864
SERVICE DATA...1866
SPECIFICATIONS...1866
SERVICE DATA...1866
TIGHTENING TORQUE LIST...1872
01. ENGINE...1877
PRECAUTIONS...1881
PRECAUTIONS...1881
PRECAUTIONS FOR ENGINE...1881
ENGINE GENERAL INFORMATION AND DIAGNOSIS...1882
GENERAL DESCRIPTION...1882
INJECTION TIMING DESCRIPTION...1882
SCHEMATIC AND ROUTING DIAGRAM...1885
FI SYSTEM WIRING DIAGRAM...1885
TERMINAL ALIGNMENT OF ECM COUPLER...1886
COMPONENT LOCATION...1887
FI SYSTEM PARTS LOCATION...1887
DIAGNOSTIC INFORMATION AND PROCEDURES...1889
ENGINE SYMPTOM DIAGNOSIS...1889
SELF-DIAGNOSTIC PROCEDURES...1892
USE OF SDS DIAGNOSIS RESET PROCEDURES...1894
SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC)...1895
SDS CHECK...1896
DTC TABLE...1900
FAIL-SAFE FUNCTION TABLE...1900
FI SYSTEM TROUBLESHOOTING...1901
MALFUNCTION CODE AND DEFECTIVE CONDITION TABLE...1903
DTC “C12” (P0335): CKP SENSOR CIRCUIT MALFUNCTION...1905
DTC “C13” (P0105-H/L): IAP SENSOR CIRCUIT MALFUNCTION...1908
DTC “C14” (P0120-H/L): TP SENSOR CIRCUIT MALFUNCTION...1915
DTC “C15” (P0115-H/L): ECT SENSOR CIRCUIT MALFUNCTION...1922
DTC “C20” (P1752): DIFF-LOCK RELAY CIRCUIT MALFUNCTION...1928
DTC “C21” (P0110-H/L): IAT SENSOR CIRCUIT MALFUNCTION...1930
DTC “C23” (P1651-H/L): TO SENSOR CIRCUIT MALFUNCTION...1934
DTC “C24” (P0351): IGNITION COIL CIRCUIT MALFUNCTION...1940
DTC “C32” (P0201): FUEL INJECTOR CIRCUIT MALFUNCTION...1940
DTC “C40” (P05057): ISC VALVE CIRCUIT MALFUNCTION...1943
DTC “C41” (P230-H/L): FP RELAY CIRCUIT MALFUNCTION...1948
SPECIFICATIONS...1950
SERVICE DATA...1950
SPECIAL TOOLS AND EQUIPMENT...1951
SPECIAL TOOL...1951
EMISSION CONTROL DEVICES...1952
PRECAUTIONS...1952
PRECAUTIONS FOR EMISSION CONTROL DEVICES...1952
REPAIR INSTRUCTIONS...1952
CRANKCASE BREATHER (PCV) HOSE INSPECTION...1952
CRANKCASE BREATHER (PCV) HOSE REMOVAL AND INSTALLATION...1952
ENGINE ELECTRICAL DEVICES...1953
PRECAUTIONS...1953
PRECAUTIONS FOR ENGINE ELECTRICAL DEVICE...1953
COMPONENT LOCATION...1953
ENGINE ELECTRICAL COMPONENTS LOCATION...1953
DIAGNOSTIC INFORMATION AND PROCEDURES...1953
ENGINE SYMPTOM DIAGNOSIS...1953
REPAIR INSTRUCTIONS...1953
ECM REMOVAL AND INSTALLATION...1953
CKP SENSOR INSPECTION...1953
CKP SENSOR REMOVAL AND INSTALLATION...1953
IAP SENSOR INSPECTION...1953
IAP SENSOR REMOVAL AND INSTALLATION...1954
TP SENSOR INSPECTION...1954
TP SENSOR REMOVAL AND INSTALLATION...1954
TP SENSOR ADJUSTMENT...1955
IAT SENSOR INSPECTION...1955
IAT SENSOR REMOVAL AND INSTALLATION...1955
ECT SENSOR REMOVAL AND INSTALLATION...1956
ECT SENSOR INSPECTION...1956
TO SENSOR INSPECTION...1957
TO SENSOR REMOVAL AND INSTALLATION...1957
ISC VALVE INSPECTION...1957
ISC VALVE REMOVAL AND INSTALLATION...1957
GP SWITCH INSPECTION...1958
GP SWITCH REMOVAL AND INSTALLATION...1958
SPECIFICATIONS...1958
SERVICE DATA...1958
TIGHTENING TORQUE SPECIFICATIONS...1958
SPECIAL TOOLS AND EQUIPMENT...1959
RECOMMENDED SERVICE MATERIAL...1959
SPECIAL TOOL...1959
ENGINE MECHANICAL...1960
SCHEMATIC AND ROUTING DIAGRAM...1960
THROTTLE CABLE ROUTING DIAGRAM...1960
DIAGNOSTIC INFORMATION AND PROCEDURES...1961
ENGINE MECHANICAL SYMPTOM DIAGNOSIS...1961
COMPRESSION PRESSURE CHECK...1961
REPAIR INSTRUCTIONS...1962
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE...1962
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION...1964
AIR CLEANER ELEMENT INSPECTION AND CLEANING...1964
AIR CLEANER BOX REMOVAL AND INSTALLATION...1964
THROTTLE CABLE REMOVAL AND INSTALLATION...1965
THROTTLE CABLE INSPECTION...1965
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...1965
THROTTLE BODY COMPONENTS...1966
THROTTLE BODY CONSTRUCTION...1967
THROTTLE BODY REMOVAL AND INSTALLATION...1968
THROTTLE BODY DISASSEMBLY AND ASSEMBLY...1969
THROTTLE BODY INSPECTION AND CLEANING...1972
ENGINE ASSEMBLY REMOVAL...1972
ENGINE ASSEMBLY INSTALLATION...1975
ENGINE TOP SIDE DISASSEMBLY...1976
ENGINE TOP SIDE ASSEMBLY...1980
VALVE CLEARANCE INSPECTION AND ADJUSTMENT...1986
CAMSHAFT INSPECTION...1987
CAMSHAFT SPROCKET INSPECTION...1989
CAM CHAIN TENSION ADJUSTER INSPECTION...1989
CAM CHAIN GUIDE REMOVAL AND INSTALLATION...1989
CAM CHAIN GUIDE INSPECTION...1989
CAM CHAIN TENSIONER INSPECTION...1990
CYLINDER HEAD DISASSEMBLY AND ASSEMBLY...1990
CYLINDER HEAD RELATED PARTS INSPECTION...1994
VALVE GUIDE REPLACEMENT...1997
VALVE SEAT REPAIR...1999
CAM DRIVE IDLE GEAR / SPROCKET THRUST CLEARANCE INSPECTION AND ADJUSTMENT...1999
CYLINDER DISASSEMBLY AND ASSEMBLY...2000
CYLINDER INSPECTION...2000
PISTON RING REMOVAL AND INSTALLATION...2001
PISTON AND PISTON RING INSPECTION...2002
ENGINE BOTTOM SIDE DISASSEMBLY...2004
ENGINE BOTTOM SIDE ASSEMBLY...2010
CONROD AND CRANKSHAFT INSPECTION...2018
WIDTH BETWEEN CRANKSHAFT WEBS...2019
CRANKSHAFT OIL SEAL INSPECTION...2020
BEARING INSPECTION...2020
BEARING REMOVAL AND INSTALLATION...2020
SPECIFICATIONS...2025
SERVICE DATA...2025
TIGHTENING TORQUE SPECIFICATIONS...2027
SPECIAL TOOLS AND EQUIPMENT...2028
RECOMMENDED SERVICE MATERIAL...2028
SPECIAL TOOL...2028
ENGINE LUBRICATION SYSTEM...2032
PRECAUTIONS...2032
PRECAUTIONS FOR ENGINE OIL...2032
SCHEMATIC AND ROUTING DIAGRAM...2032
ENGINE LUBRICATION SYSTEM CHART DIAGRAM...2032
DIAGNOSTIC INFORMATION AND PROCEDURES...2033
ENGINE LUBRICATION SYMPTOM DIAGNOSIS...2033
OIL PRESSURE CHECK...2033
REPAIR INSTRUCTIONS...2034
ENGINE OIL AND FILTER REPLACEMENT...2034
ENGINE OIL LEVEL INSPECTION...2034
OIL SUMP FILTER REMOVAL AND INSTALLATION...2034
OIL SUMP FILTER INSPECTION AND CLEANING...2035
OIL JET REMOVAL AND INSTALLATION...2035
OIL JET INSPECTION...2036
OIL PUMP REMOVAL AND INSTALLATION...2036
OIL PUMP INSPECTION...2038
SPECIFICATIONS...2038
SERVICE DATA...2038
TIGHTENING TORQUE SPECIFICATIONS...2038
SPECIAL TOOLS AND EQUIPMENT...2039
RECOMMENDED SERVICE MATERIAL...2039
SPECIAL TOOL...2039
ENGINE COOLING SYSTEM...2040
PRECAUTIONS...2040
PRECAUTIONS FOR ENGINE COOLING SYSTEM...2040
PRECAUTIONS FOR ENGINE COOLANT...2040
GENERAL DESCRIPTION...2040
ENGINE COOLANT DESCRIPTION...2040
SCHEMATIC AND ROUTING DIAGRAM...2041
COOLING CIRCUIT DIAGRAM...2041
WATER HOSE ROUTING DIAGRAM...2042
DIAGNOSTIC INFORMATION AND PROCEDURES...2043
ENGINE COOLING SYMPTOM DIAGNOSIS...2043
REPAIR INSTRUCTIONS...2043
COOLING CIRCUIT INSPECTION...2043
RADIATOR CAP INSPECTION...2044
RADIATOR INSPECTION AND CLEANING...2044
COOLING FAN ASSEMBLY / RADIATOR REMOVAL AND INSTALLATION...2044
COOLING FAN INSPECTION...2046
RADIATOR RESERVOIR TANK REMOVAL AND INSTALLATION...2047
RADIATOR RESERVOIR TANK INSPECTION...2047
WATER HOSE INSPECTION...2047
ECT SENSOR REMOVAL AND INSTALLATION...2048
ECT SENSOR INSPECTION...2048
COOLING FAN THERMO-SWITCH REMOVAL AND INSTALLATION...2048
COOLING FAN THERMO-SWITCH INSPECTION...2049
THERMOSTAT REMOVAL AND INSTALLATION...2050
THERMOSTAT INSPECTION...2051
WATER PUMP COMPONENTS...2052
WATER PUMP REMOVAL AND INSTALLATION...2052
WATER PUMP DISASSEMBLY AND ASSEMBLY...2053
WATER PUMP RELATED PARTS INSPECTION...2057
SPECIFICATIONS...2058
SERVICE DATA...2058
TIGHTENING TORQUE SPECIFICATIONS...2058
SPECIAL TOOLS AND EQUIPMENT...2059
RECOMMENDED SERVICE MATERIAL...2059
SPECIAL TOOL...2059
FUEL SYSTEM...2060
PRECAUTIONS...2060
PRECAUTIONS FOR FUEL SYSTEM...2060
GENERAL DESCRIPTION...2061
FUEL SYSTEM DESCRIPTION...2061
SCHEMATIC AND ROUTING DIAGRAM...2062
FUEL HOSE ROUTING DIAGRAM...2062
FUEL TANK BREATHER HOSE ROUTING DIAGRAM...2063
DIAGNOSTIC INFORMATION AND PROCEDURES...2064
FUEL SYSTEM DIAGNOSIS...2064
REPAIR INSTRUCTIONS...2065
FUEL PRESSURE INSPECTION...2065
FUEL PUMP INSPECTION...2065
FUEL DISCHARGE AMOUNT INSPECTION...2066
FUEL PUMP RELAY INSPECTION...2066
FUEL HOSE INSPECTION...2067
FUEL FEED HOSE REMOVAL AND INSTALLATION...2067
FUEL LEVEL GAUGE INSPECTION...2067
FUEL LEVEL INDICATOR INSPECTION...2067
FUEL TANK REMOVAL AND INSTALLATION...2067
FUEL PUMP COMPONENTS...2068
FUEL PUMP ASSEMBLY REMOVAL AND INSTALLATION...2068
FUEL PUMP DISASSEMBLY AND ASSEMBLY...2069
FUEL MESH FILTER INSPECTION AND CLEANING...2069
FUEL INJECTOR INSPECTION AND CLEANING...2069
FUEL INJECTOR / FUEL DELIVERY PIPE REMOVAL AND INSTALLATION...2069
FUEL TANK PRESSURE CONTROL (FTPC) VALVE REMOVAL AND INSTALLATION...2071
FUEL TANK PRESSURE CONTROL (FTPC) VALVE INSPECTION...2072
SPECIFICATIONS...2072
SERVICE DATA...2072
TIGHTENING TORQUE SPECIFICATIONS...2073
SPECIAL TOOLS AND EQUIPMENT...2073
SPECIAL TOOL...2073
IGNITION SYSTEM...2074
GENERAL DESCRIPTION...2074
OVERRIDE SWITCH DESCRIPTION...2074
SCHEMATIC AND ROUTING DIAGRAM...2074
IGNITION SYSTEM DIAGRAM...2074
IGNITION SYSTEM COMPONENTS LOCATION...2074
DIAGNOSTIC INFORMATION AND PROCEDURES...2075
IGNITION SYSTEM SYMPTOM DIAGNOSIS...2075
NO SPARK OR POOR SPARK...2075
REPAIR INSTRUCTIONS...2076
SPARK PLUG CAP AND SPARK PLUG REMOVAL AND INSTALLATION...2076
SPARK PLUG INSPECTION AND CLEANING...2076
IGNITION COIL AND PLUG CAP INSPECTION...2076
CKP SENSOR INSPECTION...2078
CKP SENSOR REMOVAL AND INSTALLATION...2079
ENGINE STOP SWITCH INSPECTION...2079
IGNITION SWITCH INSPECTION...2079
IGNITION SWITCH REMOVAL AND INSTALLATION...2080
OVERRIDE SWITCH INSPECTION...2080
SPECIFICATIONS...2081
SERVICE DATA...2081
TIGHTENING TORQUE SPECIFICATIONS...2081
SPECIAL TOOLS AND EQUIPMENT...2081
SPECIAL TOOL...2081
STARTING SYSTEM...2082
SCHEMATIC AND ROUTING DIAGRAM...2082
STARTING SYSTEM DIAGRAM...2082
COMPONENT LOCATION...2082
STARTING SYSTEM COMPONENTS LOCATION...2082
DIAGNOSTIC INFORMATION AND PROCEDURES...2082
STARTING SYSTEM SYMPTOM DIAGNOSIS...2082
STARTER MOTOR WILL NOT RUN...2083
STARTER MOTOR RUNS BUT DOES NOT CRANK THE ENGINE...2083
ENGINE DOES NOT TURN THOUGH THE STARTER MOTOR RUNS...2083
REPAIR INSTRUCTIONS...2084
STARTER MOTOR COMPONENTS...2084
STARTER MOTOR REMOVAL AND INSTALLATION...2085
STARTER MOTOR DISASSEMBLY AND ASSEMBLY...2085
STARTER MOTOR INSPECTION...2086
STARTER RELAY REMOVAL AND INSTALLATION...2087
STARTER RELAY INSPECTION...2088
NEUTRAL RELAY REMOVAL AND INSTALLATION...2088
NEUTRAL RELAY INSPECTION...2089
NEUTRAL RELAY DIODE INSPECTION...2089
PARKING BRAKE RELAY REMOVAL AND INSTALLATION...2089
PARKING BRAKE RELAY INSPECTION...2090
PARKING BRAKE SWITCH INSPECTION...2090
GEAR POSITION SWITCH INSPECTION...2090
STARTER TORQUE LIMITER / STARTER CLUTCH REMOVAL AND INSTALLATION...2091
STARTER DRIVEN GEAR BEARING REMOVAL AND INSTALLATION...2093
STARTER RELATED PARTS INSPECTION...2093
STARTER BUTTON INSPECTION...2094
RECOIL STARTER COMPONENTS...2095
RECOIL STARTER ASSEMBLY REMOVAL AND INSTALLATION...2095
RECOIL STARTER DISASSEMBLY AND ASSEMBLY...2096
RECOIL STARTER INSPECTION...2098
SPECIFICATIONS...2099
SERVICE DATA...2099
TIGHTENING TORQUE SPECIFICATIONS...2099
SPECIAL TOOLS AND EQUIPMENT...2099
RECOMMENDED SERVICE MATERIAL...2099
SPECIAL TOOL...2100
CHARGING SYSTEM...2101
SCHEMATIC AND ROUTING DIAGRAM...2101
CHARGING SYSTEM DIAGRAM...2101
COMPONENT LOCATION...2101
CHARGING SYSTEM COMPONENTS LOCATION...2101
DIAGNOSTIC INFORMATION AND PROCEDURES...2101
CHARGING SYSTEM SYMPTOM DIAGNOSIS...2101
BATTERY RUNS DOWN QUICKLY...2102
REPAIR INSTRUCTIONS...2103
BATTERY CURRENT LEAKAGE INSPECTION...2103
REGULATED VOLTAGE INSPECTION...2103
GENERATOR INSPECTION...2103
GENERATOR REMOVAL AND INSTALLATION...2104
REGULATOR / RECTIFIER INSPECTION...2108
BATTERY COMPONENTS...2109
BATTERY CHARGING...2109
BATTERY REMOVAL AND INSTALLATION...2112
BATTERY VISUAL INSPECTION...2112
SPECIFICATIONS...2112
SERVICE DATA...2112
TIGHTENING TORQUE SPECIFICATIONS...2113
SPECIAL TOOLS AND EQUIPMENT...2113
RECOMMENDED SERVICE MATERIAL...2113
SPECIAL TOOL...2113
EXHAUST SYSTEM...2114
PRECAUTIONS...2114
PRECAUTIONS FOR EXHAUST SYSTEM...2114
REPAIR INSTRUCTIONS...2114
EXHAUST SYSTEM CONSTRUCTION...2114
EXHAUST PIPE / MUFFLER REMOVAL AND INSTALLATION...2115
EXHAUST SYSTEM INSPECTION...2116
SPARK ARRESTER INSPECTION...2116
SPECIFICATIONS...2117
TIGHTENING TORQUE SPECIFICATIONS...2117
02. SUSPENSION...2119
PRECAUTIONS...2120
PRECAUTIONS...2120
PRECAUTIONS FOR SUSPENSION...2120
SUSPENSION GENERAL DIAGNOSIS...2121
DIAGNOSTIC INFORMATION AND PROCEDURES...2121
SUSPENSION AND WHEEL SYMPTOM DIAGNOSIS...2121
FRONT SUSPENSION...2122
REPAIR INSTRUCTIONS...2122
FRONT SUSPENSION COMPONENTS...2122
FRONT SUSPENSION ASSEMBLY CONSTRUCTION...2123
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATION...2124
FRONT SUSPENSION INSPECTION...2124
FRONT SHOCK ABSORBER INSPECTION...2124
SPRING PRE-LOAD ADJUSTMENT...2125
FRONT WHEEL HUB / STEERING KNUCKLE REMOVAL AND INSTALLATION...2125
FRONT HUB BEARING INSPECTION...2128
FRONT HUB BEARING REMOVAL AND INSTALLATION...2128
FRONT SUSPENSION UPPER / LOWER ARM REMOVAL AND INSTALLATION...2130
STEERING KNUCKLE END INSPECTION...2131
STEERING KNUCKLE END REMOVAL AND INSTALLATION...2132
FRONT SUSPENSION ARM RELATED PARTS INSPECTION...2133
FRONT SUSPENSION UPPER ARM BUSHING AND INNER DUST SEAL REMOVAL AND INSTALLATION...2134
FRONT SUSPENSION LOWER ARM BUSHING REMOVAL AND INSTALLATION...2135
SPECIFICATIONS...2136
SERVICE DATA...2136
TIGHTENING TORQUE SPECIFICATIONS...2136
SPECIAL TOOLS AND EQUIPMENT...2136
RECOMMENDED SERVICE MATERIAL...2136
SPECIAL TOOL...2137
REAR SUSPENSION...2138
REPAIR INSTRUCTIONS...2138
REAR SUSPENSION COMPONENTS...2138
REAR SUSPENSION ASSEMBLY CONSTRUCTION...2139
REAR SHOCK ABSORBER REMOVAL AND INSTALLATION...2140
REAR SUSPENSION INSPECTION...2141
REAR SHOCK ABSORBER INSPECTION...2141
SPRING PRE-LOAD ADJUSTMENT...2141
REAR WHEEL HUB / SUSPENSION KNUCKLE REMOVAL AND INSTALLATION...2141
REAR HUB BEARING INSPECTION...2143
REAR HUB BEARING REMOVAL AND INSTALLATION...2143
REAR SUSPENSION ARM UPPER / LOWER REMOVAL AND INSTALLATION...2145
REAR SUSPENSION ARM RELATED PARTS INSPECTION...2146
REAR SUSPENSION UPPER ARM BUSHING REMOVAL AND INSTALLATION...2148
REAR SUSPENSION LOWER ARM BUSHING REMOVAL AND INSTALLATION...2149
REAR SUSPENSION KNUCKLE BUSHING REMOVAL AND INSTALLATION...2150
REAR STABILIZER REMOVAL AND INSTALLATION...2151
STABILIZER PARTS INSPECTION...2152
SPECIFICATIONS...2153
SERVICE DATA...2153
TIGHTENING TORQUE SPECIFICATIONS...2153
SPECIAL TOOLS AND EQUIPMENT...2153
RECOMMENDED SERVICE MATERIAL...2153
SPECIAL TOOL...2154
WHEELS AND TIRES...2155
PRECAUTIONS...2155
PRECAUTIONS FOR WHEEL AND TIRE...2155
REPAIR INSTRUCTIONS...2155
FRONT AND REAR WHEEL COMPONENTS...2155
FRONT / REAR WHEEL REMOVAL AND INSTALLATION...2156
TIRE REMOVAL AND INSTALLATION...2156
SPECIFICATIONS...2158
SERVICE DATA...2158
TIGHTENING TORQUE SPECIFICATIONS...2158
03. DRIVELINE / AXLE...2159
PRECAUTIONS...2161
PRECAUTIONS...2161
PRECAUTIONS FOR DRIVELINE / AXLE...2161
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT...2162
DIAGNOSTIC INFORMATION AND PROCEDURES...2162
DRIVE SHAFT SYMPTOM DIAGNOSIS...2162
REPAIR INSTRUCTIONS...2162
FRONT DRIVE SHAFT COMPONENTS...2162
FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION...2163
FRONT DRIVE SHAFT DISASSEMBLY AND ASSEMBLY...2163
FRONT DRIVE SHAFT INSPECTION...2166
REAR DRIVE SHAFT COMPONENTS...2167
REAR DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION...2167
REAR DRIVE SHAFT DISASSEMBLY AND ASSEMBLY...2168
REAR DRIVE SHAFT INSPECTION...2168
SPECIAL TOOLS AND EQUIPMENT...2168
RECOMMENDED SERVICE MATERIAL...2168
SPECIAL TOOL...2168
DIFFERENTIAL...2169
DIAGNOSTIC INFORMATION AND PROCEDURES...2169
DRIVE TRAIN SYMPTOM DIAGNOSIS...2169
DTC “C20” (P1752) DIFF-LOCK RELAY CIRCUIT MALFUNCTION...2169
REPAIR INSTRUCTIONS...2170
FRONT DRIVE (DIFFERENTIAL) COMPONENTS...2170
FRONT DRIVE (DIFFERENTIAL) CONSTRUCTION...2171
FRONT DRIVE (DIFFERENTIAL) GEAR OIL LEVEL INSPECTION...2172
FRONT DRIVE (DIFFERENTIAL) GEAR OIL REPLACEMENT...2172
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY REMOVAL AND INSTALLATION...2172
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY DISASSEMBLY AND ASSEMBLY...2173
FRONT DRIVE (DIFFERENTIAL) RELATED PARTS INSPECTION...2180
BREATHER RUBBER CASE INSPECTION...2182
FRONT DRIVE (DIFFERENTIAL) GEAR SHIM INSPECTION AND SELECTION...2182
2WD/4WD/DIFF-LOCK SYSTEM INSPECTION...2185
REAR DRIVE BREATHER HOSE ROUTING DIAGRAM...2188
FINAL GEAR COMPONENTS...2189
FINAL GEAR CONSTRUCTION...2190
FINAL GEAR OIL LEVEL INSPECTION...2191
FINAL GEAR OIL REPLACEMENT...2191
FINAL GEAR ASSEMBLY REMOVAL AND INSTALLATION...2191
FINAL GEAR ASSEMBLY DISASSEMBLY AND ASSEMBLY...2192
FINAL GEAR RELATED PARTS INSPECTION...2198
FINAL GEAR SHIM INSPECTION AND SELECTION...2199
SPECIFICATIONS...2202
SERVICE DATA...2202
TIGHTENING TORQUE SPECIFICATIONS...2202
SPECIAL TOOLS AND EQUIPMENT...2203
RECOMMENDED SERVICE MATERIAL...2203
SPECIAL TOOL...2203
TRANSFER...2205
DIAGNOSTIC INFORMATION AND PROCEDURES...2205
TRANSFER SYMPTOM DIAGNOSIS...2205
REPAIR INSTRUCTIONS...2206
TRANSFER COMPONENTS...2206
TRANSFER REMOVAL AND INSTALLATION...2207
TRANSFER CONSTRUCTION...2210
COUNTER SHAFT / REVERSE IDLE GEAR DISASSEMBLY AND ASSEMBLY...2210
GEARSHIFT CAM COMPONENTS...2213
GEARSHIFT SYSTEM CONSTRUCTION...2214
GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY...2215
TRANSFER GEAR BEARING REMOVAL AND INSTALLATION...2216
TRANSFER GEAR BEARING INSPECTION...2216
TRANSFER RELATED PARTS INSPECTION...2216
TRANSFER RELATED BEARING INSPECTION...2217
GEAR POSITION (GP) SWITCH INSPECTION...2217
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION...2217
GEARSHIFT SHAFT NO. 2 / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION...2218
GEARSHIFT LINKAGE INSPECTION...2221
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION...2221
SPECIFICATIONS...2222
SERVICE DATA...2222
SPECIAL TOOLS AND EQUIPMENT...2222
RECOMMENDED SERVICE MATERIAL...2222
SPECIAL TOOL...2222
PROPELLER SHAFTS...2223
REPAIR INSTRUCTIONS...2223
FRONT OUTPUT SHAFT COMPONENTS...2223
FRONT OUTPUT SHAFT REMOVAL AND INSTALLATION...2223
FRONT OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY...2224
FRONT OUTPUT SHAFT RELATED PARTS INSPECTION...2227
REAR OUTPUT SHAFT COMPONENTS...2228
REAR OUTPUT SHAFT REMOVAL AND INSTALLATION...2228
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY...2230
REAR OUTPUT SHAFT RELATED PARTS INSPECTION...2232
REAR OUTPUT SHAFT DRIVE BEVEL GEAR SHIM INSPECTION AND ADJUSTMENT...2233
FRONT PROPELLER SHAFT COMPONENTS...2236
FRONT PROPELLER SHAFT REMOVAL AND INSTALLATION...2236
FRONT PROPELLER SHAFT RELATED PARTS INSPECTION...2238
REAR PROPELLER SHAFT COMPONENTS...2239
REAR PROPELLER SHAFT REMOVAL AND INSTALLATION...2239
REAR PROPELLER SHAFT RELATED PARTS INSPECTION...2244
SPECIFICATIONS...2245
SERVICE DATA...2245
TIGHTENING TORQUE SPECIFICATIONS...2245
SPECIAL TOOLS AND EQUIPMENT...2245
RECOMMENDED SERVICE MATERIAL...2245
SPECIAL TOOL...2246
04. BRAKE...2247
PRECAUTIONS...2249
PRECAUTIONS...2249
PRECAUTIONS FOR BRAKE SYSTEM...2249
BRAKE FLUID INFORMATION...2249
BRAKE CONTROL SYSTEM AND DIAGNOSIS...2250
SCHEMATIC AND ROUTING DIAGRAM...2250
FRONT BRAKE HOSE ROUTING DIAGRAM...2250
REAR BLAKE CABLE ROUTING DIAGRAM...2251
DIAGNOSTIC INFORMATION AND PROCEDURES...2252
BRAKE SYMPTOM DIAGNOSIS...2252
REPAIR INSTRUCTIONS...2253
BRAKE PEDAL HEIGHT INSPECTION AND ADJUSTMENT...2253
FRONT BRAKE LIGHT SWITCH INSPECTION...2253
REAR BRAKE LIGHT SWITCH INSPECTION...2253
REAR BRAKE SWITCH INSPECTION AND ADJUSTMENT...2253
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION...2254
PARKING BRAKE LEVER SWITCH INSPECTION...2254
BRAKE FLUID LEVEL CHECK...2254
FRONT BRAKE HOSE INSPECTION...2254
AIR BLEEDING FROM FRONT BRAKE FLUID CIRCUIT...2254
BRAKE FLUID REPLACEMENT...2255
FRONT BRAKE HOSE REMOVAL AND INSTALLATION...2256
REAR BRAKE CABLE REMOVAL AND INSTALLATION...2257
FRONT BRAKE MASTER CYLINDER COMPONENTS...2258
FRONT BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION...2258
FRONT BRAKE MASTER CYLINDER / BRAKE LEVER DISASSEMBLY AND ASSEMBLY...2260
FRONT BRAKE MASTER CYLINDER PARTS INSPECTION...2261
REAR BRAKE PEDAL CONSTRUCTION...2262
REAR BRAKE PEDAL REMOVAL AND INSTALLATION...2263
SPECIFICATIONS...2264
SERVICE DATA...2264
TIGHTENING TORQUE SPECIFICATIONS...2264
SPECIAL TOOLS AND EQUIPMENT...2265
RECOMMENDED SERVICE MATERIAL...2265
SPECIAL TOOL...2265
FRONT BRAKES...2266
PRECAUTIONS...2266
PRECAUTIONS FOR FRONT BRAKES...2266
REPAIR INSTRUCTIONS...2266
FRONT BRAKE COMPONENTS...2266
FRONT BRAKE PAD INSPECTION...2267
FRONT BRAKE PAD REPLACEMENT...2267
FRONT BRAKE CALIPER REMOVAL AND INSTALLATION...2268
FRONT BRAKE CALIPER DISASSEMBLY AND ASSEMBLY...2269
FRONT BRAKE CALIPER PARTS INSPECTION...2271
FRONT BRAKE DISC REMOVAL AND INSTALLATION...2272
FRONT BRAKE DISC INSPECTION...2273
SPECIFICATIONS...2273
SERVICE DATA...2273
TIGHTENING TORQUE SPECIFICATIONS...2274
SPECIAL TOOLS AND EQUIPMENT...2274
RECOMMENDED SERVICE MATERIAL...2274
SPECIAL TOOL...2274
REAR BRAKES...2275
PRECAUTIONS...2275
PRECAUTIONS FOR REAR BRAKE...2275
REPAIR INSTRUCTIONS...2275
REAR BRAKE COMPONENTS...2275
REAR BRAKE FRICTION PLATE INSPECTION...2276
REAR BRAKE FRICTION PLATE REPLACEMENT...2276
REAR BRAKE ASSEMBLY REMOVAL AND INSTALLATION...2276
REAR BRAKE DISASSEMBLY AND ASSEMBLY...2277
REAR BRAKE PARTS INSPECTION...2281
SPECIFICATIONS...2283
SERVICE DATA...2283
TIGHTENING TORQUE SPECIFICATIONS...2283
SPECIAL TOOLS AND EQUIPMENT...2284
RECOMMENDED SERVICE MATERIAL...2284
SPECIAL TOOL...2284
PARKING BRAKE...2285
SCHEMATIC AND ROUTING DIAGRAM...2285
PARKING / REAR BRAKE CABLE ROUTING DIAGRAM...2285
REPAIR INSTRUCTIONS...2287
PARKING / REAR BRAKE INSPECTION AND ADJUSTMENT...2287
PARKING / REAR BRAKE CABLE REMOVAL AND INSTALLATION...2287
PARKING / REAR BRAKE LEVER COMPONENTS...2288
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATION...2288
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION...2288
PARKING / REAR BRAKE RELAY INSPECTION...2288
SPECIFICATIONS...2289
TIGHTENING TORQUE SPECIFICATIONS...2289
SPECIAL TOOLS AND EQUIPMENT...2289
RECOMMENDED SERVICE MATERIAL...2289
05. TRANSMISSION / TRANSAXLE...2291
PRECAUTIONS...2292
PRECAUTIONS...2292
PRECAUTIONS FOR TRANSMISSION / TRANSAXLE...2292
AUTOMATIC TRANSMISSION...2293
SCHEMATIC AND ROUTING DIAGRAM...2293
DRIVE TRAIN SYSTEM...2293
DIAGNOSTIC INFORMATION AND PROCEDURES...2294
AUTOMATIC TRANSMISSION SYMPTOM DIAGNOSIS...2294
REPAIR INSTRUCTIONS...2295
AUTOMATIC TRANSMISSION COMPONENTS...2295
V-BELT COOLING DUCT CONSTRUCTION...2296
V-BELT COOLING DUCT REMOVAL AND INSTALLATION...2297
CLUTCH ENGAGEMENT AND LOCK-UP SPEED INSPECTION...2297
V-BELT TYPE CONTINUOUSLY VARIABLE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION...2297
MOVABLE DRIVE FACE DISASSEMBLY AND ASSEMBLY...2301
MOVABLE DRIVEN FACE DISASSEMBLY AND ASSEMBLY...2303
DRIVE V-BELT INSPECTION...2306
MOVABLE / FIXED DRIVE FACE PARTS INSPECTION...2307
MOVABLE / FIXED DRIVEN FACE PARTS INSPECTION...2307
CLUTCH SHOE REMOVAL AND INSTALLATION...2308
CLUTCH HOUSING CASE DISASSEMBLY AND ASSEMBLY...2311
CLUTCH PARTS INSPECTION...2312
MOVABLE DRIVE FACE COVER DISASSEMBLY AND ASSEMBLY...2314
CLUTCH HOUSING COVER PARTS INSPECTION...2315
SHIFT LEVER ASSEMBLY COMPONENTS...2315
GEAR SHIFT KNOB REMOVAL AND INSTALLATION...2316
SHIFT LEVER ASSEMBLY REMOVAL AND INSTALLATION...2316
SHIFT LEVER DISASSEMBLY AND ASSEMBLY...2317
SHIFT ROD ADJUSTMENT...2317
SPECIFICATIONS...2318
SERVICE DATA...2318
TIGHTENING TORQUE SPECIFICATIONS...2319
SPECIAL TOOLS AND EQUIPMENT...2319
RECOMMENDED SERVICE MATERIAL...2319
SPECIAL TOOL...2320
06. STEERING...2321
PRECAUTIONS...2322
PRECAUTIONS...2322
PRECAUTIONS FOR STEERING...2322
STEERING GENERAL DIAGNOSIS...2323
DIAGNOSTIC INFORMATION AND PROCEDURES...2323
STEERING SYMPTOM DIAGNOSIS...2323
STEERING / HANDLEBAR...2324
REPAIR INSTRUCTIONS...2324
STEERING / HANDLEBARS COMPONENTS...2324
STEERING / HANDLEBARS ASSEMBLY CONSTRUCTION...2325
HANDLEBARS REMOVAL AND INSTALLATION...2326
HANDLEBARS INSPECTION...2328
STEERING SHAFT REMOVAL AND INSTALLATION...2329
TIE-ROD / TIE-ROD END REMOVAL AND INSTALLATION...2332
STEERING PARTS INSPECTION...2333
SPECIFICATIONS...2334
SERVICE DATA...2334
TIGHTENING TORQUE SPECIFICATIONS...2335
SPECIAL TOOLS AND EQUIPMENT...2335
RECOMMENDED SERVICE MATERIAL...2335
SPECIAL TOOL...2335
09. BODY AND ACCESSORIES...2337
PRECAUTIONS...2339
PRECAUTIONS...2339
PRECAUTIONS FOR ELECTRICAL SYSTEM...2339
COMPONENT LOCATION...2339
ELECTRICAL COMPONENTS LOCATION...2339
WIRING SYSTEMS...2340
SCHEMATIC AND ROUTING DIAGRAM...2340
WIRING DIAGRAM...2340
WIRING HARNESS ROUTING DIAGRAM...2343
SPECIFICATIONS...2345
SERVICE DATA...2345
LIGHTING SYSTEMS...2346
REPAIR INSTRUCTIONS...2346
HEADLIGHT COMPONENTS...2346
HEADLIGHT REMOVAL AND INSTALLATION...2346
HEADLIGHT BULB REPLACEMENT...2347
HEADLIGHT BEAM ADJUSTMENT...2347
AUXILIARY HEADLIGHT COMPONENTS...2348
AUXILIARY HEADLIGHT REMOVAL AND INSTALLATION...2348
AUXILIARY HEADLIGHT BULB REPLACEMENT...2349
AUXILIARY HEADLIGHT BEAM ADJUSTMENT...2350
REAR COMBINATION LIGHT COMPONENTS...2350
REAR COMBINATION LIGHT REMOVAL AND INSTALLATION...2351
REAR COMBINATION LIGHT BULB REPLACEMENT...2351
REVERSING LIGHT BULB REPLACEMENT (FOR P-17)...2352
REVERSING LIGHT RELAY INSPECTION (FOR P-17)...2352
DIMMER SWITCH INSPECTION...2352
SPECIFICATIONS...2353
SERVICE DATA...2353
SPECIAL TOOLS AND EQUIPMENT...2353
SPECIAL TOOL...2353
COMBINATION METER / FUEL METER / HORN...2354
GENERAL DESCRIPTION...2354
COMBINATION METER SYSTEM DESCRIPTION...2354
REPAIR INSTRUCTIONS...2355
COMBINATION METER COMPONENTS...2355
COMBINATION METER REMOVAL AND INSTALLATION...2356
COMBINATION METER DISASSEMBLY AND ASSEMBLY...2356
COMBINATION METER INSPECTION...2357
ENGINE COOLANT TEMPERATURE INDICATOR LIGHT INSPECTION...2357
ENGINE COOLANT TEMPERATURE REMOVAL AND INSTALLATION...2357
FUEL LEVEL INDICATOR INSPECTION...2358
FUEL LEVEL GAUGE INSPECTION...2359
SPEEDOMETER INSPECTION...2359
SPEED SENSOR REMOVAL AND INSTALLATION...2359
SPEED SENSOR INSPECTION...2360
IGNITION SWITCH INSPECTION...2360
IGNITION SWITCH REMOVAL AND INSTALLATION...2360
HORN INSPECTION (FOR P-17, 24)...2361
HORN REMOVAL AND INSTALLATION (FOR P-17, 24)...2361
SPECIFICATIONS...2361
SERVICE DATA...2361
TIGHTENING TORQUE SPECIFICATIONS...2361
SPECIAL TOOLS AND EQUIPMENT...2362
RECOMMENDED SERVICE MATERIAL...2362
SPECIAL TOOL...2362
EXTERIOR PARTS...2363
REPAIR INSTRUCTIONS...2363
EXTERIOR PARTS CONSTRUCTION...2363
REAR FENDER HEAT SHIELD CONSTRUCTION...2366
FUEL TANK LOWER COVER HEAT SHIELD INSTALLATION...2367
FASTENER REMOVAL AND INSTALLATION...2368
FRONT SIDE EXTERIOR PARTS REMOVAL AND INSTALLATION...2368
REAR SIDE EXTERIOR PARTS REMOVAL AND INSTALLATION...2371
SEAT REMOVAL AND INSTALLATION...2373
UNDER COVER COMPONENTS...2374
UNDER COVER REMOVAL AND INSTALLATION...2374
BODY STRUCTURE...2376
REPAIR INSTRUCTIONS...2376
BODY FRAME CONSTRUCTION...2376
FOOTREST CONSTRUCTION...2376
FOOTREST REMOVAL AND INSTALLATION...2377
CARRIER CONSTRUCTION...2378
FRONT CARRIER REMOVAL AND INSTALLATION...2379
REAR CARRIER REMOVAL AND INSTALLATION...2380
FRONT GRIP BAR CONSTRUCTION...2381
FRONT GRIP BAR REMOVAL AND INSTALLATION...2381
TRAILER TOWING CONSTRUCTION...2382
TRAILER TOWING REMOVAL AND INSTRUCTION...2382
SPECIFICATIONS...2383
TIGHTENING TORQUE SPECIFICATIONS...2383
SPECIAL TOOLS AND EQUIPMENT...2383
RECOMMENDED SERVICE MATERIAL...2383
10. LT-A750XK9 ('09-MODEL)...2384
SPECIFICATIONS...2385
11. LT-A750XPK9 ('09-MODEL)...2386
FOREWORD...2387
TABLE OF CONTENTS...2388
00. PRECAUTIONS...2390
PRECAUTIONS...2391
0. GENERAL INFORMATION...2392
GENERAL INFORMATION...2393
MAINTENANCE AND LUBRICATION...2398
SERVICE DATA...2402
01. ENGINE...2412
STARTING SYSTEM...2416
CHARGING SYSTEM...2421
03. DRIVELINE / AXLE...2424
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT...2426
04. BRAKE...2432
BRAKE CONTROL SYSTEM AND DIAGNOSIS...2434
06. STEERING...2440
PRECAUTIONS...2442
STEERING GENERAL DIAGNOSIS...2443
STEERING / HANDLEBAR...2444
POWER ASSISTED STEERING SYSTEM...2455
09. BODY AND ACCESSORIES...2510
WIRING SYSTEMS...2512
BODY STRUCTURE...2519
Suzuki LT-F250 (LT-F250K2, LT-F250K3, LT-F250K4, LT-F250K5, LT-F250K6, LT-F250K7, LT-F250K8, LT-F250K9) Service Manual 2002-2009...2520
FOREWORD...2520
HOW TO USE THIS MANUAL ...2523
TO LOCATE WHAT YOU ARE LOOKING FOR...2523
COMPONENT PARTS AND WORK TO BE DONE ...2523
SYMBOL ...2524
01 GENERAL INFORMATION...2526
WARNING/CAUTION/NOTE ...2527
GENERAL PRECAUTIONS ...2527
SUZUKI LT-F250K2 (2002-MODEL) ...2529
SERIAL NUMBER LOCATION ...2529
FUEL AND OIL RECOMMENDATION ...2529
FUEL...2529
ENGINE OIL...2530
REAR DRIVE GEAR OIL ...2530
BRAKE FLUID ...2530
BREAK-lN PROCEDURES...2530
INFORMATION LABELS ...2531
SPECIFICATIONS ...2532
COUNTRY AND AREA CODES ...2534
02 PERIODIC MAINTENANCE ...2536
PERIODIC MAINTENANCE SCHEDULE ...2537
PERIODIC MAINTENANCE CHART ...2537
MAINTENANCE AND TUNE-UP PROCEDURES ...2538
AIR CLEANER ...2538
EXHAUST PIPE NUTS AND MUFFLER BOLTS ...2539
VALVE CLEARANCE ...2540
SPARK PLUG ...2541
FUEL HOSE ...2542
THROTTLE CABLE PLAY ...2543
ENGINE IDLE SPEED ...2543
ENGINE OIL AND OIL FILTER ...2543
FINAL BEVEL GEAR OIL ...2545
SPARK ARRESTER ...2546
CLUTCH ...2546
BRAKES ...2547
BRAKE FLUID ...2548
BRAKE HOSE ...2550
TIRES ...2550
STEERING ...2551
SUSPENSIONS ...2552
CHASSIS BOLTS AND NUTS ...2553
GENERAL LUBRICATION ...2556
COMPRESSION PRESSURE CHECK ...2557
COMPRESSION TEST PROCEDURE ...2557
OIL PRESSURE CHECK ...2558
OIL PRESSURE TEST PROCEDURE ...2558
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION ...2559
INITIAL ENGAGEMENT INSPECTION ...2559
CLUTCH LOCK-UP INSPECTION ...2559
03 ENGINE ...2560
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...2561
ENGINE LEFT SIDE ...2561
ENGINE RIGHT SIDE ...2561
ENGINE CENTER ...2561
ENGINE REMOVAL AND INSTALLATION ...2562
ENGINE REMOVAL ...2562
ENGINE INSTALLATION ...2567
ENGINE DISASSEMBLY ...2571
ENGINE TOP SIDE ...2571
ENGINE BOTTOM SIDE ...2574
ENGINE COMPONENTS INSPECTION AND SERVICING ...2583
CYLINDER HEAD COVER ...2583
CYLINDER HEAD ...2584
CAMSHAFT ...2592
CAM CHAIN TENSION ADJUSTER ...2593
CYLINDER ...2594
PISTON ...2594
CONROD/CRANKSHAFT ...2597
CLUTCH ...2598
TRANSMISSION ...2601
GEARSHIFT FORK ...2604
GENERATOR COVER ...2605
CLUTCH COVER ...2606
CRANKCASE...2607
CRANKSHAFT ...2609
RECOIL STARTER ...2610
DRIVE TRAIN ...2613
SECONDARY GEAR SHIMS ADJUSTMENT ...2617
REASSEMBLY INFORMATION ...2619
ENGINE REASSEMBLY ...2620
ENGINE BOTTOM SIDE ...2620
ENGINE TOP SIDE ...2632
04 DRIVE TRAIN...2640
REAR DRIVING SYSTEM ...2641
REAR DRIVE REMOVAL ...2642
REAR DRIVE DISASSEMBLY ...2644
REAR DRIVE INSPECTION ...2648
REAR DRIVE REASSEMBLY ...2650
REAR DRIVE INSTALLATION ...2655
SHIM ADJUSTMENT ...2657
REASSEMBLY INFORMATION ...2660
05 FUEL SYSTEM ...2662
FUEL TANK ...2663
CONSTRUCTION ...2663
FUEL LINE INSPECTION ...2664
REMOUNTING ...2664
FUEL VALVE ...2665
REMOVAL AND INSPECTION ...2665
FUEL STRAINER ...2665
REMOUNTING ...2665
CARBURETOR ...2666
CONSTRUCTION ...2666
SPECIFICATIONS ...2667
I.D. NO. LOCATION ...2667
REMOVAL ...2668
DISASSEMBLY ...2669
CLEANING ...2673
INSPECTION ...2674
REASSEMBLY ...2675
REMOUNTING ...2677
06 LUBRICATION SYSTEM...2678
LUBRICATION SYSTEM ...2679
ENGINE LUBRICATION CIRCUIT ...2679
ENGINE LUBRICATION FLOW CHART ...2681
OIL PRESSURE ...2682
OIL FILTER ...2682
OIL STRAINER ...2682
OIL PUMP ...2682
07 CHASSIS ...2684
EXTERIOR PARTS ...2685
CONSTRUCTION ...2685
REMOVAL ...2687
REMOUNTING ...2692
FRONT AND REAR WHEELS ...2693
CONSTRUCTION ...2693
REMOVAL ...2693
INSPECTION AND DISASSEMBLY ...2694
REMOUNTING AND REMOUNTING ...2695
TIRES ...2698
TIRE REPLACEMENT ...2698
FRONT BRAKE ...2700
CONSTRUCTION ...2700
BRAKE PAD REPLACEMENT ...2701
BRAKE FLUID REPLACEMENT ...2702
BRAKE CALIPER REMOVAL AND DISASSEMBLY ...2702
BRAKE CALIPER INSPECTION ...2704
BRAKE CALIPER REASSEMBLY AND REMOUNTING ...2705
BRAKE DISC REMOVAL AND DISASSEMBLY ...2707
BRAKE DISC INSPECTION ...2707
BRAKE DISC REASSEMBLY AND REMOUNTING ...2707
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...2708
MASTER CYLINDER INSPECTION ...2709
MASTER CYLINDER REASSEMBLY AND REMOUNTING ...2709
FRONT SUSPENSION ...2711
CONSTRUCTION ...2711
REMOVAL AND DISASSEMBLY ...2712
INSPECTION ...2713
REASSEMBLY AND REMOUNTING ...2715
STEERING ...2718
CONSTRUCTION ...2718
REMOVAL ...2719
INSPECTION AND DISASSEMBLY ...2721
REASSEMBLY AND REMOUNTING ...2723
TOE-IN ADJUSTMENT ...2726
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION ...2727
REAR BRAKE ...2728
CONSTRUCTION ...2728
REMOVAL AND DISASSEMBLY ...2729
INSPECTION ...2731
REASSEMBLY AND REMOUNTING ...2732
REAR SUSPENSION ...2736
CONSTRUCTION ...2736
REMOVAL ...2737
INSPECTION AND DISASSEMBLY ...2737
REASSEMBLY AND REMOUNTING ...2738
REAR AXLE ...2739
CONSTRUCTION ...2739
REMOVAL ...2740
INSPECTION ...2741
REASSEMBLY AND REMOUNTING ...2741
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION ...2743
REVERSE LOCK RELEASE CABLE ...2744
REMOVAL AND INSTALLATION ...2744
08 ELECTRICAL SYSTEM ...2746
CAUTIONS IN SERVICING ...2747
CONNECTORS ...2747
COUPLERS ...2747
CLAMPS ...2747
FUSES ...2747
SEMI-CONDUCTOR EQUIPPED PARTS ...2747
BATTERY ...2748
CONNECTING THE BATTERY ...2748
WIRING PROCEDURE ...2748
USING THE MULTI CIRCUIT TESTER ...2748
LOCATION OF ELECTRICAL COMPONENTS ...2749
CHARGING SYSTEM ...2751
TROUBLESHOOTING ...2751
INSPECTION ...2753
STARTER SYSTEM ...2756
TROUBLESHOOTING ...2756
STARTER MOTOR REMOVAL AND DISASSEMBLY ...2757
STARTER MOTOR INSPECTION ...2758
STARTER MOTOR REASSEMBLY AND REMOUNTING ...2759
STARTER RELAY INSPECTION ...2760
NEUTRAL RELAY INSPECTION ...2761
PARKING BRAKE SWITCH ...2761
IGNITION SYSTEM ...2762
TROUBLESHOOTING ...2762
INSPECTION ...2764
LAMPS ...2767
HEADLIGHT ...2767
BRAKE LIGHT/TAILLIGHT ...2768
INDICATOR LIGHT ...2769
INSPECTION ...2769
INDICATOR LIGHT POSITION ...2769
DIODE ...2770
SWITCHES ...2771
BATTERY ...2772
SPECIFICATIONS ...2772
INITIAL CHARGING ...2772
SERVICING ...2774
RECHARGING OPERATION...2774
09 SERVICING INFORMATION ...2776
TROUBLESHOOTING ...2777
ENGINE ...2777
DRIVE TRAIN ...2780
CARBURETOR ...2780
CHASSIS ...2781
BRAKES ...2782
ELECTRICAL ...2783
BATTERY ...2784
WIRING DIAGRAM ...2785
WIRING HARNESS, CABLE, AND HOSE ROUTING ...2787
WIRING HARNESS ROUTING ...2787
CABLE ROUTING ...2789
FUEL HOSE ROUTING ...2791
CARBURETOR HOSE ROUTING ...2792
FRONT BRAKE HOSE ROUTING ...2793
REAR BRAKE BREATHER HOSE ROUTING ...2794
SPECIAL TOOLS ...2795
TIGHTENING TORQUE ...2798
ENGINE ...2798
DRIVE TRAIN ...2799
CHASSIS ...2799
TIGHTENING TORQUE CHART ...2800
SERVICE DATA ...2801
10 LT-F250K3 (’03-MODEL) ...2808
SPECIFICATIONS ...2809
SERVICE DATA ...2811
TIGHTENING TORQUE ...2818
CHASSIS ...2818
CLUTCH ...2819
11 LT-F250K4 (’04-MODEL) ...2820
SPECIFICATIONS ...2821
SERVICE DATA ...2823
TIGHTENING TORQUE ...2830
DRIVE TRAIN ...2830
CHASSIS ...2830
ENGINE ...2831
CLUTCH SLEEVE HUB NUT TIGHTENING TORQUE ...2832
REASSEMBLY ...2832
DRIVE TRAIN ...2833
UNIVERSAL JOINT ...2833
GEARSHIFT LINKAGE...2834
12 LT-F250K5 (’05-MODEL) ...2835
SPECIFICATIONS...2836
SERVICE DATA...2838
TIGHTENING TORQUE ...2845
FRONT BRAKE CALIPER MOUNTING BOLT...2845
WIRING DIAGRAM...2846
13 LT-F250K6 (’06-MODEL) ...2848
E-17, 24, 28, 33 ...2849
SPECIFICATIONS...2849
SERVICE DATA ...2850
E-04 ...2857
SPECIFICATIONS...2857
SERVICE DATA ...2858
SPEEDOMETER/ODOMETER GEAR ...2865
EXTERIOR PARTS ...2866
STEERING ...2868
LAMPS ...2869
SWITCHES ...2875
CABLE ROUTING ...2876
REGULATOR/RECTIFIER INSTALLATION ...2877
WIRING DIAGRAM ...2878
14 LT-F250K7 ('07-MODEL) ...2880
SPECIFICATIONS...2881
INFORMATION LABEL INSTALLATION (For E-33)...2883
FRONT BRAKE HOSE ROUTING...2884
15 LT-F250K8 ('08-MODEL) ...2886
INFORMATION LABELS ...2887
CAMSHAFT DRIVE CHAIN ...2887
16 LT-F250K9 ('09 MODEL) ...2888
SPECIFICATIONS...2889
SERVICE DATA...2890
FUEL...2891
CARBURETOR...2892
INFORMATION LABELS...2893
Suzuki LT-F300, LT-F300F KingQuad 300 (LT-F300X, LT-F300X, LT-F300Y, LT-F300FY, LT-F300K1, LT-F300FK1, LT-F300K2, LT-F300FK2) Service Manual '99-'02...2894
LT-F300/300F SERVICE MANUAL...2894
GROUP INDEX...2895
GENERAL INFORMATION...2898
PERIODIC MAINTENANCE...2907
ENGINE...2933
SHAFT DRIVE AND DIFFERENTIAL (LT-F300F)...3007
FUEL AND LUBRICATION SYSTEM...3041
CHASSIS...3059
ELECTRICAL SYSTEM...3122
SERVICING INFORMATION...3153
LT-F300Y/300FY (2000-MODEL)...3199
LT-F300K1/300FK1 ('01-MODEL)...3225
LT-F300FK2 ('02-MODEL)...3238
Suzuki LT-R450 Service Manual '06...3278
1 (General Info)...3278
2 (Periodic Maintenance)...3290
3 (Engine)...3328
4 (FI System Diagnosis)...3408
5 (Fuel System And Throttle Body)...3470
6 (Cooling and Lubrication System)...3488
7 (Chassis)...3514
8 (Electrical System)...3622
9 (Servicing Information)...3654
10 (Emission Control Information)...3700
11 (Wiring Diagram)...3704
Suzuki LT-Z250K4, LT-Z250K5, LT-Z250K6, LT-Z250K7, LT-Z90K8, LT-Z90K9 Service Manual '04-'09...3705
FOREWORD...3705
HOW TO USE THIS MANUAL...3708
TO LOCATE WHAT YOU ARE LOOKING FOR...3708
COMPONENT PARTS AND WORK TO BE DONE...3708
SYMBOL...3709
01 GENERAL INFORMATION...3711
WARNING/CAUTION/NOTE...3712
GENERAL PRECAUTIONS...3712
SUZUKI LT-Z250K4 (2004-MODEL)...3714
SERIAL NUMBER LOCATION...3714
FUEL AND OIL RECOMMENDATION...3714
FUEL (FOR CANADA AND USA)...3714
FUEL (FOR THE OTHER COUNTRIES)...3714
ENGINE OIL (FOR USA)...3715
ENGINE OIL (FOR THE OTHER COUNTRIES)...3715
REAR DRIVE GEAR OIL...3715
BRAKE FLUID...3715
BREAK-lN PROCEDURES...3715
INFORMATION LABELS...3716
SPECIFICATIONS...3717
DIMENSIONS AND DRY MASS...3717
ENGINE...3717
DRIVE TRAIN...3717
CHASSIS...3718
ELECTRICAL...3718
CAPACITIES...3718
COUNTRY AND AREA CODES...3719
02 PERIODIC MAINTENANCE...3721
PERIODIC MAINTENANCE SCHEDULE...3722
PERIODIC MAINTENANCE CHART...3722
MAINTENANCE AND TUNE-UP PROCEDURES...3723
AIR CLEANER...3723
EXHAUST PIPE NUTS AND MUFFLER BOLTS...3725
VALVE CLEARANCE...3725
SPARK PLUG...3727
FUEL LINE...3728
THROTTLE CABLE PLAY...3729
ENGINE IDLE SPEED...3729
ENGINE OIL AND OIL FILTER...3730
FINAL GEAR OIL...3731
SPARK ARRESTER...3732
CLUTCH...3733
BRAKES...3734
BRAKE FLUID...3735
BRAKE HOSE...3737
TIRES...3737
STEERING...3739
SUSPENSIONS...3739
CHASSIS BOLTS AND NUTS...3740
GENERAL LUBRICATION...3743
COMPRESSION PRESSURE CHECK...3744
COMPRESSION TEST PROCEDURE...3744
OIL PRESSURE CHECK...3745
OIL PRESSURE TEST PROCEDURE...3745
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION...3746
INITIAL ENGAGEMENT INSPECTION...3746
CLUTCH LOCK-UP INSPECTION...3746
03 ENGINE...3747
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE...3748
ENGINE REMOVAL AND INSTALLATION...3749
ENGINE REMOVAL...3749
ENGINE INSTALLATION...3754
ENGINE DISASSEMBLY...3758
ENGINE TOP SIDE...3758
ENGINE BOTTOM SIDE...3761
ENGINE COMPONENTS INSPECTION AND SERVICE...3769
CYLINDER HEAD COVER...3769
CYLINDER HEAD...3771
CAMSHAFT...3779
CAM CHAIN TENSION ADJUSTER...3780
CAM CHAIN TENSIONER AND CAM CHAIN GUIDE...3780
CYLINDER...3781
PISTON AND PISTON RING...3781
CONROD AND CRANKSHAFT...3784
CLUTCH...3785
TRANSMISSION...3788
GEARSHIFT FORK...3791
GENERATOR COVER...3791
CLUTCH COVER...3792
CRANKCASE...3793
CRANKSHAFT...3796
DRIVE TRAIN...3797
SECONDARY GEAR SHIMS ADJUSTMENT...3801
REASSEMBLY INFORMATION...3804
ENGINE REASSEMBLY...3805
ENGINE BOTTOM SIDE...3805
ENGINE TOP SIDE...3816
04 DRIVE TRAIN...3823
REAR DRIVING SYSTEM...3824
REAR DRIVE REMOVAL...3825
REAR DRIVE DISASSEMBLY...3826
REAR DRIVE INSPECTION...3831
REAR DRIVE REASSEMBLY...3833
REAR DRIVE INSTALLATION...3838
SHIM ADJUSTMENT...3840
REASSEMBLY INFORMATION...3843
05 FUEL SYSTEM...3845
FUEL TANK...3846
CONSTRUCTION...3846
FUEL LINE INSPECTION...3847
REMOVAL...3847
REMOUNTING...3847
FUEL VALVE...3848
REMOVAL AND INSPECTION...3848
FUEL STRAINER...3848
REMOUNTING...3848
CARBURETOR...3849
CONSTRUCTION...3849
SPECIFICATIONS...3850
I.D. NO. LOCATION...3850
REMOVAL...3851
DISASSEMBLY...3852
CLEANING...3856
INSPECTION...3856
REASSEMBLY...3857
REMOUNTING...3859
06 LUBRICATION SYSTEM...3861
LUBRICATION SYSTEM...3862
ENGINE LUBRICATION CIRCUIT...3862
ENGINE LUBRICATION FLOW CHART...3864
OIL PRESSURE...3865
OIL FILTER...3865
OIL STRAINER...3865
OIL PUMP...3865
07 CHASSIS ...3867
EXTERIOR PARTS...3869
CONSTRUCTION...3869
REMOVAL...3871
REMOUNTING...3874
FRONT AND REAR WHEELS...3876
CONSTRUCTION...3876
REMOVAL...3877
INSPECTION AND DISASSEMBLY...3878
REASSEMBLY AND REMOUNTING...3879
TIRES...3882
TIRE REPLACEMENT...3882
FRONT BRAKE...3884
CONSTRUCTION...3884
BRAKE PAD REPLACEMENT...3885
BRAKE FLUID REPLACEMENT...3885
BRAKE CALIPER REMOVAL AND DISASSEMBLY...3886
BRAKE CALIPER INSPECTION...3887
BRAKE CALIPER REASSEMBLY AND REMOUNTING...3889
BRAKE DISC REMOVAL AND DISASSEMBLY...3890
BRAKE DISC INSPECTION...3891
BRAKE DISC REASSEMBLY AND REMOUNTING...3891
MASTER CYLINDER REMOVAL AND DISASSEMBLY...3892
MASTER CYLINDER INSPECTION...3893
MASTER CYLINDER REASSEMBLY AND REMOUNTING...3893
FRONT SUSPENSION...3895
CONSTRUCTION...3895
REMOVAL AND DISASSEMBLY...3896
INSPECTION...3897
REASSEMBLY AND REMOUNTING...3899
SUSPENSION SETTING...3900
STEERING...3901
CONSTRUCTION...3901
REMOVAL...3902
INSPECTION AND DISASSEMBLY...3904
REASSEMBLY AND REMOUNTING...3906
TOE-IN ADJUSTMENT...3909
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION...3910
REAR BRAKE...3911
CONSTRUCTION...3911
REMOVAL AND DISASSEMBLY...3912
INSPECTION...3914
REASSEMBLY AND REMOUNTING...3915
REAR SHOCK ABSORBER...3919
CONSTRUCTION...3919
REMOVAL...3919
INSPECTION...3919
REASSEMBLY...3920
REMOUNTING...3920
SUSPENSION SETTING...3921
REAR SHOCK ABSORBER DISPOSAL...3921
REAR SUSPENSION...3922
CONSTRUCTION...3922
REMOVAL...3923
INSPECTION AND DISASSEMBLY...3923
REASSEMBLY...3924
REMOUNTING...3925
REAR AXLE...3926
CONSTRUCTION...3926
REMOVAL...3927
INSPECTION...3927
REASSEMBLY AND REMOUNTING...3928
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION...3929
REVERSE LOCK RELEASE CABLE...3930
REMOVAL...3930
REMOUNTING...3931
08 ELECTRICAL SYSTEM ...3933
CAUTIONS IN SERVICING...3934
CONNECTORS...3934
COUPLERS...3934
CLAMPS...3934
FUSES...3934
SEMI-CONDUCTOR EQUIPPED PARTS...3934
BATTERY...3935
CONNECTING THE BATTERY...3935
WIRING PROCEDURE...3935
USING THE MULTI CIRCUIT TESTER...3935
LOCATION OF ELECTRICAL COMPONENTS...3936
CHARGING SYSTEM...3938
TROUBLESHOOTING...3938
INSPECTION...3940
STARTER SYSTEM...3943
TROUBLESHOOTING...3943
STARTER MOTOR REMOVAL AND DISASSEMBLY...3945
STARTER MOTOR INSPECTION...3945
STARTER MOTOR REASSEMBLY AND REMOUNTING...3946
STARTER RELAY INSPECTION...3947
NEUTRAL RELAY INSPECTION...3948
PARKING BRAKE SWITCH...3948
IGNITION SYSTEM...3949
TROUBLESHOOTING...3949
INSPECTION...3951
LAMPS...3954
HEADLIGHT...3954
BRAKE LIGHT/TAILLIGHT...3955
INDICATOR LIGHT...3956
INSPECTION...3956
INDICATOR LIGHT POSITION...3956
DIODE...3957
SWITCHES...3958
BATTERY...3959
SPECIFICATIONS...3959
INITIAL CHARGING...3959
SERVICING...3961
RECHARGING OPERATION...3961
09 SERVICING INFORMATION...3963
TROUBLESHOOTING...3964
ENGINE...3964
DRIVE TRAIN...3967
CARBURETOR...3967
CHASSIS...3968
BRAKES...3969
ELECTRICAL...3970
BATTERY...3971
WIRING DIAGRAM...3972
WIRING HARNESS, CABLE, AND HOSE ROUTING...3973
WIRING HARNESS ROUTING...3973
CABLE ROUTING...3975
STEERING SHAFT SET-UP...3977
CARBURETOR HOSE ROUTING...3978
FRONT BRAKE HOSE ROUTING...3979
REAR BRAKE BREATHER HOSE ROUTING...3980
FUEL HOSE ROUTING...3981
REAR BRAKE CAM LEVER SET-UP...3982
STEERING HEAD COVER SET-UP...3983
TAILLIGHT SET-UP...3984
SPECIAL TOOLS...3985
TIGHTENING TORQUE...3988
ENGINE...3988
DRIVE TRAIN...3989
CHASSIS...3989
TIGHTENING TORQUE CHART...3990
SERVICE DATA...3991
10 LT-Z250K5 ('05-MODEL)...3999
SPECIFICATIONS...4000
SERVICE DATA...4001
TIGHTENING TORQUE...4008
FRONT BRAKE CALIPER MOUNTING BOLT...4008
FRONT BRAKE HOSE ROUTING...4009
11 LT-Z250K6 ('06-MODEL)...4011
SPECIFICATIONS...4012
SERVICE DATA...4013
12 LT-Z250K7 ('07-MODEL)...4020
INFORMATION LABEL INSTALLATION (For E-33)...4021
13 LT-Z250K8 ('08-MODEL)...4022
INFORMATION LABELS...4023
14 LT-Z250K9 (’09 MODEL)...4024
SPECIFICATIONS...4025
SERVICE DATA...4026
FUEL TANK CONSTRUCTION...4027
CARBURETOR...4028
INFORMATION LABELS...4029
Suzuki LT-Z400 Service Manual '09...4030
FOREWORD...4030
TABLE OF CONTENTS...4032
00 PRECAUTIONS...4034
PRECAUTIONS...4035
PRECAUTIONS...4035
WARNING / CAUTION / NOTE...4035
GENERAL PRECAUTIONS...4035
PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE...4036
0 GENERAL INFORMATION...4042
GENERAL INFORMATION...4043
GENERAL DESCRIPTION...4043
SYMBOLS...4043
ABBREVIATIONS...4044
SAE-TO-FORMER SUZUKI TERM...4044
VEHICLE SIDE VIEW...4045
VEHICLE IDENTIFICATION NUMBER...4045
FUEL AND OIL RECOMMENDATION...4045
ENGINE COOLANT RECOMMENDATION...4046
BREAK-IN PROCEDURES...4046
COUNTRY AND AREA CODES...4047
WIRE COLOR SYMBOLS...4047
WARNING, CAUTION AND INFORMATION LABELS LOCATION...4048
COMPONENT LOCATION...4049
ELECTRICAL COMPONENTS LOCATION...4049
SPECIFICATIONS...4051
SPECIFICATIONS...4051
SPECIAL TOOLS AND EQUIPMENT...4053
SPECIAL TOOL...4053
MAINTENANCE AND LUBRICATION...4056
PRECAUTIONS...4056
PRECAUTIONS FOR MAINTENANCE...4056
GENERAL DESCRIPTION...4056
RECOMMENDED FLUIDS AND LUBRICANTS...4056
SCHEDULED MAINTENANCE...4057
PERIODIC MAINTENANCE SCHEDULE CHART...4057
LUBRICATION POINTS...4058
REPAIR INSTRUCTIONS...4059
AIR CLEANER ELEMENT CLEANING...4059
EXHAUST PIPE NUTS AND MUFFLER BOLT INSPECTION...4059
VALVE CLEARANCE INSPECTION AND ADJUSTMENT...4060
SPARK PLUG REPLACEMENT...4064
SPARK PLUG INSPECTION AND CLEANING...4064
SPARK ARRESTER CLEANING...4065
ENGINE IDLE SPEED INSPECTION AND ADJUSTMENT...4065
THROTTLE BODY INSPECTION...4065
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...4065
FUEL LINE REPLACEMENT...4066
FUEL LINE INSPECTION...4066
ENGINE OIL AND FILTER REPLACEMENT...4066
ENGINE OIL HOSES INSPECTION...4068
CLUTCH INSPECTION AND ADJUSTMENT...4068
COOLING SYSTEM INSPECTION...4068
DRIVE CHAIN INSPECTION AND ADJUSTMENT...4070
BRAKE SYSTEM INSPECTION...4072
TIRE INSPECTION...4074
FRONT AND REAR WHEEL SET NUTS INSPECTION...4075
REAR AXLE NUT AND LOCK-NUT INSPECTION...4075
SUSPENSIONS INSPECTION...4077
STEERING SYSTEM INSPECTION...4077
CHASSIS BOLTS AND NUTS INSPECTION...4078
COMPRESSION PRESSURE CHECK...4080
OIL PRESSURE CHECK...4080
SDS CHECK...4080
SPECIFICATIONS...4081
TIGHTENING TORQUE SPECIFICATIONS...4081
SPECIAL TOOLS AND EQUIPMENT...4082
RECOMMENDED SERVICE MATERIAL...4082
SPECIAL TOOL...4082
SERVICE DATA...4083
SPECIFICATIONS...4083
SERVICE DATA...4083
TIGHTENING TORQUE SPECIFICATIONS...4088
01 ENGINE...4092
PRECAUTIONS...4096
PRECAUTIONS...4096
PRECAUTIONS FOR ENGINE...4096
ENGINE GENERAL INFORMATION AND DIAGNOSIS...4097
GENERAL DESCRIPTION...4097
INJECTION TIMING DESCRIPTION...4097
SCHEMATIC AND ROUTING DIAGRAM...4100
FI SYSTEM WIRING DIAGRAM...4100
TERMINAL ALIGNMENT OF ECM COUPLER...4101
COMPONENT LOCATION...4102
FI SYSTEM PARTS LOCATION...4102
DIAGNOSTIC INFORMATION AND PROCEDURES...4103
ENGINE SYMPTOM DIAGNOSIS...4103
SELF-DIAGNOSTIC PROCEDURES...4106
USE OF SDS DIAGNOSIS RESET PROCEDURES...4108
SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC)...4109
SDS CHECK...4111
DTC TABLE...4114
FAIL-SAFE FUNCTION TABLE...4115
FI SYSTEM TROUBLESHOOTING...4116
DTC “C12” (P0335): CKP SENSOR CIRCUIT MALFUNCTION...4119
DTC “C14” (P0120-H/L): TP SENSOR CIRCUIT MALFUNCTION...4122
DTC “C15” (P0115-H/L): ECT SENSOR CIRCUIT MALFUNCTION...4130
DTC “C21” (P0110-H/L): IAT SENSOR CIRCUIT MALFUNCTION...4143
DTC “C23” (P1651-H/L): TO SENSOR CIRCUIT MALFUNCTION...4148
DTC “C24” (P0351): IGNITION COIL CIRCUIT MALFUNCTION...4154
DTC “C31” (P0705): GP SWITCH CIRCUIT MALFUNCTION...4154
DTC “C32” (P0201): FUEL INJECTOR CIRCUIT MALFUNCTION...4156
DTC “C41” (P0230): FP RELAY CIRCUIT MALFUNCTION...4159
DTC “C60” (P0480): COOLING FAN RELAY CIRCUIT MALFUNCTION...4161
SPECIFICATIONS...4163
SERVICE DATA...4163
SPECIAL TOOLS AND EQUIPMENT...4164
SPECIAL TOOL...4164
EMISSION CONTROL DEVICES...4165
PRECAUTIONS...4165
PRECAUTIONS FOR EMISSION CONTROL DEVICES...4165
SCHEMATIC AND ROUTING DIAGRAM...4165
OIL RETURN TANK HOSE ROUTING DIAGRAM...4165
REPAIR INSTRUCTIONS...4165
CRANKCASE BREATHER (PCV) HOSE INSPECTION...4165
CRANKCASE BREATHER (PCV) HOSE REMOVAL AND INSTALLATION...4166
OIL RETURN TANK REMOVAL AND INSTALLATION...4166
OIL RETURN TANK INSPECTION...4166
ENGINE ELECTRICAL DEVICES...4167
PRECAUTIONS...4167
PRECAUTIONS FOR ENGINE ELECTRICAL DEVICE...4167
COMPONENT LOCATION...4167
ENGINE ELECTRICAL COMPONENTS LOCATION...4167
DIAGNOSTIC INFORMATION AND PROCEDURES...4167
ENGINE SYMPTOM DIAGNOSIS...4167
REPAIR INSTRUCTIONS...4168
ECM REMOVAL AND INSTALLATION...4168
CKP SENSOR INSPECTION...4168
CKP SENSOR REMOVAL AND INSTALLATION...4168
IAP SENSOR INSPECTION...4168
IAP SENSOR REMOVAL AND INSTALLATION...4168
TP SENSOR INSPECTION...4168
TP SENSOR REMOVAL AND INSTALLATION...4169
TP SENSOR ADJUSTMENT...4170
IAT SENSOR INSPECTION...4170
IAT SENSOR REMOVAL AND INSTALLATION...4171
ECT SENSOR REMOVAL AND INSTALLATION...4171
ECT SENSOR INSPECTION...4172
TO SENSOR INSPECTION...4172
TO SENSOR REMOVAL AND INSTALLATION...4172
SPECIFICATIONS...4173
SERVICE DATA...4173
TIGHTENING TORQUE SPECIFICATIONS...4173
SPECIAL TOOLS AND EQUIPMENT...4174
RECOMMENDED SERVICE MATERIAL...4174
SPECIAL TOOL...4174
ENGINE MECHANICAL...4175
DIAGNOSTIC INFORMATION AND PROCEDURES...4175
ENGINE MECHANICAL SYMPTOM DIAGNOSIS...4175
COMPRESSION PRESSURE CHECK...4175
REPAIR INSTRUCTIONS...4176
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE...4176
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION...4178
AIR CLEANER ELEMENT CLEANING...4178
AIR CLEANER BOX REMOVAL AND INSTALLATION...4178
THROTTLE CABLE REMOVAL AND INSTALLATION...4179
THROTTLE CABLE INSPECTION...4179
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT...4179
STARTER CABLE REMOVAL AND INSTALLATION...4180
THROTTLE BODY COMPONENTS...4181
THROTTLE BODY CONSTRUCTION...4182
THROTTLE BODY INSPECTION...4183
THROTTLE BODY REMOVAL AND INSTALLATION...4183
THROTTLE BODY DISASSEMBLY AND ASSEMBLY...4184
THROTTLE BODY INSPECTION AND CLEANING...4187
ENGINE ASSEMBLY REMOVAL...4187
ENGINE ASSEMBLY INSTALLATION...4190
ENGINE TOP SIDE DISASSEMBLY...4191
ENGINE TOP SIDE ASSEMBLY...4194
VALVE CLEARANCE INSPECTION AND ADJUSTMENT...4200
CAMSHAFT INSPECTION...4200
CAM CHAIN TENSION ADJUSTER INSPECTION...4202
CAM CHAIN GUIDE REMOVAL AND INSTALLATION...4202
CAM CHAIN GUIDE INSPECTION...4202
CAM CHAIN TENSIONER INSPECTION...4203
CYLINDER HEAD DISASSEMBLY AND ASSEMBLY...4203
CYLINDER HEAD RELATED PARTS INSPECTION...4207
VALVE GUIDE REPLACEMENT...4210
VALVE SEAT REPAIR...4211
CYLINDER INSPECTION...4212
PISTON RING REMOVAL AND INSTALLATION...4213
PISTON AND PISTON RING INSPECTION...4214
ENGINE BOTTOM SIDE DISASSEMBLY...4215
ENGINE BOTTOM SIDE ASSEMBLY...4222
OIL SUMP FILTER INSPECTION...4230
OIL PUMP INSPECTION...4230
GEARSHIFT SHAFT INSPECTION...4230
CONROD AND CRANKSHAFT INSPECTION...4230
BALANCER SHAFT INSPECTION...4231
CRANKSHAFT BEARING / BALANCER SHAFT BEARING INSPECTION...4231
CRANKSHAFT BEARING / BALANCER SHAFT BEARING REMOVAL AND INSTALLATION...4232
CRANKSHAFT OIL SEAL INSPECTION...4233
CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION...4233
CLUTCH RELEASE CAMSHAFT REMOVAL AND INSTALLATION...4233
SPECIFICATIONS...4234
SERVICE DATA...4234
TIGHTENING TORQUE SPECIFICATIONS...4235
SPECIAL TOOLS AND EQUIPMENT...4236
RECOMMENDED SERVICE MATERIAL...4236
SPECIAL TOOL...4236
ENGINE LUBRICATION SYSTEM...4240
PRECAUTIONS...4240
PRECAUTIONS FOR ENGINE OIL...4240
SCHEMATIC AND ROUTING DIAGRAM...4240
ENGINE OIL HOSE AND PIPE ROUTING DIAGRAM...4240
ENGINE LUBRICATION SYSTEM CHART DIAGRAM...4241
DIAGNOSTIC INFORMATION AND PROCEDURES...4242
ENGINE LUBRICATION SYMPTOM DIAGNOSIS...4242
OIL PRESSURE CHECK...4242
REPAIR INSTRUCTIONS...4243
ENGINE OIL AND FILTER REPLACEMENT...4243
ENGINE OIL LEVEL INSPECTION...4243
OIL SUMP FILTER REMOVAL AND INSTALLATION...4243
OIL SUMP FILTER INSPECTION AND CLEANING...4243
OIL PUMP COMPONENTS...4244
OIL PUMP REMOVAL AND INSTALLATION...4244
OIL PUMP INSPECTION...4245
ENGINE OIL HOSE AND PIPE CONSTRUCTION...4246
OIL TANK INSPECTION...4247
ENGINE OIL PIPE REMOVAL AND INSTALLATION...4247
OIL TANK REMOVAL AND INSTALLATION...4248
OIL PIPE REMOVAL AND INSTALLATION...4249
OIL PIPE INSPECTION...4250
SPECIFICATIONS...4250
SERVICE DATA...4250
TIGHTENING TORQUE SPECIFICATIONS...4250
SPECIAL TOOLS AND EQUIPMENT...4251
RECOMMENDED SERVICE MATERIAL...4251
SPECIAL TOOL...4251
ENGINE COOLING SYSTEM...4252
PRECAUTIONS...4252
PRECAUTIONS FOR ENGINE COOLING SYSTEM...4252
PRECAUTIONS FOR ENGINE COOLANT...4252
GENERAL DESCRIPTION...4253
ENGINE COOLANT DESCRIPTION...4253
SCHEMATIC AND ROUTING DIAGRAM...4253
COOLING CIRCUIT DIAGRAM...4253
WATER HOSE ROUTING DIAGRAM...4254
DIAGNOSTIC INFORMATION AND PROCEDURES...4255
ENGINE COOLING SYMPTOM DIAGNOSIS...4255
REPAIR INSTRUCTIONS...4255
COOLING CIRCUIT INSPECTION...4255
RADIATOR CAP INSPECTION...4256
RADIATOR INSPECTION AND CLEANING...4256
RADIATOR REMOVAL AND INSTALLATION...4256
COOLING FAN MOTOR REMOVAL AND INSTALLATION...4258
WATER HOSE INSPECTION...4259
RADIATOR COVER REMOVAL AND INSTALLATION...4259
WATER HOSE REMOVAL AND INSTALLATION...4259
RADIATOR RESERVOIR TANK INSPECTION...4260
RADIATOR RESERVOIR TANK REMOVAL AND INSTALLATION...4260
COOLING FAN INSPECTION...4260
COOLING FAN RELAY INSPECTION...4261
ECT SENSOR REMOVAL AND INSTALLATION...4261
ECT SENSOR INSPECTION...4261
ENGINE COOLANT TEMPERATURE INDICATOR INSPECTION...4261
THERMOSTAT REMOVAL AND INSTALLATION...4261
THERMOSTAT INSPECTION...4262
WATER PUMP COMPONENTS...4263
WATER PUMP REMOVAL AND INSTALLATION...4264
WATER PUMP DISASSEMBLY AND ASSEMBLY...4265
WATER PUMP RELATED PARTS INSPECTION...4267
SPECIFICATIONS...4268
SERVICE DATA...4268
TIGHTENING TORQUE SPECIFICATIONS...4268
SPECIAL TOOLS AND EQUIPMENT...4269
RECOMMENDED SERVICE MATERIAL...4269
SPECIAL TOOL...4269
FUEL SYSTEM...4270
PRECAUTIONS...4270
PRECAUTIONS FOR FUEL SYSTEM...4270
GENERAL DESCRIPTION...4271
FUEL SYSTEM DESCRIPTION...4271
SCHEMATIC AND ROUTING DIAGRAM...4272
FUEL HOSE ROUTING DIAGRAM...4272
DIAGNOSTIC INFORMATION AND PROCEDURES...4273
FUEL SYSTEM DIAGNOSIS...4273
REPAIR INSTRUCTIONS...4274
FUEL PRESSURE INSPECTION...4274
FUEL PUMP INSPECTION...4275
FUEL DISCHARGE AMOUNT INSPECTION...4275
FUEL PUMP RELAY INSPECTION...4276
FUEL HOSE INSPECTION...4276
FUEL LEVEL INDICATOR INSPECTION...4276
FUEL LEVEL INDICATOR SWITCH (THERMISTOR) INSPECTION...4276
FUEL LEVEL GAUGE REMOVAL AND INSTALLATION...4276
FUEL TANK CONSTRUCTION...4277
FUEL TANK REMOVAL AND INSTALLATION...4278
FUEL VALVE REMOVAL AND INSTALLATION...4279
FUEL FILTER INSPECTION AND CLEANING...4280
FUEL INJECTOR INSPECTION AND CLEANING...4280
FUEL INJECTOR / FUEL DELIVERY PIPE / L-JOINT REMOVAL AND INSTALLATION...4280
FUEL PUMP REMOVAL AND INSTALLATION...4282
SPECIFICATIONS...4283
SERVICE DATA...4283
TIGHTENING TORQUE SPECIFICATIONS...4283
SPECIAL TOOLS AND EQUIPMENT...4283
SPECIAL TOOL...4283
IGNITION SYSTEM...4284
SCHEMATIC AND ROUTING DIAGRAM...4284
IGNITION SYSTEM DIAGRAM...4284
IGNITION SYSTEM COMPONENTS LOCATION...4284
DIAGNOSTIC INFORMATION AND PROCEDURES...4285
IGNITION SYSTEM SYMPTOM DIAGNOSIS...4285
NO SPARK OR POOR SPARK...4286
REPAIR INSTRUCTIONS...4287
SPARK PLUG CAP AND SPARK PLUG REMOVAL AND INSTALLATION...4287
SPARK PLUG INSPECTION AND CLEANING...4287
IGNITION COIL AND PLUG CAP INSPECTION...4287
CKP SENSOR INSPECTION...4289
CKP SENSOR REMOVAL AND INSTALLATION...4290
ENGINE STOP SWITCH INSPECTION...4290
IGNITION SWITCH INSPECTION...4290
IGNITION SWITCH REMOVAL AND INSTALLATION...4290
SPECIFICATIONS...4291
SERVICE DATA...4291
TIGHTENING TORQUE SPECIFICATIONS...4291
SPECIAL TOOLS AND EQUIPMENT...4291
SPECIAL TOOL...4291
STARTING SYSTEM...4292
SCHEMATIC AND ROUTING DIAGRAM...4292
STARTING SYSTEM DIAGRAM...4292
COMPONENT LOCATION...4292
STARTING SYSTEM COMPONENTS LOCATION...4292
DIAGNOSTIC INFORMATION AND PROCEDURES...4292
STARTING SYSTEM SYMPTOM DIAGNOSIS...4292
STARTER MOTOR WILL NOT RUN...4293
STARTER MOTOR RUNS BUT DOES NOT CRANK THE ENGINE...4293
REPAIR INSTRUCTIONS...4294
STARTER MOTOR COMPONENTS...4294
STARTER MOTOR REMOVAL AND INSTALLATION...4295
STARTER MOTOR DISASSEMBLY AND ASSEMBLY...4295
STARTER MOTOR RELATED PARTS INSPECTION...4296
STARTER RELAY REMOVAL AND INSTALLATION...4297
STARTER RELAY INSPECTION...4298
GEAR POSITION (GP) SWITCH INSPECTION...4298
STARTER TORQUE LIMITER / STARTER CLUTCH REMOVAL AND INSTALLATION...4299
STARTER TORQUE LIMITER INSPECTION...4302
STARTER CLUTCH RELATED PARTS INSPECTION...4302
STARTER DRIVEN GEAR BEARING REMOVAL AND INSTALLATION...4303
STARTER BUTTON INSPECTION...4303
SPECIFICATIONS...4304
SERVICE DATA...4304
TIGHTENING TORQUE SPECIFICATIONS...4304
SPECIAL TOOLS AND EQUIPMENT...4305
RECOMMENDED SERVICE MATERIAL...4305
SPECIAL TOOL...4305
CHARGING SYSTEM...4306
SCHEMATIC AND ROUTING DIAGRAM...4306
CHARGING SYSTEM DIAGRAM...4306
COMPONENT LOCATION...4306
CHARGING SYSTEM COMPONENTS LOCATION...4306
DIAGNOSTIC INFORMATION AND PROCEDURES...4306
CHARGING SYSTEM SYMPTOM DIAGNOSIS...4306
BATTERY RUNS DOWN QUICKLY...4307
REPAIR INSTRUCTIONS...4308
BATTERY CURRENT LEAKAGE INSPECTION...4308
REGULATED VOLTAGE INSPECTION...4308
GENERATOR INSPECTION...4309
GENERATOR REMOVAL AND INSTALLATION...4310
REGULATOR / RECTIFIER INSPECTION...4313
BATTERY COMPONENTS...4314
BATTERY CHARGING...4314
BATTERY REMOVAL AND INSTALLATION...4317
BATTERY VISUAL INSPECTION...4317
SPECIFICATIONS...4318
SERVICE DATA...4318
TIGHTENING TORQUE SPECIFICATIONS...4318
SPECIAL TOOLS AND EQUIPMENT...4319
RECOMMENDED SERVICE MATERIAL...4319
SPECIAL TOOL...4319
EXHAUST SYSTEM...4320
PRECAUTIONS...4320
PRECAUTIONS FOR EXHAUST SYSTEM...4320
REPAIR INSTRUCTIONS...4321
EXHAUST SYSTEM CONSTRUCTION...4321
MUFFLER / EXHAUST PIPE REMOVAL AND INSTALLATION...4322
EXHAUST SYSTEM INSPECTION...4323
SPARK ARRESTER INSPECTION...4323
SPECIFICATIONS...4324
TIGHTENING TORQUE SPECIFICATIONS...4324
SPECIAL TOOLS AND EQUIPMENT...4324
RECOMMENDED SERVICE MATERIAL...4324
02 SUSPENSION...4326
PRECAUTIONS...4327
PRECAUTIONS...4327
PRECAUTIONS FOR SUSPENSION...4327
SUSPENSION GENERAL DIAGNOSIS...4328
DIAGNOSTIC INFORMATION AND PROCEDURES...4328
SUSPENSION AND WHEEL SYMPTOM DIAGNOSIS...4328
FRONT SUSPENSION...4329
REPAIR INSTRUCTIONS...4329
FRONT SUSPENSION COMPONENTS...4329
FRONT SUSPENSION / STEERING ASSEMBLY CONSTRUCTION...4330
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATION...4331
FRONT SUSPENSION INSPECTION...4331
FRONT SHOCK ABSORBER PARTS INSPECTION...4331
FRONT SUSPENSION ADJUSTMENT...4332
FRONT SHOCK ABSORBER DISPOSAL...4333
FRONT WHEEL HUB / STEERING KNUCKLE REMOVAL AND INSTALLATION...4334
FRONT WHEEL HUB PARTS INSPECTION...4336
STEERING KNUCKLE INSPECTION...4337
FRONT WHEEL HUB DUST SEAL / BEARING REMOVAL AND INSTALLATION...4337
FRONT SUSPENSION UPPER / LOWER WISHBONE ARM REMOVAL AND INSTALLATION...4338
KNUCKLE END BOOT INSPECTION...4340
KNUCKLE END REMOVAL AND INSTALLATION...4340
FRONT SUSPENSION WISHBONE ARM DUST SEAL / BEARING REMOVAL AND INSTALLATION...4341
FRONT SUSPENSION WISHBONE ARM RELATED PARTS INSPECTION...4342
SPECIFICATIONS...4344
SERVICE DATA...4344
TIGHTENING TORQUE SPECIFICATIONS...4344
SPECIAL TOOLS AND EQUIPMENT...4344
RECOMMENDED SERVICE MATERIAL...4344
SPECIAL TOOL...4345
REAR SUSPENSION...4346
REPAIR INSTRUCTIONS...4346
REAR SUSPENSION COMPONENTS...4346
REAR SUSPENSION ASSEMBLY CONSTRUCTION...4347
REAR SHOCK ABSORBER REMOVAL AND INSTALLATION...4348
REAR SUSPENSION INSPECTION...4349
REAR SHOCK ABSORBER INSPECTION...4349
REAR SUSPENSION ABSORBER ADJUSTMENT...4349
REAR SHOCK ABSORBER DISPOSAL...4350
REAR WHEEL HUB REMOVAL AND INSTALLATION...4351
REAR WHEEL HUB INSPECTION...4351
CUSHION ROD / CUSHION LEVER REMOVAL AND INSTALLATION...4352
CUSHION LEVER DUST SEAL / BEARING REMOVAL AND INSTALLATION...4353
CUSHION ROD DUST SEAL / BEARING REMOVAL AND INSTALLATION...4355
CUSHION LEVER / CUSHION ROD RELATED PARTS INSPECTION...4356
SWINGARM REMOVAL AND INSTALLATION...4357
SWINGARM DUST SEAL / BEARING REMOVAL AND INSTALLATION...4359
SWINGARM RELATED PARTS INSPECTION...4360
SPECIFICATIONS...4361
SERVICE DATA...4361
TIGHTENING TORQUE SPECIFICATIONS...4361
SPECIAL TOOLS AND EQUIPMENT...4362
RECOMMENDED SERVICE MATERIAL...4362
SPECIAL TOOL...4362
WHEELS AND TIRES...4363
PRECAUTIONS...4363
PRECAUTIONS FOR WHEEL AND TIRE...4363
REPAIR INSTRUCTIONS...4363
FRONT AND REAR WHEEL COMPONENTS...4363
FRONT / REAR WHEEL REMOVAL AND INSTALLATION...4364
TIRE REMOVAL AND INSTALLATION...4365
WHEEL / TIRE INSPECTION...4367
SPECIFICATIONS...4367
SERVICE DATA...4367
TIGHTENING TORQUE SPECIFICATIONS...4367
03 DRIVELINE / AXLE...4368
PRECAUTIONS...4369
PRECAUTIONS...4369
PRECAUTIONS FOR DRIVELINE / AXLE...4369
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT...4370
DIAGNOSTIC INFORMATION AND PROCEDURES...4370
DRIVE CHAIN AND SPROCKET SYMPTOM DIAGNOSIS...4370
REPAIR INSTRUCTIONS...4371
DRIVE CHAIN / REAR AXLE RELATED COMPONENTS...4371
REAR AXLE ASSEMBLY CONSTRUCTION...4372
ENGINE SPROCKET REMOVAL AND INSTALLATION...4373
REAR SPROCKET REMOVAL AND INSTALLATION...4374
REAR AXLE NUT AND LOCK-NUT TIGHTENING TORQUE...4376
DRIVE CHAIN RELATED PARTS INSPECTION...4377
DRIVE CHAIN REPLACEMENT...4377
DRIVE CHAIN ROLLER CONSTRUCTION...4380
DRIVE CHAIN ROLLER INSPECTION...4381
DRIVE CHAIN ROLLER REMOVAL AND INSTALLATION...4381
REAR AXLE HOUSING REMOVAL AND INSTALLATION...4381
REAR AXLE RELATED PARTS INSPECTION...4382
REAR AXLE DUST SEAL / BEARING REMOVAL AND INSTALLATION...4383
SPECIFICATIONS...4385
SERVICE DATA...4385
TIGHTENING TORQUE SPECIFICATIONS...4385
SPECIAL TOOLS AND EQUIPMENT...4386
RECOMMENDED SERVICE MATERIAL...4386
SPECIAL TOOL...4386
04 BRAKE...4388
PRECAUTIONS...4390
PRECAUTIONS...4390
PRECAUTIONS FOR BRAKE SYSTEM...4390
BRAKE FLUID INFORMATION...4390
BRAKE CONTROL SYSTEM AND DIAGNOSIS...4391
SCHEMATIC AND ROUTING DIAGRAM...4391
FRONT BRAKE HOSE ROUTING DIAGRAM...4391
REAR BRAKE HOSE ROUTING DIAGRAM...4392
HOSE AND CABLE ROUTING DIAGRAM...4393
DIAGNOSTIC INFORMATION AND PROCEDURES...4395
BRAKE SYMPTOM DIAGNOSIS...4395
REPAIR INSTRUCTIONS...4395
BRAKE PEDAL HEIGHT INSPECTION AND ADJUSTMENT...4395
FRONT BRAKE LIGHT SWITCH INSPECTION...4395
REAR BRAKE LIGHT SWITCH INSPECTION...4396
REAR BRAKE SWITCH INSPECTION AND ADJUSTMENT...4396
BRAKE FLUID LEVEL CHECK...4396
BRAKE HOSE INSPECTION...4396
AIR BLEEDING FROM BRAKE FLUID CIRCUIT...4396
BRAKE FLUID REPLACEMENT...4398
BRAKE HOSE REMOVAL AND INSTALLATION...4399
FRONT BRAKE MASTER CYLINDER COMPONENTS...4400
FRONT BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION...4401
FRONT BRAKE MASTER CYLINDER / BRAKE LEVER DISASSEMBLY AND ASSEMBLY...4402
FRONT BRAKE MASTER CYLINDER PARTS INSPECTION...4403
REAR BRAKE PEDAL CONSTRUCTION...4404
REAR BRAKE PEDAL REMOVAL AND INSTALLATION...4405
REAR BRAKE MASTER CYLINDER COMPONENTS...4406
REAR BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION...4407
REAR BRAKE MASTER CYLINDER DISASSEMBLY AND ASSEMBLY...4408
REAR BRAKE MASTER CYLINDER PARTS INSPECTION...4409
SPECIFICATIONS...4410
SERVICE DATA...4410
TIGHTENING TORQUE SPECIFICATIONS...4410
SPECIAL TOOLS AND EQUIPMENT...4411
RECOMMENDED SERVICE MATERIAL...4411
SPECIAL TOOL...4411
FRONT BRAKES...4412
REPAIR INSTRUCTIONS...4412
FRONT BRAKE COMPONENTS...4412
FRONT BRAKE PAD INSPECTION...4413
FRONT BRAKE PAD REPLACEMENT...4413
FRONT BRAKE CALIPER REMOVAL AND INSTALLATION...4414
FRONT BRAKE CALIPER DISASSEMBLY AND ASSEMBLY...4415
FRONT BRAKE CALIPER PARTS INSPECTION...4417
FRONT BRAKE DISC REMOVAL AND INSTALLATION...4419
FRONT BRAKE DISC INSPECTION...4419
FRONT BRAKE DISC COVER INSPECTION...4420
SPECIFICATIONS...4420
SERVICE DATA...4420
TIGHTENING TORQUE SPECIFICATIONS...4420
SPECIAL TOOLS AND EQUIPMENT...4421
RECOMMENDED SERVICE MATERIAL...4421
SPECIAL TOOL...4421
REAR BRAKES...4422
REPAIR INSTRUCTIONS...4422
REAR BRAKE COMPONENTS...4422
REAR BRAKE PAD INSPECTION...4423
REAR BRAKE PAD REPLACEMENT...4423
REAR BRAKE CALIPER REMOVAL AND INSTALLATION...4424
REAR BRAKE CALIPER DISASSEMBLY AND ASSEMBLY...4425
REAR BRAKE CALIPER PARTS INSPECTION...4428
REAR BRAKE DISC REMOVAL AND INSTALLATION...4429
REAR BRAKE DISC INSPECTION...4431
REAR BRAKE DISC PLATE HOUSING INSPECTION...4431
SPECIFICATIONS...4431
SERVICE DATA...4431
TIGHTENING TORQUE SPECIFICATIONS...4432
SPECIAL TOOLS AND EQUIPMENT...4432
RECOMMENDED SERVICE MATERIAL...4432
SPECIAL TOOL...4432
PARKING BRAKE...4433
REPAIR INSTRUCTIONS...4433
PARKING BRAKE INSPECTION AND ADJUSTMENT...4433
PARKING BRAKE CABLE REMOVAL AND INSTALLATION...4433
PARKING BRAKE COMPONENTS...4433
PARKING BRAKE LOCK / KNOB REMOVAL AND INSTALLATION...4434
PARKING BRAKE REMOVAL AND INSTALLATION...4434
PARKING BRAKE INSPECTION...4435
SPECIFICATIONS...4436
TIGHTENING TORQUE SPECIFICATIONS...4436
SPECIAL TOOLS AND EQUIPMENT...4436
RECOMMENDED SERVICE MATERIAL...4436
05 TRANSMISSION / TRANSAXLE...4438
PRECAUTIONS...4439
PRECAUTIONS...4439
PRECAUTIONS FOR TRANSMISSION / TRANSAXLE...4439
MANUAL TRANSMISSION...4440
DIAGNOSTIC INFORMATION AND PROCEDURES...4440
MANUAL TRANSMISSION SYMPTOM DIAGNOSIS...4440
REPAIR INSTRUCTIONS...4440
REVERSE LOCK CABLE PLAY INSPECTION AND ADJUSTMENT...4440
REVERSE LOCK CABLE REMOVAL AND INSTALLATION...4441
TRANSMISSION COMPONENTS...4443
TRANSMISSION REMOVAL AND INSTALLATION...4444
TRANSMISSION CONSTRUCTION...4446
COUNTERSHAFT GEAR / DRIVESHAFT GEAR / REVERSE IDLE GEAR DISASSEMBLY AND ASSEMBLY...4446
TRANSMISSION RELATED PARTS INSPECTION...4447
TRANSMISSION OIL SEAL / BEARING INSPECTION...4449
TRANSMISSION OIL SEAL / BEARING REMOVAL AND INSTALLATION...4449
GEAR POSITION (GP) SWITCH INSPECTION...4451
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION...4451
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE COMPONENTS...4453
GEARSHIFT CONSTRUCTION...4453
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION...4453
GEARSHIFT LINKAGE INSPECTION...4456
GEARSHIFT SHAFT OIL SEAL / BEARING REMOVAL AND INSTALLATION...4457
SPECIFICATIONS...4458
SERVICE DATA...4458
TIGHTENING TORQUE SPECIFICATIONS...4458
SPECIAL TOOLS AND EQUIPMENT...4459
RECOMMENDED SERVICE MATERIAL...4459
SPECIAL TOOL...4459
CLUTCH...4460
PRECAUTIONS...4460
PRECAUTIONS FOR CLUTCH SYSTEM...4460
DIAGNOSTIC INFORMATION AND PROCEDURES...4460
CLUTCH SYSTEM SYMPTOM DIAGNOSIS...4460
REPAIR INSTRUCTIONS...4460
CLUTCH LEVER POSITION SWITCH INSPECTION...4460
CLUTCH CABLE INSPECTION AND ADJUSTMENT...4461
CLUTCH CABLE REMOVAL AND INSTALLATION...4461
CLUTCH LEVER COMPONENTS...4462
CLUTCH LEVER REMOVAL AND INSTALLATION...4462
CLUTCH RELEASE CAMSHAFT REMOVAL AND INSTALLATION...4464
CLUTCH COMPONENTS...4465
CLUTCH REMOVAL...4466
CLUTCH INSTALLATION...4468
CLUTCH PARTS INSPECTION...4470
SPECIFICATIONS...4472
SERVICE DATA...4472
TIGHTENING TORQUE SPECIFICATIONS...4472
SPECIAL TOOLS AND EQUIPMENT...4473
RECOMMENDED SERVICE MATERIAL...4473
SPECIAL TOOL...4473
06 STEERING ...4474
PRECAUTIONS...4475
PRECAUTIONS...4475
PRECAUTIONS FOR STEERING...4475
STEERING GENERAL DIAGNOSIS...4476
DIAGNOSTIC INFORMATION AND PROCEDURES...4476
STEERING SYMPTOM DIAGNOSIS...4476
STEERING / HANDLEBAR...4477
REPAIR INSTRUCTIONS...4477
STEERING / HANDLEBARS COMPONENTS...4477
HANDLEBAR CONSTRUCTION...4478
HANDLEBARS REMOVAL AND INSTALLATION...4479
HANDLEBARS INSPECTION...4481
STEERING SHAFT / TIE-ROD REMOVAL AND INSTALLATION...4481
STEERING PARTS INSPECTION...4486
TOE-OUT ADJUSTMENT...4487
SPECIFICATIONS...4487
SERVICE DATA...4487
TIGHTENING TORQUE SPECIFICATIONS...4488
SPECIAL TOOLS AND EQUIPMENT...4488
RECOMMENDED SERVICE MATERIAL...4488
SPECIAL TOOL...4488
09 BODY AND ACCESSORIES...4490
PRECAUTIONS...4491
PRECAUTIONS...4491
PRECAUTIONS FOR ELECTRICAL SYSTEM...4491
COMPONENT LOCATION...4491
ELECTRICAL COMPONENTS LOCATION...4491
WIRING SYSTEMS...4492
SCHEMATIC AND ROUTING DIAGRAM...4492
WIRING DIAGRAM...4492
WIRING HARNESS ROUTING DIAGRAM...4494
SPECIFICATIONS...4497
SERVICE DATA...4497
TIGHTENING TORQUE SPECIFICATIONS...4497
LIGHTING SYSTEMS...4498
REPAIR INSTRUCTIONS...4498
HEADLIGHT COMPONENTS...4498
HEADLIGHT REMOVAL AND INSTALLATION...4499
HEADLIGHT BULB REPLACEMENT...4499
HEADLIGHT BEAM ADJUSTMENT...4500
REAR COMBINATION LIGHT COMPONENTS...4500
REAR COMBINATION LIGHT REMOVAL AND INSTALLATION...4501
REAR COMBINATION LIGHT BULB REPLACEMENT...4501
DIMMER SWITCH INSPECTION...4502
SPECIFICATIONS...4502
SERVICE DATA...4502
SPECIAL TOOLS AND EQUIPMENT...4502
SPECIAL TOOL...4502
COMBINATION METER / FUEL METER / HORN...4503
REPAIR INSTRUCTIONS...4503
INDICATOR LIGHT COMPONENTS...4503
INDICATOR LIGHT REMOVAL AND INSTALLATION...4503
INDICATOR LIGHT REPLACEMENT...4504
INDICATOR LIGHT INSPECTION...4504
FUEL LEVEL INDICATOR SWITCH (THERMISTOR) INSPECTION...4504
ENGINE COOLANT TEMPERATURE INDICATOR LIGHT INSPECTION...4505
ENGINE COOLANT TEMPERATURE REMOVAL AND INSTALLATION...4505
NEUTRAL INDICATOR SWITCH INSPECTION...4505
REVERSE INDICATOR SWITCH INSPECTION...4505
IGNITION SWITCH INSPECTION...4506
IGNITION SWITCH REMOVAL AND INSTALLATION...4506
SPECIFICATIONS...4506
SERVICE DATA...4506
SPECIAL TOOLS AND EQUIPMENT...4506
SPECIAL TOOL...4506
EXTERIOR PARTS...4507
REPAIR INSTRUCTIONS...4507
EXTERIOR PARTS CONSTRUCTION...4507
FUEL TANK COVER CUSHION INSTALLATION...4509
FASTENER REMOVAL AND INSTALLATION...4510
EXTERIOR PARTS REMOVAL AND INSTALLATION...4510
SPECIFICATIONS...4514
TIGHTENING TORQUE SPECIFICATIONS...4514
SPECIAL TOOLS AND EQUIPMENT...4514
RECOMMENDED SERVICE MATERIAL...4514
BODY STRUCTURE...4515
REPAIR INSTRUCTIONS...4515
BODY FRAME CONSTRUCTION...4515
FOOTREST REMOVAL AND INSTALLATION...4516
FRONT GRIP REMOVAL AND INSTALLATION...4516
REAR GRIP REMOVAL AND INSTALLATION...4516
SEAT RAIL REMOVAL AND INSTALLATION...4517
SPECIFICATIONS...4518
TIGHTENING TORQUE SPECIFICATIONS...4518
SPECIAL TOOLS AND EQUIPMENT...4518
RECOMMENDED SERVICE MATERIAL...4518
Suzuki LT-Z400K3 Parts Catalog...4522
Suzuki LT-Z400K3 Service Manual '03...4597
1GENERAL_INFO...4597
2PERIODIC_MAINTENANCE...4607
3ENGINE...4637
4FUEL_SYSTEM...4701
5COOLING___LUBRICATION...4715
6_1CHASSIS_UP_TO_6_58...4741
6_2CHASSIS_6_59_TO_6_93...4801
7ELECTRICAL_SYSTEM...4837
8SERVICING_INFO...4865
Suzuki LT-Z50K6, LT-Z50K7, LT-Z50K8, LT-Z50K9 Service Manual '06-'09...4899
FOREWORD ...4899
HOW TO USE THIS MANUAL ...4902
TO LOCATE WHAT YOU ARE LOOKING FOR...4902
COMPONENT PARTS AND WORK TO BE DONE ...4902
SYMBOL ...4903
01 GENERAL INFORMATION...4904
WARNING/CAUTION/NOTE...4905
GENERAL PRECAUTIONS...4905
SUZUKI LT-Z50K6 (’06-MODEL) ...4907
SERIAL NUMBER LOCATION ...4907
FUEL AND OIL RECOMMENDATION ...4908
FUEL (FOR USA AND CANADA) ...4908
FUEL (FOR OTHER COUNTRIES) ...4908
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR USA) ...4908
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR OTHER COUNTRIES) ...4908
BREAK-IN PROCEDURES ...4909
INFORMATION LABELS ...4910
INFORMATION MARKS ...4910
SPECIFICATIONS ...4911
DIMENSIONS AND DRY MASS ...4911
ENGINE ...4911
DRIVE TRAIN ...4911
CHASSIS ...4912
ELECTRICAL ...4912
CAPACITIES ...4912
02 PERIODIC MAINTENANCE...4914
PERIODIC MAINTENANCE SCHEDULE ...4915
PERIODIC MAINTENANCE CHART ...4915
MAINTENANCE AND TUNE-UP PROCEDURES ...4916
AIR CLEANER ...4916
EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT ...4918
VALVE CLEARANCE ...4918
SPARK PLUG ...4920
SPARK ARRESTER ...4921
FUEL LINE ...4921
ENGINE OIL ...4922
FINAL REDUCTION GEAR BOX OIL ...4923
THROTTLE CABLE PLAY ...4923
ENGINE IDLE SPEED...4924
DRIVE BELT ...4924
DRIVE CHAIN ...4927
BRAKES ...4930
TIRES...4931
STEERING ...4932
SUSPENSIONS ...4932
CHASSIS NUTS AND BOLTS ...4933
GENERAL LUBRICATIONS ...4935
COMPRESSION PRESSURE CHECK ...4936
COMPRESSION TEST PROCEDURE ...4936
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION ...4937
INITIAL ENGAGEMENT INSPECTION ...4937
CLUTCH LOCK-UP INSPECTION ...4938
03 ENGINE...4940
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...4941
ENGINE CENTER ...4941
ENGINE LEFT SIDE ...4941
ENGINE RIGHT SIDE...4941
ENGINE REMOVAL AND INSTALLATION ...4942
ENGINE REMOVAL ...4942
ENGINE INSTALLATION ...4945
POWER REDUCTION SPACER ...4947
ENGINE DISASSEMBLY ...4948
ENGINE COMPONENTS INSPECTION AND SERVICING ...4954
CYLINDER HEAD ...4954
ROCKER ARM PUSH ROD ...4959
CAMSHAFT ASSEMBLY ...4960
UPPER CRANKCASE/CYLINDER ...4960
PISTON AND PISTON RING ...4961
CONROD AND CRANKSHAFT ...4963
CAM ROCKER ARM ...4966
FINAL REDUCTION GEAR BOX AND CVT CASE ...4969
CVT CASE COVER ...4974
GENERATOR CASE ...4974
STARTER PINION ...4975
MOVABLE AND FIXED DRIVE AND DRIVEN FACE ...4976
RECOIL STARTER ...4984
ENGINE REASSEMBLY ...4988
04 FUEL SYSTEM ...4998
FUEL TANK AND FUEL VALVE ...4999
REMOVAL ...5000
FUEL FILTER INSPECTION AND CLEANING ...5000
REMOUNTING ...5001
CARBURETOR ...5002
SPECIFICATIONS ...5003
I.D. NO. LOCATION ...5003
REMOVAL ...5004
DISASSEMBLY ...5005
CLEANING ...5008
INSPECTION AND ADJUSTMENT ...5008
REASSEMBLY AND REMOUNTING ...5009
05 CHASSIS...5012
EXTERIOR PARTS ...5013
CONSTRUCTION ...5013
FASTENER REMOVAL AND INSTALLATION ...5014
REMOVAL ...5015
REMOUNTING ...5017
FRONT AND REAR WHEELS ...5018
CONSTRUCTION ...5018
REMOVAL ...5018
REMOUNTING ...5018
TIRES ...5019
TIRE REPLACEMENT ...5019
FRONT BRAKE ...5021
CONSTRUCTION ...5021
REMOVAL ...5022
INSPECTION AND DISASSEMBLY ...5023
REASSEMBLY AND REMOUNTING ...5025
STEERING AND FRONT SUSPENSION ...5027
CONSTRUCTION ...5027
REMOVAL AND DISASSEMBLY ...5029
INSPECTION ...5032
REASSEMBLY AND REMOUNTING ...5034
TOE-IN ADJUSTMENT ...5038
REAR BRAKE AND REAR AXLE HOUSING ...5039
CONSTRUCTION ...5039
REMOVAL ...5040
INSPECTION AND DISASSEMBLY ...5042
REASSEMBLY AND REMOUNTING ...5044
REAR SUSPENSION ...5049
CONSTRUCTION ...5049
REMOVAL AND DISASSEMBLY ...5050
INSPECTION ...5051
REASSEMBLY AND REMOUNTING ...5051
06 ELECTRICAL SYSTEM...5054
CAUTIONS IN SERVICING ...5055
CONNECTOR ...5055
COUPLER...5055
CLAMP ...5055
FUSE ...5055
SEMI-CONDUCTOR EQUIPPED PART ...5056
BATTERY ...5056
CONNECTING THE BATTERY ...5056
WIRING PROCEDURE ...5056
USING THE MULTI-CIRCUIT TESTER ...5057
LOCATION OF ELECTRICAL COMPONENTS ...5058
CHARGING SYSTEM ...5060
TROUBLESHOOTING ...5060
INSPECTION ...5061
STARTER SYSTEM ...5064
TROUBLESHOOTING ...5064
STARTER MOTOR REMOVAL ...5065
STARTER MOTOR DISASSEMBLY ...5066
STARTER MOTOR INSPECTION ...5067
STARTER MOTOR REASSEMBLY ...5068
STARTER MOTOR INSTALLATION ...5069
STARTER RELAY INSPECTION ...5069
IGNITION SYSTEM ...5071
TROUBLESHOOTING ...5071
INSPECTION ...5073
SWITCHES ...5076
BATTERY ...5077
SPECIFICATIONS ...5077
INITIAL CHARGING ...5077
SERVICING ...5079
RECHARGING OPERATION ...5079
07 SERVICING INFORMATION...5080
TROUBLESHOOTING ...5081
ENGINE ...5081
CARBURETOR ...5085
CHASSIS ...5086
BRAKES ...5088
ELECTRICAL ...5089
BATTERY ...5091
WIRING DIAGRAM ...5092
WIRING HARNESS, CABLE AND HOSE ROUTING ...5093
WIRING HARNESS ROUTING ...5093
CABLE ROUTING ...5095
FUEL HOSE PIPING ...5096
CARBURETOR AND CVT CASE HOSE ROUTING ...5097
HANDLEBARS AND HANDLEBAR PAD INSTALLATION ...5098
HEAT SHIELD INSTALLATION ...5099
SPECIAL TOOLS ...5100
TIGHTENING TORQUE ...5102
ENGINE ...5102
FUEL ...5102
CHASSIS ...5103
TIGHTENING TORQUE CHART ...5104
SERVICE DATA ...5105
08 LT-Z50K9 ('09-MODEL)...5112
SPECIFICATIONS...5113
Suzuki LT-Z90K7, LT-Z90K8, LT-Z90K9 Service Manual '07-'09...5114
FOREWORD...5114
HOW TO USE THIS MANUAL ...5117
TO LOCATE WHAT YOU ARE LOOKING FOR...5117
COMPONENT PARTS AND WORK TO BE DONE ...5117
SYMBOL ...5118
01 GENERAL INFORMATION...5120
WARNING/CAUTION/NOTE...5121
GENERAL PRECAUTIONS...5121
SUZUKI LT-Z90K7 (’07-MODEL) ...5123
SERIAL NUMBER LOCATION ...5123
FUEL AND OIL RECOMMENDATION ...5124
FUEL (FOR USA AND CANADA) ...5124
FUEL (FOR OTHER COUNTRIES) ...5124
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR USA) ...5124
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR OTHER COUNTRIES) ...5124
BREAK-IN PROCEDURES ...5125
INFORMATION LABELS ...5126
SPECIFICATIONS ...5127
DIMENSIONS AND DRY MASS ...5127
ENGINE ...5127
DRIVE TRAIN ...5127
CHASSIS ...5128
ELECTRICAL ...5128
CAPACITIES ...5128
02 PERIODIC MAINTENANCE...5130
PERIODIC MAINTENANCE SCHEDULE ...5131
PERIODIC MAINTENANCE CHART ...5131
MAINTENANCE AND TUNE-UP PROCEDURES ...5132
AIR CLEANER ...5132
EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT ...5134
VALVE CLEARANCE ...5135
SPARK PLUG ...5137
SPARK ARRESTER ...5138
FUEL LINE ...5138
ENGINE OIL AND OIL FILTER ...5139
FINAL REDUCTION GEAR BOX OIL ...5141
THROTTLE CABLE PLAY ...5142
ENGINE IDLE SPEED...5142
DRIVE BELT ...5143
DRIVE CHAIN ...5147
BRAKES ...5149
TIRES...5151
STEERING ...5152
SUSPENSIONS ...5152
CHASSIS NUTS AND BOLTS ...5153
GENERAL LUBRICATIONS ...5156
COMPRESSION PRESSURE CHECK ...5157
COMPRESSION TEST PROCEDURE ...5157
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION ...5158
INITIAL ENGAGEMENT INSPECTION ...5158
CLUTCH LOCK-UP INSPECTION ...5159
OIL PRESSURE CHECK ...5160
OIL PRESSURE TEST PROCEDURE ...5160
03 ENGINE...5162
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...5163
ENGINE LEFT SIDE ...5163
ENGINE RIGHT SIDE ...5163
ENGINE CENTER ...5163
ENGINE REMOVAL AND REMOUNTING ...5164
ENGINE REMOVAL ...5164
ENGINE REMOUNTING ...5168
ENGINE DISASSEMBLY ...5170
ENGINE COMPONENTS INSPECTION AND SERVICE ...5179
CYLINDER HEAD COVER ...5179
CYLINDER HEAD ...5180
CAMSHAFT ...5189
CAM CHAIN TENSION ADJUSTER AND TENSIONER/GUIDE ...5192
CYLINDER ...5192
PISTON AND PISTON RING ...5193
CONROD ...5195
CRANKSHAFT ...5196
STARTER CLUTCH ...5196
GENERATOR ...5198
OIL PUMP ...5199
ENGINE MOUNTING BUSH ...5202
FINAL REDUCTION GEAR BOX ...5203
MOVABLE AND FIXED DRIVE AND DRIVEN FACE ...5211
RECOIL STARTER ...5219
ENGINE REASSEMBLY ...5223
04 FUEL SYSTEM...5240
FUEL TANK AND FUEL VALVE...5241
REMOVAL ...5242
FUEL FILTER INSPECTION AND CLEANING ...5242
INSTALLATION ...5243
CARBURETOR ...5244
SPECIFICATIONS ...5245
I.D. NO. LOCATION ...5245
REMOVAL ...5246
DISASSEMBLY ...5247
CLEANING ...5250
INSPECTION AND ADJUSTMENT ...5250
REASSEMBLY AND INSTALLATION ...5251
05 CHASSIS...5254
EXTERIOR PARTS ...5255
CONSTRUCTION ...5255
FASTENER REMOVAL AND INSTALLATION ...5256
REMOVAL ...5257
INSTALLATION ...5260
FRONT AND REAR WHEELS ...5261
CONSTRUCTION ...5261
REMOVAL ...5261
INSTALLATION ...5262
TIRES ...5263
TIRE REPLACEMENT ...5263
FRONT BRAKE ...5265
CONSTRUCTION ...5265
REMOVAL ...5266
INSPECTION AND DISASSEMBLY ...5267
REASSEMBLY AND INSTALLATION ...5269
STEERING AND FRONT SUSPENSION ...5273
CONSTRUCTION ...5273
REMOVAL AND DISASSEMBLY ...5275
INSPECTION ...5276
REASSEMBLY AND INSTALLATION ...5277
REASSEMBLY AND INSTALLATION...5281
INSTALLATION ...5283
TOE-IN ADJUSTMENT ...5285
REAR BRAKE AND REAR AXLE HOUSING ...5286
CONSTRUCTION ...5286
REMOVAL ...5287
INSPECTION AND DISASSEMBLY ...5290
REASSEMBLY AND INSTALLATION ...5293
REAR SUSPENSION ...5300
CONSTRUCTION ...5300
REMOVAL ...5301
INSPECTION AND DISASSEMBLY ...5302
REASSEMBLY AND INSTALLATION ...5305
06 ELECTRICAL SYSTEM...5310
CAUTIONS IN SERVICING...5311
CONNECTOR ...5311
COUPLER...5311
CLAMP ...5311
FUSE ...5311
SEMI-CONDUCTOR EQUIPPED PART ...5312
BATTERY ...5312
CONNECTING THE BATTERY ...5312
WIRING PROCEDURE ...5312
USING THE MULTI-CIRCUIT TESTER ...5313
LOCATION OF ELECTRICAL COMPONENTS ...5314
CHARGING SYSTEM ...5316
TROUBLESHOOTING ...5316
INSPECTION ...5317
STARTER SYSTEM ...5320
TROUBLESHOOTING ...5320
STARTER MOTOR REMOVAL ...5321
STARTER MOTOR DISASSEMBLY ...5322
STARTER MOTOR INSPECTION ...5323
STARTER MOTOR REASSEMBLY ...5324
STARTER MOTOR INSTALLATION ...5325
STARTER RELAY INSPECTION ...5325
IGNITION SYSTEM ...5327
TROUBLESHOOTING ...5327
INSPECTION ...5329
SWITCHES ...5332
BATTERY ...5333
SPECIFICATIONS ...5333
INITIAL CHARGING ...5333
SERVICING ...5335
RECHARGING OPERATION ...5335
07 SERVICING INFORMATION ...5336
TROUBLESHOOTING ...5337
ENGINE ...5337
CARBURETOR ...5341
CHASSIS ...5342
BRAKES ...5344
ELECTRICAL ...5345
BATTERY ...5347
LUBRICATION SYSTEM ...5348
OIL PRESSURE ...5348
OIL FILTER ...5348
OIL STRAINER ...5348
OIL PUMP ...5348
ENGINE LUBRICATION SYSTEM CHART...5348
WIRING DIAGRAM ...5349
WIRING HARNESS, CABLE AND HOSE ROUTING ...5350
WIRING HARNESS ROUTING ...5350
CABLE ROUTING ...5352
FUEL HOSE PIPING ...5353
REAR BRAKE BREATHER HOSE ROUTING ...5354
COOLING DUCT ROUTING ...5355
EXHAUST PIPE COVER ...5356
SPECIAL TOOLS ...5357
TIGHTENING TORQUE ...5360
ENGINE ...5360
FUEL ...5360
CHASSIS ...5361
TIGHTENING TORQUE CHART ...5362
SERVICE DATA ...5363
08 LT-Z90K9 ('09-MODEL)...5370
SPECIFICATIONS...5371
Suzuki LT250R Quadracer ATV (LT250RG, LT250RH, LT250RI, LT250RJ, LT250RK, LT250RL, LT250RM, LT250RN) '85-'92 Service Manual...5372
00-Index...5372
01-General Information...5375
02-Periodic Maintenance...5384
03-Engine...5406
04-Cooling System...5461
05-Fuel System...5473
06-Electrical System...5485
07-Chassis...5492
08-Service Information...5551
09-LT250RJ (88-Model)...5573
10-LT250RK (89-Model)...5589
11-LT250RL (90-Model)...5595
12-LT250RM (91-Model)...5602
13-LT250RN (92-Model)...5612
Suzuki LT500R QuadZilla (LT500RH, LT500RJ, LT500RK, LT500RL) '87-'90 Service Manual...5618
(A) General Inf-1& Maintenance-2...5618
(B) Engined-3 & Cooling-4...5649
(C) Fuel-5, Eletrical-6, & Chassis-7...5717
(D) Service Info.-8 & Appendix-9...5800
Suzuki Porting instruction...5858
Suzuki Tuning Guide Instruction...5872
Suzuki LT-Z50, LT80, LT-Z90, LT-F250, LT250R, LT-Z250, LT-F300F, LT-A400, LT-F400, LT-Z400, LT-R450, LT500R, LT-A500F, LT-A700, LT-A750 ATV Repair Service Manuals
