Suzuki LT-A400 Service Manual Download

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1I-1 Starting System:

Engine

Starting System

Schematic and Routing Diagram

Starting System Diagram

B827H11902001

Refer to “Wire Color Symbols in Section 0A (Page 0A-4)”.

Component Location

Starting System Components Location

B827H11903001

Refer to “Electrical Components Location in Section 0A (Page 0A-6)”.

Diagnostic Information and Procedures

Starting System Symptom Diagnosis

B827H11904001

Starter

motor

Fuse

Starter relay

B/W

Y/B

Neutral relay

Starter

button

Engine

stop switch

Emergency

switch (E-17)

Fuse

Ignition

switch

Ignition/
starter
control
realy

CDI

Parking
brake
switch

Neutral
indicator
light

O/Y

Y/G

Batter

Neutral

switch

To reverse
indicator light

B/Bl

R/W

Reverse

switch

I827H1190001-02

Condition

Possible cause

Correction / Reference Item

Starter button is not
effective

Run down battery.

Repair or replace.

Defective switch contacts.

Replace.

Brushes not seating properly on starter
motor commutator.

Repair or replace.

Defective starter relay or neutral relay.

Replace.

Defective main fuse or ignition fuse.

Replace.

Summary of Contents for LT-A400

Page 1: ...Printed in Japan K8 9 9 5 0 0 4 3 0 7 0 0 1 E K8 ...

Page 2: ...st specifications at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual vehicle exactly in detail This manual is written for persons who have enough knowledge skills and...

Page 3: ...Front Suspension 2B 1 Rear Suspension 2C 1 Wheels and Tires 2D 1 Driveline Axle 3 i Precautions 3 1 Drive Chain Drive Train Drive Shaft 3A 1 Differential 3B 1 Transfer 3C 1 Propeller Shafts 3D 1 Brake 4 i Precautions 4 1 Brake Control System and Diagnosis 4A 1 Front Brakes 4B 1 Rear Brakes 4C 1 Parking Brake 4D 1 Transmission Transaxle 5 i Precautions 5 1 Automatic Transmission 5A 1 Manual Transmi...

Page 4: ......

Page 5: ...Table of Contents 00 i 00 Section 00 CONTENTS Precautions Precautions 00 1 Precautions 00 1 Warning Caution Note 00 1 General Precautions 00 1 Precautions for Electrical Circuit Service 00 2 ...

Page 6: ...u follow all of the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil radiator and exhaust system until they have cooled After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for leaks CAUTION If parts replacement is necessary replace the parts with Suzuki...

Page 7: ...each terminal on the connector coupler for looseness or bending Push in the coupler straightly An angled or skewed insertion may cause the terminal to be deformed possibly resulting in poor electrical contact Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact Before refitting the sealed coupl...

Page 8: ...ace the fuse Do not use a fuse of different capacity Do not use wire or any other substitute for the fuse Switch Never apply grease material to switch contact points to prevent damage CDI unit Various sensors Since each component is a high precision part great care should be taken not to apply any severe impacts during removal and installation Be careful not to touch the electrical terminals of th...

Page 9: ...asurements may not be obtained and personal injury may result Electrical Circuit Inspection Procedure While there are various methods for electrical circuit inspection described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter Open circuit check Possible causes for the open circuit are as follows As the cause can exist in the connector coupler or termi...

Page 10: ... A and C 2 Disconnect the coupler B and measure resistance between couplers A and B 1 If no continuity is indicated the circuit is open between couplers A and B 1 If continuity is indicated there is an open circuit between couplers B 2 and C or an abnormality in coupler B 2 or coupler C Voltage check If voltage is supplied to the circuit being checked voltage check can be used as circuit check 1 W...

Page 11: ...e checked branches to other parts as shown disconnect all connectors couplers of those parts Otherwise diagnosis will be misled 3 Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals A and C 4 Disconnect the connector coupler included in circuit coupler B and measure resistance...

Page 12: ...splay Check that no voltage is applied before making the measurement If voltage is applied the tester may be damaged After using the tester turn the power off Special tool 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them Use the needle pointed probe to p...

Page 13: ...aning 0B 6 Spark Arrester Cleaning 0B 7 Fuel Line Inspection 0B 7 Engine Oil and Filter Replacement 0B 7 Front Differential Gear Oil Inspection LT A400F LT F400F 0B 9 Front Differential Gear Oil Replacement LT A400F LT F400F 0B 10 Final Gear Oil Inspection 0B 11 Final Gear Oil Replacement 0B 11 Throttle Cable Play Inspection and Adjustment 0B 13 Engine Idle Speed Adjustment 0B 13 Drive V belt Insp...

Page 14: ...tic Trouble Code G GEN Generator GND Ground GP Switch Gear Position Switch H HC Hydrocarbons I IG Ignition J JASO Japanese Automobile Standards Organization L LCD Liquid Crystal Display LED Light Emitting Diode Malfunction Indicator Lamp LH Left Hand Symbol Definition Torque control required Data beside it indicate specified torque Apply oil Use engine oil unless otherwise specified Apply molybden...

Page 15: ...nkcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers Vehicle Side View B827H10101004 NOTE Difference between illustration and actual vehicle may exist depending on the markets SUZUKI LT A400 F 2008 model Right Side Left Side SUZUKI LT F400 F 2008 model Right Side Left Side I827H1010003 01 I827H1010004 01 I827H1010005 01 I827H1010006 01 ...

Page 16: ...ASO Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select and alternative according to the chart Engine Oil For Other Countries Oil quality is a major contributor to your engine s performance and life Always select good quality engine oil Use of SF SG or SH SJ in API with MA in JASO Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engin...

Page 17: ... 24 Australia 5SAAK48A87100001 LT F400K8 P 28 Canada 5SAAK48A87100001 LT F400K8 P 33 U S A 5SAAK48A87100001 LT F400FK8 P 17 Sweden 5SAAK49A87100001 LT F400FK8 P 24 Australia 5SAAK49A87100001 LT F400FK8 P 28 Canada 5SAAK49A87100001 LT F400FK8 P 33 U S A 5SAAK49A87100001 Symbol Wire Color Symbol Wire Color B Black Br W Brown with White tracer Bl Blue G B Green with Black tracer Br Brown Gr R Gray wi...

Page 18: ...28 33 20 Rear carrier warning label English French For P 17 28 6 Tire air pressure label French For P 28 21 Trailer tow warning label English For P 17 24 28 33 7 General warning AGE 16 label English For P 17 24 28 33 22 Trailer tow warning label French For P 28 8 General warning label French For P 28 23 ICES Canada label French For P 28 9 AGE 16 label French For P 28 24 Compliance label English Fo...

Page 19: ...2 13 14 15 4 2 9 I827H1010007 01 1 Battery 6 Ignition switch 11 Starter motor 2 Main fuse 7 Output terminal 12 Brake light switch 3 Starter relay 8 Handlebar switch LH 13 Neutral switch 4 Neutral relay 9 Parking brake switch 14 Cooling fan thermo switch 5 Fuse box 10 Brake light switch 15 Engine oil temperature switch ...

Page 20: ...ral Information 16 17 18 19 21 22 23 20 I827H1010008 02 16 Ignition coil 19 Regulator Rectifier 22 Reverse diode 17 Cooling fan 20 CDI unit 23 Generator 18 Ignition starter control relay 21 Neutral switch diode ...

Page 21: ...10009 02 1 Battery 6 Handlebar switch LH 11 Brake light switch 2 Main fuse 7 Parking brake switch 12 Starter motor 3 Starter relay 8 Burke light switch 13 Cooling fan thermo switch 4 Neutral relay 9 Ignition switch 14 Engine oil temperature switch 5 Fuse box 10 Output terminal ...

Page 22: ...ormation 23 15 16 17 18 21 22 19 20 I827H1010010 04 15 Ignition coil 18 Regulator Rectifier 21 Neutral diode 16 Cooling fan 19 CDI unit 22 Generator 17 Ignition starter control relay 20 Reverse switch 23 Neutral switch ...

Page 23: ...tem Specification Remark Type 4 stroke Air cooled with SACS OHC Number of cylinders 1 Bore 82 0 mm 3 228 in Stroke 71 2 mm 2 803 in Displacement 376 cm3 22 9 cu in Compression ratio 9 0 1 Carburetor KEIHIN CVK32 single Air cleaner Polyurethane foam element Starter system Electric and recoil starter Lubrication system Wet sump Idle speed 1 500 100 r min Item Specification Remark Clutch Wet shoe aut...

Page 24: ... 10 B T D C at 1 500 r min Spark plug NGK CR7E or DENSO U22ESR N Battery 12 V 43 2 kC 12 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 10 10 10 A Headlight 12 V 35 35 W x 2 HS1 x 2 Brake light Taillight 12 V 21 5 W Speedometer light 12 V 1 7 W Oil temperature indicator light 12 V 3 4 W Neutral indicator light 12 V 3 4 W High beam indicator light 12 V 3 4 W P 17 Reverse ...

Page 25: ...oled with SACS OHC Number of cylinders 1 Bore 82 0 mm 3 228 in Stroke 71 2 mm 2 803 in Displacement 376 cm3 22 9 cu in Compression ratio 9 0 1 Carburetor KEIHIN CVK32 single Air cleaner Polyurethane foam element Starter system Electric and recoil starter Lubrication system Wet sump Idle speed 1 500 100 r min Item Specification Remark Clutch Wet multi plate automatic centrifugal type Transmission 5...

Page 26: ... 10 B T D C at 1 500 r min Spark plug NGK CR7E or DENSO U22ESR N Battery 12 V 43 2 kC 12 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 10 10 10 10 A Headlight 12 V 35 35 W x 2 HS1 x 2 Brake light Taillight 12 V 21 5 W Speedometer light 12 V 1 7 W Oil temperature indicator light 12 V 3 4 W Neutral indicator light 12 V 3 4 W High beam indicator light 12 V 3 4 W P 17 Reverse ...

Page 27: ... gauge 1 1000 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block 100 mm 09900 22302 Plastigauge 0 051 0 152 mm 09900 22403 Small bore gauge 18 35 mm 09900 25008 Multi circuit tester set 09900 26006 Engine tachometer solar cell type 09910 32812 Crankshaft in...

Page 28: ...de remover installer 09916 84511 Tweezers 09917 14910 Valve adjuster driver 09917 23711 Ring nut wrench 09920 13120 Crankcase separating tool 09920 20310 Clutch spring hook 09920 53730 Clutch sleeve hub holder 09920 53740 Clutch sleeve hub holder 09921 20210 Bearing remover 09921 20240 Bearing remover set 09921 21910 Bearing holder 09922 31430 Clutch spring compressor 09923 73210 Bearing remover 0...

Page 29: ...Spark plug wrench set 09930 30104 Rotor remover slide shaft 09930 30141 Attachment A 09930 30721 Rotor remover 09930 31921 Rotor remover 09930 40113 Rotor holder 09930 44541 Rotor holder 09930 73190 Output shaft holder 09940 52861 Front fork oil seal installer 09941 64511 Bearing remover 09942 72410 Tie rod end remover ...

Page 30: ...0A 3 Scheduled Maintenance Periodic Maintenance Schedule Chart B827H10205001 NOTE I Inspect and clean adjust replace or lubricate as necessary C Clean R Replace T Tighten Item Interval km Initial 200 Every 1 000 Every 2 000 miles Initial 100 Every 600 Every 1 200 months 1 3 6 Air cleaner element C C Exhaust pipe nuts and muffler bolts T T T Valve clearance I I Spark plug I Replace every 6 000 km 4...

Page 31: ...n operated under wet or rainy conditions Lubricate exposed parts Every 1 000 km 600 miles 3 months LT A400 F LT F400 F Chassis nuts and bolts T T T General lubrications L L Item Interval km Initial 200 Every 1 000 Every 2 000 miles Initial 100 Every 600 Every 1 200 months 1 3 6 5 1 4 2 3 1 6 I827H1020033 02 1 Brake lever holder 4 Brake pedal Apply grease 2 Throttle lever 5 Brake cam 3 Steering sha...

Page 32: ...s largely on this component Inspect the air cleaner element for tears A torn element must be replaced 1 Remove the air cleaner element Refer to Air Cleaner Element Removal and Installation in Section 1D Page 1D 5 2 Fill a wash pan of a proper size with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it 3 Press the air cleaner element between the pa...

Page 33: ... clearance Initially at 200 km 100 miles 1 month and every 2 000 km 1 200 miles 6 months thereafter Inspection Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification if necessary 1 Remove the fuel tank R...

Page 34: ...cold IN 0 05 0 10 mm 0 002 0 004 in EX 0 22 0 27 mm 0 009 0 011 in Adjustment 1 If the clearance is out of specification bring it into the specified range using the special tool Special tool A 09917 14910 Valve adjuster driver Tightening torque Valve clearance adjuster lock nut 10 N m 1 0 kgf m 7 0 lb ft 2 Install the removed parts Tightening torque TDC plug 23 N m 2 3 kgf m 16 5 lb ft Spark Plug ...

Page 35: ...ve the spark plug Refer to Spark Plug Removal and Installation in Section 1H Page 1H 3 2 Measure the spark plug gap using the thickness gauge Adjust the spark plug gap if necessary Special tool 09900 20803 Thickness gauge Spark plug gap 0 7 0 8 mm 0 028 0 030 in 3 After finishing the spark plug inspection reinstall the removed parts Electrodes Condition 1 Remove the spark plug Refer to Spark Plug ...

Page 36: ... and Installation in Section 9D Page 9D 3 2 Inspect the fuel hose 1 for damage and fuel leakage If any defects are found the fuel feed hose must be replaced 3 After finishing the fuel feed hose inspection or replacement reinstall the removed parts Engine Oil and Filter Replacement B827H10206008 Replace engine oil Initially at 200 km 100 miles 1 month and every 2 000 km 1 200 miles 6 months thereaf...

Page 37: ... 2 3 Tighten the drain plug 1 to the specified torque CAUTION Replace the gasket washer with a new one Tightening torque Engine oil drain plug a 23 N m 2 3 kgf m 16 5 lb ft 4 Remove the left inner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 5 Remove the oil filter 3 using the special tool Special tool 09915 40610 Oil filter wrench 6 Apply engine oil lightly to t...

Page 38: ...tion Page 0B 7 11 Install the removed parts Front Differential Gear Oil Inspection LT A400F LT F400F B827H10206009 Inspect front differential gear oil Every 2 000 km 1 200 miles 6 months Inspect the front differential gear oil level in the following procedures 1 Place the vehicle on level ground 2 Remove the front under cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3...

Page 39: ...ear oil drain plug a 32 N m 3 2 kgf m 23 0 lb ft 6 Pour fresh oil through the oil filler hole until it overflows from the oil level hole When performing an oil change the front differential will hold about 300 ml 10 1 10 6 US Imp oz of oil Use hypoid gear oil SAE 90 API grade GL 5 NOTE Use hypoid gear oil SAE 80 API grade GL 5 if the vehicle is ridden where the ambient temperature is below 0 C 32 ...

Page 40: ...id gear oil SAE 90 API grade GL 5 NOTE Use hypoid gear oil SAE 80 API grade GL 5 if the vehicle is ridden where the ambient temperature is below 0 C 32 F 4 Tighten the oil level plug 3 and oil filler plug 2 to the specified torque CAUTION Replace the gasket washers with new ones Tightening torque Final gear oil level plug a 10 N m 1 0 kgf m 7 0 lb ft Tightening torque Final gear oil filler plug b ...

Page 41: ...l hold about 350 ml 11 8 12 3 US lmp oz of oil Use hypoid gear oil SAE 90 API grade GL 5 NOTE Use hypoid gear oil SAE 80 API grade GL 5 if the vehicle is ridden where the ambient temperature is below 0 C 32 F Front differential gear oil capacity 350 ml 11 8 12 3 US Imp oz 7 Tighten the oil level plug 3 and oil filler plug 2 to the specified torque CAUTION Replace the gasket washers with new ones T...

Page 42: ...ove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Connect the electric tachometer or multi circuit tester to the high tension cord 3 Start the engine and set the engine idle speed between 1 400 and 1 600 r min by turning the throttle stop screw knob 1 Engine idle speed 1 500 100 r min Special tool 09900 26006 Engine tachometer solar cell type 09900 ...

Page 43: ...lutch wheel Refer to Clutch Related Parts Inspection LT F400 F in Section 5C Page 5C 6 Initial engagement speed 1 500 2000 r min Clutch Lock Up Inspection Perform this inspection to determine if the clutch is engaging fully and not slipping 1 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Connect the tachometer or multi circuit tester to the s...

Page 44: ...ne replenish with brake fluid that meets the following specification BF Brake fluid DOT 4 Brake Fluid Replacement Replace brake fluid Every 2 years Refer to Brake Fluid Replacement in Section 4A Page 4A 6 Air Bleeding from Brake Fluid Circuit Refer to Air Bleeding from Front Brake Fluid Circuit in Section 4A Page 4A 5 Front Brake Pad Inspection The extent of front brake pad wear can be checked by ...

Page 45: ...e pedal check the rear brake lever play a The brake lever play a as measured at the lever holder should be between 3 5 mm 0 1 0 2 in when the lever is lightly pulled in towards the grip If adjustment is necessary slacken the cable by loosening the lock nut 1 and screwing the cable adjuster 2 on the brake lever holder all the way in Rear brake lever play a 3 5 mm 0 1 0 2 in 2 Turn the adjust nut 3 ...

Page 46: ...vice limit Front 4 0 mm 0 16 in Rear 4 0 mm 0 16 in Tire Pressure If the tire pressure is too high or too low steering will be adversely affected and tire wear increased Therefore maintain the correct tire pressure for good roadability or shorter tire life will result Cold inflation tire pressure is as follows Cold inflation tire pressure Vehicle load capacity limit 172 kg 380 lbs CAUTION To minim...

Page 47: ... the toe in is within the specified range Toe in A B Standard 10 mm 0 4 in If the toe in is out of specification bring it into the specified range Refer to Toe In Adjustment Page 0B 18 Toe In Adjustment B827H10206023 Adjust the toe out as follows 1 Loosen the lock nuts 1 2 on each tie rod CAUTION The lock nuts 2 have left hand threads NOTE Hold the concave part a of tie rod with a wrench 2 Tempora...

Page 48: ... and rear shock absorbers for oil leakage or damage If any damages are found replace them with new ones Chassis Bolt and Nut Inspection B827H10206025 Tighten chassis bolt and nut Initially at 200 km 100 miles 1 month and every 1 000 km 600 miles 3 months thereafter Check that all chassis bolts and nuts are tightened to their specified torque 1 Handlebar clamp bolt 26 N m 2 6 kgf m 19 0 lb ft 2 Ste...

Page 49: ...bolt 26 N m 2 6 kgf m 19 0 lb ft 17 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft i 10 i 11 h 7 I827H1020057 02 f 9 j 8 I827H1020058 02 k 12 a 13 b 17 a 13 I827H1020059 02 14 Footrest bolt M8 25 N m 2 5 kgf m 18 0 lb ft 15 Footrest bolt M10 55 N m 5 5 kgf m 40 0 lb ft 19 Brake pedal bolt 12 N m 1 2 kgf m 8 5 lb ft 16 Brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft 17 Brake hose ...

Page 50: ...tachometer and install the frame front cover Clutch Lock up Inspection Perform this inspection to determine if the clutch is engaging fully and not slipping 1 Warn up the engine 2 Connect a tachometer onto the spark plug high tension code 3 Start the engine 4 Shift the transfer range lever to the High position 5 Apply the front and rear brakes as firm as possible 6 Fully open the throttle fully an...

Page 51: ...Muffler connecting bolt 23 2 3 16 5 Page 0B 4 Muffler mounting bolt 23 2 3 16 5 Page 0B 4 Valve clearance adjuster lock nut 10 1 0 7 0 Page 0B 5 TDC plug 23 2 3 16 5 Page 0B 5 Spark plug 11 1 1 8 0 Page 0B 6 Engine oil drain plug 23 2 3 16 5 Page 0B 8 Oil filter 20 2 0 14 5 Page 0B 9 Front drive differential gear oil level plug 8 0 8 6 0 Page 0B 9 Page 0B 10 Front drive differential gear oil fille...

Page 52: ...00 25008 09900 26006 Multi circuit tester set Engine tachometer solar cell type Page 0B 13 Page 0B 14 Page 0B 21 Page 0B 13 Page 0B 14 Page 0B 21 09915 40610 09917 14910 Oil filter wrench Valve adjuster driver Page 0B 8 Page 0B 9 Page 0B 5 ...

Page 53: ...ard Limit Cam height IN EX 33 130 33 170 1 3043 1 3059 32 830 1 2925 Camshaft journal oil clearance φ 22 0 032 0 066 0 0013 0 0026 0 150 0 0059 φ 17 5 0 028 0 059 0 0011 0 0023 0 150 0 0059 Camshaft journal holder I D φ 22 22 012 22 025 0 8666 0 8671 φ 17 5 17 512 17 525 0 6894 0 6900 Camshaft journal O D φ 22 21 959 21 980 0 8645 0 8654 φ 17 5 17 466 17 484 0 6876 0 6883 Camshaft runout 0 10 0 00...

Page 54: ...1 1 kgf cm2 16 psi Below 150 kPa 1 5 kgf cm2 21 psi at 3 000 r min Item Standard Limit Clutch wheel I D 140 0 140 2 5 512 5 520 140 5 5 53 Clutch shoe thickness No groove at any part Clutch engagement r min 1 700 2 200 r min Clutch lock up r min 3 300 3 900 r min Item Standard Limit Automatic transmission ratio Variable change 2 938 0 813 Secondary reduction ratio 2 730 42 19 x 21 17 Final reducti...

Page 55: ...e play 0 5 1 0 mm 0 02 0 04 in Item Specification Note Spark plug Type NGK CR7E DENSO U22ESR N Gap 0 7 0 8 0 028 0 031 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance 130 250 Ω BI G CKP sensor peak voltage 4 0 V and more Bl G Ignition coil resistance Primary 0 1 1 0 Ω Terminal Terminal Secondary 12 22 kΩ Plug cap Terminal Generator coil resistance 0 3 1 5 Ω B B Generator no load voltag...

Page 56: ...3 878 33 928 1 3338 1 3357 Brake fluid type DOT 4 Steering angle Right 47 3 0 0 20 Left 47 Turning radius 3 1 m 10 2 ft Toe in with 75 kg 165 lbs 10 4 0 39 0 16 20 2 0 80 Camber 0 3 Caster 3 Wheel rim size Front 12 x 6 0 AT Rear 12 x 7 5 AT Item Standard Note Cold inflation tire pressure Front 32 5 kPa 0 325 kgf cm2 4 7 psi Load capacity up to 172 kg 380 lbs Rear 30 kPa 0 30 kgf cm2 4 4 psi Tire s...

Page 57: ... deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 2 3 0 09 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX 40 9 1 61 Valve spring tension IN EX Approx 196 N 20 0 kgf 44 1 lbs at length 31 5 mm 1 24 in Item Standard Limit Cam height IN EX 33 130 33 170 1 ...

Page 58: ... 20 014 0 7876 0 7879 20 040 0 7890 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 00 0 55 0 000 0 022 1 0 0 04 Conrod big end width 21 95 22 00 0 864 0 866 Conrod web to web width 59 9 60 1 2 36 2 37 Crankshaft runout 0 080 0 0031 Item Standard Limit Oil pressure at 60 C 140 F Above 60 kPa 0 6 kgf cm2 9 psi Below 100 kPa 1 0 kgf cm2 14 psi at 3 000 r min Item Standard Limit Clutch rel...

Page 59: ... 10 0 002 0 004 Final gear backlash 0 08 0 13 0 0031 0 0051 Item Standard Limit Item Standard Specification Limit Engine oil temp indicator light switch operating temperature OFF ON Approx 160 C 320 F ON OFF Approx 140 C 284 F Cooling fan thermo switch operating temperature OFF ON Approx 120 C 248 F ON OFF Approx 110 C 230 F Item Specification P 17 24 28 P 33 Carburetor type KEIHIN CVK 32 Bore siz...

Page 60: ...ght HI 35 x 2 LO 35 x 2 Brake light Taillight 21 5 Speedometer light 1 7 Reverse indicator light 3 4 Neutral indicator light 3 4 Engine oil temp indicator light 3 4 High beam indicator light 3 4 Reversing light 21 Item Standard Limit Rear brake cable play 3 5 0 12 0 20 Rear brake pedal free travel 20 30 0 8 1 2 Brake disc thickness Front 3 3 3 7 0 130 0 146 3 0 0 20 Brake drum runout Front 0 30 0 ...

Page 61: ...F SG or SH SJ with JASO MA Engine oil capacity Change 3 000 ml 3 2 2 6 US lmp qt Filter change 3 200 ml 3 4 2 8 US lmp qt Overhaul 3 500 ml 3 7 3 1 US lmp qt Front Rear drive gear oil type Hypoid gear oil SAE 90 API grade GL 5 Front drive differential gear oil capacity 300 ml 10 1 10 6 US lmp oz Final gear oil capacity 350 ml 11 8 12 3 US lmp oz Item N m kgf m lb ft Cylinder head cover bolt 10 1 0...

Page 62: ... 6 0 6 4 3 Speedometer gearbox bolt 10 1 0 7 0 Gear shift cam stopper nut 10 1 0 7 0 Item N m kgf m lb ft Front drive Differential gear oil drain plug 32 3 2 23 0 Front drive Differential gear oil level plug 8 0 8 6 0 Front drive Differential gear oil filler plug 35 3 5 25 5 Front drive Differential gear case mounting nut 45 4 5 32 5 Front drive Differential gear case cover bolt 23 2 3 16 5 Final ...

Page 63: ...g bolt 28 2 8 20 0 Rear carrier mounting bolt 28 2 8 20 0 Front grip bar mounting bolt 28 2 8 20 0 Item N m kgf m lb ft Item N m kgf m lb ft Cylinder head cover bolt 10 1 0 7 0 Camshaft sprocket bolt 15 1 5 11 0 Cylinder head bolt initial 25 2 5 18 0 Final 37 3 7 26 5 Cylinder head nut initial 10 1 0 7 0 Final 25 2 5 18 0 Cylinder base nut 10 1 0 7 0 Cam chain tensioner bolt 13 1 3 9 5 Cam chain t...

Page 64: ...ential gear oil drain plug 32 3 2 23 0 Front drive Differential gear oil level plug 8 0 8 6 0 Front drive Differential gear oil filler plug 35 3 5 25 5 Front drive Differential gear case mounting nut 45 4 5 32 5 Front drive Differential gear case bolt 23 2 3 16 5 Final gear case bolt 23 2 3 16 5 Final gear oil filler plug 33 3 3 24 0 Final gear oil level plug 10 1 0 7 0 Final gear oil drain plug 3...

Page 65: ...2 1 2 8 5 Front brake pad mounting pin 18 1 8 13 0 Front brake hose union bolt 23 2 3 16 5 Caliper holder slide pin nut 23 2 3 16 5 Caliper holder pin 18 1 8 13 0 Rear brake anchor panel nut 32 3 2 23 0 Steering shaft lower nut 49 4 9 35 5 Front carrier mounting bolt 28 2 8 20 0 Rear carrier mounting bolt 28 2 8 20 0 Front grip bar mounting bolt 28 2 8 20 0 Item N m kgf m lb ft Bolt Diameter a mm ...

Page 66: ...0C 14 Service Data ...

Page 67: ...t Inspection 1D 27 Cam Chain Tension Adjuster Inspection 1D 29 Cam Chain Tensioner Inspection 1D 29 Cam Chain Guide Inspection 1D 29 Cylinder Inspection 1D 29 Piston Ring Removal and Installation 1D 30 Piston and Piston Ring Inspection 1D 31 Engine Bottom Side Disassembly 1D 33 Engine Bottom Side Assembly 1D 42 Conrod and Crankshaft Inspection 1D 57 Width Between Crankshaft Webs 1D 58 Crankshaft O...

Page 68: ... 22 Service Data LT A400 F LT F400 F 1G 22 Tightening Torque Specifications 1G 23 Special Tools and Equipment 1G 23 Recommended Service Material 1G 23 Special Tool 1G 23 Ignition System 1H 1 Schematic and Routing Diagram 1H 1 Ignition System Diagram 1H 1 Ignition System Components Location 1H 1 Diagnostic Information and Procedures 1H 1 Ignition System Symptom Diagnosis 1H 1 No Spark or Poor Spark...

Page 69: ... Repair Instructions 1J 3 Battery Current Leakage Inspection 1J 3 Regulated Voltage Inspection 1J 3 Generator Inspection 1J 4 Generator Removal and Installation 1J 5 Regulator Rectifier Inspection 1J 10 Battery Components 1J 11 Battery Charging 1J 11 Battery Removal and Installation 1J 13 Battery Visual Inspection 1J 13 Specifications 1J 14 Service Data LT A400 F LT F400 F 1J 14 Tightening Torque ...

Page 70: ... Precautions Engine Precautions Precautions Precautions for Engine B827H11000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 00 2 ...

Page 71: ... or defective fuel valve Clean or replace Defective carburetor needle valve Replace Clogged fuel hose Clean or replace Clogged fuel filter Clean or replace Engine stalls easily Fouled spark plug Clean or replace Defective generator Replace Defective CDI unit Replace Clogged or defective fuel valve Clean or replace Clogged carburetor jet Clean Valve clearance out of adjustment Adjust Engine noisy E...

Page 72: ...or heavy exhaust smoke Too much engine oil in the engine Check with inspection window drain out excess oil Worn piston rings or cylinders Replace Worn valve guides Replace Cylinder wall scored or scuffed Replace Worn valve stems Replace Defective stem seals Replace Engine lacks power Loss of valve clearance Adjust Weakened valve springs Replace Valve timing out of adjustment Adjust Worn piston rin...

Page 73: ...w are machined to much closer tolerances than standard machined jets If replacement of the jets is needed be sure to replace them only with the same type of jets A jet needle with only one clip position is also used If jet needle replacement is necessary only replace it with a jet needle of the same type Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possibl...

Page 74: ...Inspect the PCV hose 1 for wear or damage If it is worn or damaged replace the PCV hose with a new one Check that the PCV hose 1 is securely connected Crankcase Breather PCV Hose Removal and Installation B827H11206002 Removal 1 Remove the right side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Disconnect the PCV hose 1 Installation Install the PCV hose in the re...

Page 75: ...0F b 70 10 mm 2 8 0 4 in 4 Throttle cable A Pass the throttle cable into the concave side of the transfer lever holder LT A400F LT F400F 5 Parking brake cable B Pass the starter cable and rear brake cable to inside of the guide 6 Starter cable C Pass the parking brake cable to outside of the throttle cable 7 Clamp D Fix the rubber of throttle cable to the cable guide 8 Brake adjuster nut E Pass th...

Page 76: ...ection 1H Page 1H 3 3 Install the compression gauge with attachment to the spark plug hole Make sure that the connection is tight Special tool A 09915 64512 Compression gauge B 09915 63311 Compression gauge attachment 4 Keep the throttle lever in the fully opened position 5 Press the starter button and crank the engine for a few seconds Record the maximum gauge reading as the cylinder compression ...

Page 77: ...y Page 1D 10 Refer to Cam Chain Tension Adjuster Inspection Page 1D 30 Refer to Engine Top Side Assembly Page 1D 13 Spark plug Refer to Spark Plug Removal and Installation in Section 1H Page 1H 3 Refer to Spark Plug Inspection and Cleaning in Section 1H Page 1H 3 Refer to Spark Plug Removal and Installation in Section 1H Page 1H 3 Cylinder head cover Refer to Valve Clearance Inspection and Adjustm...

Page 78: ... F400 F in Section 1E Page 1E 6 Gearshift LT F400 F Refer to Gearshift Shaft Gearshift Cam Plate Removal and Installation LT F400 F in Section 5B Page 5B 11 Refer to Gearshift Linkage Inspection LT F400 F in Section 5B Page 5B 12 Refer to Gearshift Shaft Gearshift Cam Plate Removal and Installation LT F400 F in Section 5B Page 5B 11 Item Removal Inspection Installation Item Removal Inspection Inst...

Page 79: ...ction 0B Page 0B 3 Air Cleaner Box Removal and Installation B827H11406004 Removal 1 Remove the rear fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Remove the air cleaner box mounting bolts 3 Loosen the air cleaner box clamp screw and remove the air cleaner box 1 Installation Install the air cleaner box in the reverse order of removal Pay attention to the followin...

Page 80: ...or Parts Removal and Installation in Section 9D Page 9D 3 Footrest mudguards Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 Under covers Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 4 Remove the V belt cooling ducts 1 LT A400 F Refer to V belt Cooling Duct Removal and Installation LT A400 F in Section 5A Page 5A 6 5 Remove the fuel tank 2 Refer...

Page 81: ...2 14 Disconnect the engine ground lead wire 13 and starter motor lead wire 14 15 Disconnect the cooling fan thermo switch lead wire coupler 15 and oil temperature switch coupler 16 16 Remove the brake pedal 17 Refer to Rear Brake Pedal Removal and Installation in Section 4A Page 4A 12 17 Remove the right footrest 18 7 I827H1140238 02 8 9 10 I827H1140239 01 11 I827H1140240 01 12 13 14 I827H1140241 ...

Page 82: ...d Installation LT A400F LT F400F in Section 3B Page 3B 4 20 Remove the engine mounting bracket 20 21 Remove the engine mounting bolts and nuts WARNING Care should be taken not to drop the engine accidentally when the engine mounting bolts and nuts are removed 22 Remove the engine from the right side I827H1140245 01 I827H1140246 01 I827H1140247 01 19 I827H1140248 01 20 I827H1140249 01 I827H1140250 ...

Page 83: ...t Drive Differential Assembly Removal and Installation LT A400F LT F400F in Section 3B Page 3B 4 Install the right footrest Refer to Footrest Removal and Installation in Section 9E Page 9E 2 Install the rear brake pedal Refer to Rear Brake Pedal Removal and Installation in Section 4A Page 4A 12 Install the exhaust pipe and muffler Refer to Muffler Exhaust Pipe Removal and Installation in Section 1...

Page 84: ...he engine assembly from the frame when servicing the engine top side CAUTION Identify the position of each removed part Organize the parts in their respective groups e g intake exhaust so that they can be reinstalled in their original positions Spark Plug 1 Remove the spark plug Special tool 09930 10121 Spark plug wrench set Cam Chain Tension Adjuster 1 Remove the spring holder bolt 1 and spring 2...

Page 85: ...haft 1 Flatten the lock washer 2 Remove the cam chain sprocket bolts and lock washer 3 Remove the cam chain tensioner bolt 4 Drop the camshaft sprocket to the camshaft groove A 5 Remove the cam chain tensioner 1 6 Remove the C ring 2 7 Remove the camshaft and sprocket 1 I827H1140005 01 I827H1140006 01 2 I827H1140007 01 I827H1140008 01 1 A I827H1140009 01 2 I827H1140010 01 ...

Page 86: ...ve the dowel pins and gasket 1 2 Remove the cam chain guide 2 3 Remove the cylinder 3 4 Remove the dowel pins and gasket 4 Piston 1 Remove the piston pin circlip 1 NOTE Place a rag under the piston so as not to drop the piston pin circlip into the crankcase 2 Draw out the piston pin 2 and remove the piston I827H1140011 01 1 I827H1140012 02 1 I827H1140013 01 2 3 I827H1140014 02 4 I827H1140015 02 1 ...

Page 87: ... a cloth beneath the piston install the circlip 1 CAUTION Use new piston pin circlips 1 to prevent circlip failure which will occur when it is bent NOTE End gap of the circlip 1 should not be aligned with the cutaway in the piston pin bore Position the gaps of the three rings and side rails as shown in the figure Before inserting piston into the cylinder check that the gaps are properly positioned...

Page 88: ... and new cylinder head gasket 1 CAUTION Use the new gasket to prevent gas leakage NOTE The rounded side of the washer 2 should be positioned upside Apply engine oil to the both sides of washers 2 and thread of the cylinder head bolts before installing them Install the cylinder head and tighten the cylinder head bolts diagonally to the specified torque Tightening torque Cylinder head bolt initial 2...

Page 89: ...and cam drive sprocket Install the C ring 1 and cam chain tensioner 2 Install the camshaft and camshaft sprocket CAUTION Install the camshaft sprocket so that the stamped mark side faces outside Align the marks C on the camshaft so that they are parallel with the surface of the cylinder head Engage the hole of the camshaft sprocket with the locating pin D on the camshaft NOTE Do not rotate the gen...

Page 90: ... lock the bolts Apply engine oil to the cam faces and journals Cylinder Head Cover Clean the mating surface of the cylinder head and head cover before mating Install the dowell pins to the cylinder head Apply bond to the camshaft end cap Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent 1 Camshaft 4 Bolt 2 Locating pin 5 Lock washer 3 Camshaft sprocket b 4 I827H1140029 01 1 3 5 4 2 I827H11400...

Page 91: ...Engine Mechanical 1D 17 Apply bond to the mating surface of the cylinder head cover Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent I827H1140034 01 ...

Page 92: ... 1 Apply grease to the new O rings and install the valve timing inspection caps Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Replace the O ring with new ones Cam Chain Tension Adjuster With the spring holder bolt and spring removed from the cam chain tension adjuster release locking of the ratchet mechanism 1 and push the push rod all the way in FWD 1 5 4 2 6 5 3 3 I827H1140035 0...

Page 93: ... has been installed check for cam chain tension to determine if the tension adjuster is functioning properly Turn the crankshaft and check that all the moving parts work properly Inspect the valve clearance Refer to Valve Clearance Inspection and Adjustment in Section 0B Page 0B 4 Recoil Starter Install the recoil starter assembly 1 Apply a small quantity of thread lock to the bolts and tighten th...

Page 94: ...op Side Disassembly Page 1D 10 2 Remove the rocker arm shaft bolts 1 3 Remove the rocker arm shaft 2 using 6 mm bolt A 4 Remove each rocker arm 3 and wave washer 4 Assembly Assembly is in the reverse order of disassembly Pay attention to the following points NOTE Intake rocker arm shaft 1 has the oil holes Apply engine oil to the rocker arm shafts Install the rocker arms and tighten the rocker arm...

Page 95: ...20 2 Measure each rocker arm shaft out side diameter using the micrometer If the diameter exceeds the limit replace the rocker arm shaft with a new one Special tool 09900 20205 Micrometer 0 25 mm Rocker arm shaft O D IN EX Standard 11 973 11 984 mm 0 4714 0 4718 in 3 Reinstall the removed parts Rocker Arm Inspection When checking the rocker arm the inside diameter of the rocker arm and wear of the...

Page 96: ... valve spring retainer and valve spring 5 Remove the valve from the other side 6 Remove the oil seal with long nose pliers 7 Remove the valve spring seat 8 Remove other valves in the same manner NOTE Remove of valves completes ordinary disassembling work If valve guides have to be removed for replacement after inspecting the related parts carry out the steps shown in the valve guide servicing Asse...

Page 97: ...p 2 of the cotter fits snugly into the groove 3 in the stem end Special tool A 09916 14510 Valve spring compressor 09916 14910 Valve spring compressor attachment 09916 84511 Tweezers CAUTION Be sure to restore each spring valve and spring retainer to their original positions Cylinder Head Related Parts Inspection B827H11406025 Cylinder Head Distortion 1 Decarbonize the combustion chamber 2 Check t...

Page 98: ...ly inspect each valve face for wear or damage If any abnormal wear is found replace the respective valve with a new one Measure the valve head thickness T If the valve head thickness is not within the specified value replace the value with a new one Special tool 09900 20101 Vernier calipers 1 15 mm 150 mm Valve head thickness T Service limit 0 5 mm 0 02 in Valve Stem Deflection Lift the valve abou...

Page 99: ...es less than the service limit the valve must be replaced Valve stem end length Service limit 2 3 mm 0 09 in Valve Spring The force of the coil spring keeps the valve seat tight A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism Check the valve springs for proper strength by measuring their free length and also by th...

Page 100: ...ure to check the valve clearance after the cylinder head has been reinstalled 1 Clean and assemble the head and valve components 2 Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing WARNING Always use extreme caution when handling gasoline Valve Guide Replacement B...

Page 101: ...e installer CAUTION Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head Special tool A 09916 44310 Valve guide remover installer 9 After installing the valve guides refinish their guiding bores using the reamer Be sure to clean and oil the guides after reaming Special tool B 09916 34542 Reamer handle C 09916 34570 Valve guide reamer 5 0...

Page 102: ...en noted to produce abnormal noise or vibration or to lack output power Any of these malconditions could be caused by a worn camshaft Camshaft Cam Wear Worn down cams are often the cause of mistimed valve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cam in terms of cam height H which is to be measured with a micrometer Replace camshaft ...

Page 103: ...lope scale This measurement should be taken at the widest part If the camshaft journal oil clearance exceeds the limit measure the outside diameter of the camshaft Replace either the cylinder head set or camshaft if it the clearance is incorrect Special tool 09900 20205 Micrometer 0 25 mm Camshaft journal O D IN EX Standard Sprocket side 21 959 21 980 mm 0 8645 0 8654 in Standard Other side 17 466...

Page 104: ...orn or damaged replace it with a new one 3 Install the cam chain tensioner Refer to Engine Top Side Assembly Page 1D 13 Cam Chain Guide Inspection B827H11406022 Inspect the cam chain guide in the following procedures 1 Remove the cam chain guides Refer to Engine Top Side Disassembly Page 1D 10 2 Check the contacting surface of the cam chain guide If it is worn or damaged replace it with a new one ...

Page 105: ...t ring to remove it NOTE Do not expand the piston ring excessively since it is apt to be broken down 3 Remove the 2nd ring and oil ring in the same manner Installation NOTE When installing the piston ring be careful not to damage the piston Do not expand the piston ring excessively since it is apt to be broken down 1 Install the piston rings in the order of the oil ring second ring and top ring a ...

Page 106: ...eter at the place shown in figure If the measurement is less than the limit replace the piston Special tool 09900 20210 Micrometer 100 125 mm Piston diameter Service limit 81 880 mm 3 2236 in Piston to cylinder Clearance Subtract the piston diameter from the cylinder bore diameter If the piston to cylinder clearance exceeds the following limit overhaul the cylinder and use an oversize piston or re...

Page 107: ... 0 0791 0 0799 in Piston ring thickness Standard 1st 0 97 0 99 mm 0 0382 0 0390 in Standard 2nd 0 97 0 99 mm 0 0382 0 0390 in Piston Ring Free End Gap and Piston Ring End Gap Before installing piston rings measure the free end gap of each ring using vernier calipers Next fit the ring in the cylinder and measure each ring end gap using a thickness gauge If any ring has an excess end gap replace the...

Page 108: ...ns Special tool 09900 20205 Micrometer 0 25 mm Piston pin O D Service limit 19 980 mm 0 7866 in Engine Bottom Side Disassembly B827H11406033 LT A400 F NOTE The crankcase must be separated to service the crankshaft and conrod 1 Remove the engine assembly from the frame Refer to Engine Assembly Removal Page 1D 6 2 Remove the engine top side Refer to Engine Top Side Disassembly Page 1D 10 Starter Mot...

Page 109: ...Remove the transfer gearshift related parts Refer to Transfer Gearshift Shaft No 2 Gearshift Cam Plate Removal and Installation LT A400 F in Section 3C Page 3C 17 Transfer Drive Gear No 2 1 Remove the transfer drive gear No 2 1 by removing the snap ring Special tool 09900 06107 Snap ring pliers 2 Remove the spacer 2 Oil Filter Remove the oil filter with the special tool Special tool A 09915 40610 ...

Page 110: ...ngs Cam Chain Remove the cam chain 1 Oil Pump 1 Remove the oil pump drive gear bolt with holding the oil pump driven gear 1 using the special tool 2 Remove the washer 2 and oil pump drive gear 3 from the oil pump Special tool A 09930 40113 Rotor holder 3 Remove the pin 4 4 Remove the snap ring 5 Special tool 09900 06107 Snap ring pliers 5 Remove the oil pump driven gear 1 6 Remove the pin 6 and wa...

Page 111: ... A 09920 13120 Crankcase separating tool Transfer Gearshift 1 Remove the reverse idle gear assembly 1 2 Remove the transfer input shaft 2 3 Remove the gearshift forks and transfer output shaft assembly 3 4 Remove the gearshift cam assembly 4 5 Remove the front output shaft 5 and rear output shaft 6 LT A400F 6 Remove the rear output shaft 6 LT A400 I827H1140112 01 I827H1140113 01 A I827H1140114 01 ...

Page 112: ... Drive Bevel Gear and Output Shaft Remove the drive bevel gear 1 and output shaft Refer to Transfer Removal and Installation LT F400 F in Section 3C Page 3C 7 LT F400 F NOTE The crankcase must be separated to service the crankshaft and conrod 1 Remove the engine assembly from the frame Refer to Engine Assembly Removal Page 1D 6 2 Remove the engine top side Refer to Engine Top Side Disassembly Page...

Page 113: ...e starter idle gear No 1 1 and No 2 2 Transfer Gearshift System Remove the transfer related parts Refer to Transfer Removal and Installation LT F400 F in Section 3C Page 3C 7 Gear Position Switch 1 Remove the gear position switch 1 2 Remove the switch contacts and springs Clutch Remove the clutch component parts 1 Refer to Clutch Removal and Installation LT F400 F in Section 5C Page 5C 3 1 2 I827H...

Page 114: ...il filter wrench Oil Pump 1 Remove the oil pump drive gear bolt with holding the oil pump driven gear 1 using the special tool 2 Remove the washer 2 and oil pump drive gear 3 Special tool A 09930 40113 Rotor holder 3 Remove the pin 4 4 Remove the snap ring 5 Special tool 09900 06107 Snap ring pliers 5 remove the oil pump driven gear 1 1 I827H1140132 01 2 3 I827H1140133 01 1 I827H1140134 01 A I827H...

Page 115: ...l tool attachment to the crankshaft end Special tool B 09930 31921 Rotor remover 3 Remove the generator rotor 1 with the special tool Special tool C 09930 30721 Rotor remover Starter Driven Gear 1 Remove the generator rotor 1 with the special tool 2 Remove the starter driven gear 2 Crankcase 1 Remove the oil separator 1 6 7 8 I827H1140138 01 A I827H1140139 01 B I827H1140140 01 1 C I827H1140141 01 ...

Page 116: ... in the crankcase half Special tool A 09920 13120 Crankcase separating tool Gearshift Cam Remove the transfer reverse gearshift cam assembly 1 gearshift cam 2 and gearshift forks 3 Transmission 1 Remove the reverse idle gear assembly 1 2 Remove the driveshaft assembly 2 and countershaft assembly 3 I827H1140144 01 I827H1140145 01 A I827H1140146 01 1 2 3 3 I827H1140147 01 1 I827H1140148 01 2 3 I827H...

Page 117: ...evel Gear and Output Shaft Remove the drive bevel gear 1 and output shaft Refer to Drive Bevel Gear Removal and Installation LT F400 F in Section 3D Page 3D 15 Engine Bottom Side Assembly B827H11406034 Assemble the engine bottom side in the reverse order of disassembly Pay attention to the following points NOTE Apply engine oil to each running and sliding part before reassembling LT A400 F CAUTION...

Page 118: ...ment will be affected Install the gearshift cam stopper Refer to Transfer Gearshift Shaft No 2 Gearshift Cam Plate Removal and Installation LT A400 F in Section 3C Page 3C 17 Balancer Install the balancershaft 1 Install the key 2 Install the balancershaft driven gear 3 with aligning the punch marks Transfer Gearshift Install the front output shaft 1 and rear output shaft 2 LT A400F Install the rea...

Page 119: ...e shaft 12 spacer 13 and bearing 14 Install the reverse idle gear 15 and washer 16 Crankcase Wipe the crankcase mating surfaces both surfaces with a cleaning solvent Fit the dowel pins onto the left half on the crankcase Apply engine oil to the conrod big end the gears A 44D TL For reverse gear B 44D TM For HIgh Low gear A A I827H1140156 01 5 4 6 7 I827H1140157 01 8 9 10 I827H1140158 01 A B I827H1...

Page 120: ...to the bolt A Tightening torque Crankcase bolt M6 11 N m 1 1 kgf m 8 0 lb ft Crankcase bolt M8 26 N m 2 6 kgf m 19 0 lb ft After the crankcase bolts have been tightened check if the each shaft rotates smoothly If a large resistance is felt to rotation try to free the shafts by tapping them with a plastic hammer Oil Pump Install the dowel pins Install the oil pump 1 Install the washer 2 and pin 3 L...

Page 121: ...D LOCK CEMENT SUPER 1303 or equivalent NOTE Flange side of the oil pump drive gear is positioned inside Tighten the oil pump drive gear bolt to the specified torque with the special tool Tightening torque Oil pump drive gear bolt 80 N m 8 0 kgf m 58 0 lb ft Special tool A 09930 40113 Rotor holder Cam Chain Install the cam chain 1 Gear Position Switch Install the springs and switch contacts Install...

Page 122: ...tall the oil filter Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 7 Special tool A 09915 40610 Oil filter wrench Transfer Output Drive Gear Install the spacer 1 Install the transfer output drive gear 2 and new snap ring 3 CAUTION Never reuse the removed snap ring Special tool 09900 06107 Snap ring pliers Gearshift System Install the transfer gearshift related parts Refer to Tran...

Page 123: ...tall the speedometer gearbox CAUTION Use new gasket to prevent oil leakage Apply thread lock to the bolts and tighten them to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Speedometer gearbox bolt a 10 N m 1 0 kgf m 7 0 lb ft Starter Cup Apply grease to the to the O ring and lip of the oil seal Install the starter cup 1 Grease 990...

Page 124: ...Bearing installer set CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tools otherwise the accuracy of the crankshaft alignment will be affected Balancer Install the balancershaft 1 Install the key 2 Install the balancershaft driven gear 3 with aligning the punch marks Transmission Install the front output shaft 1 and rear output shaft...

Page 125: ...embly 5 Install the reverse idle gear shaft 6 Install the snap ring 7 washer 8 and spacer 9 Special tool 09900 06107 Snap ring pliers Install the reverse idle gear 10 and washer 11 Gearshift Cam Install the spacer into the transfer reverse gearshift cam shaft 3 I827H1140184 01 A A I827H1140185 01 5 4 I827H1140186 01 6 7 8 9 I827H1140187 01 11 10 I827H1140188 01 I827H1140267 01 ...

Page 126: ...solvent Fit the dowel pins to the left on the crankcase Apply engine oil to the conrod big end the gears Apply bond to the mating surface of the right crankcase Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent 1 2 3 5 6 I827H1140189 01 4 I827H1140190 01 1 38F6 A For reverse gear 2 19B 1U For 1st driven 3rd driven gear 3 19B 2 For 2nd driven gear 4 19B 30 For High Low gear 1 3 4 2 C D A B I82...

Page 127: ...he starter driven gear 1 Install the key 2 NOTE Degrease the tapered portion of the generator rotor assembly and of the crankshaft Use nonflammable cleaning solvent to wipe off the oily or greasy matter to make these surfaces completely dry Generator Rotor Install the generator rotor assembly CAUTION Make sure that the one way clutch on the crankshaft is fitted into the generator rotor properly Ti...

Page 128: ...all the pin 5 Install the oil pump drive gear 6 and washer 7 Apply thread lock to the oil pump drive gear bolt Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent NOTE Flange side of the oil pump drive gear is positioned inside Tighten the oil pump drive gear bolt to the specified torque with the special tool Tightening torque Oil pump drive gear bolt 80 N m 8 0 kgf m 58 0 l...

Page 129: ...gearshift cam plate 1 Install the spring to the gearshift cam shaft properly Install the gearshift cam shaft assembly while aligning the spring ends with the stopper pin Install the gearshift cam plate guide 2 Clutch install the clutch component parts 1 Refer to Clutch Removal and Installation LT F400 F in Section 5C Page 5C 3 A I827H1140201 01 1 I827H1140202 01 1 I827H1140203 01 I827H1520029 01 I...

Page 130: ...nstall the transfer related parts Refer to Transfer Removal and Installation LT F400 F in Section 3C Page 3C 7 Starter idle Gear Install the starter idle gear No 1 1 and No 2 2 Generator cover Install the dowel pins and new gasket 1 Install the generator cover NOTE Fit the clamp to the bolt A Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 8 1 I827H1140207 01 I827H1140208 01 I827H114...

Page 131: ...y thread lock to the bolts and tighten them to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Speedometer gearbox bolt a 10 N m 1 0 kgf m 7 0 lb ft Stater Cup Apply grease to the to the O ring and lip of the oil seal Install the starter cup 1 Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the starter cup nut with a ...

Page 132: ...and B 09900 20607 Dial gauge 1 100 mm 10 mm C 09900 21304 V block 100 mm Conrod deflection Service Limit 3 0 mm 0 12 in Conrod Big End Side Clearance 1 Check the conrod big end side clearance with the thickness gauge Special tool A 09900 20803 Thickness gauge Conrod big end side clearance Service limit 1 0 mm 0 04 in 2 If the clearance exceeds the limit replace the crankshaft assembly and conrod w...

Page 133: ...D 34 and Bearing Removal and Installation Page 1D 60 Bearing Inspection B827H11406038 Refer to Engine Bottom Side Disassembly Page 1D 34 Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase Replace the bearing if there is anything unusual LT A400 F left crankcase LT A400 F right crankcase LT F400 F left crankcase LT ...

Page 134: ...nsfer input shaft bearing and balancer shaft bearing with the special tool Special tool B 09921 20240 Bearing remover set 4 Remove other bearings with the special tool Special tool C 09913 70210 Bearing installer set LT A400 F Right crankcase 1 Remove the transfer countershaft bearing with the special tool Special tool B 09921 20240 Bearing remover set I827H1140305 01 I827H1140276 01 1 A I827H1140...

Page 135: ... special tool Special tool A 09921 20240 Bearing remover set 3 Remove the other bearings with the special tool Special tool B 09913 70210 Bearing installer set LT F400 F right crankcase 1 Remove the retainers 2 Remove the drive shaft bearing with the special tool Special tool A 09913 70210 Bearing installer set C I827H1140281 01 I827H1140282 02 A I827H1140283 02 B I827H1140284 02 I827H1140285 02 A...

Page 136: ...ection 1J Page 1J 5 2 Remove the oil seal retainer 3 Remove the oil seal 1 with the special tool Special tool A 09913 50121 Oil seal remover 4 Remove the spacer 2 5 Remove the bearings with the special tools Special tool B 09913 70210 Bearing installer set C 09921 20240 Bearing remover set 6 Remove the oil seal A A I827H1140286 03 I827H1140287 02 A 2 1 I827H1140288 03 B I827H1140289 02 C I827H1140...

Page 137: ... Remove the spacer 2 5 Remove the bearings with the special tools Special tool B 09913 70210 Bearing installer set C 09921 20240 Bearing remover set 6 Remove the oil seals Installation LT A400 F right crankcase Install the bearings with the special tool CAUTION Use the suitable size attachment for each bearing Special tool A 09913 70210 Bearing installer set I827H1140307 01 A 2 1 I827H1140308 01 B...

Page 138: ...a new one 3 Apply thread lock to the screws and install the retainers by tightening them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent LT F400 F right crankcase 1 Install the bearings with the special tool CAUTION Use the suitable size attachment for each bearing Special tool A 09913 70210 Bearing installer set 2 Apply thread lock to the screws and tighten them Thread ...

Page 139: ... tighten them Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent LT A400 F Generator cover CAUTION The removed bearings and oil seals must be replaced with new ones Special tool A 09913 70210 Bearing installer set Install the bearing with the special tool Install the bearings with the special tool Special tool A 09913 70210 Bearing installer set I827H1140302 02 I827H1140303...

Page 140: ...s outside Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent LT F400 F Generator cover CAUTION The removed bearings and oil seals must be replaced with new ones Special tool A 09913 70210 Bearing installer set Install the bearing with the special tool Install the bearings with the special tool Special tool A 09913 70210 Bearing installer set A I827H1140294 03 A I827H1140295 03 A I827H1140296 0...

Page 141: ...iam IN 30 6 1 20 EX 27 0 1 06 Valve clearance when cold IN 0 05 0 10 0 002 0 004 EX 0 22 0 27 0 009 0 011 Valve guide to valve stem clearance IN 0 010 0 037 0 0004 0 0015 EX 0 030 0 057 0 0012 0 0022 Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 975 4 990 0 1959 0 1965 EX 4 955 4 970 0 1951 0 1957 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve...

Page 142: ...0 075 0 0026 0 0030 0 120 0 0047 Cylinder bore 82 000 82 015 3 2283 3 2289 82 070 3 2311 Piston diam 81 930 81 945 3 2256 3 2262 Measure at 15 mm 0 6 in from the skirt end 81 880 3 2236 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st R Approx 8 9 0 35 7 1 0 28 2nd R Approx 10 4 0 41 8 3 0 33 Piston ring end gap 1st 0 15 0 27 0 006 0 011 0 50 0 020 2nd 0 15 0 27 0 006 0 011 0 50 0 020 P...

Page 143: ...sprocket bolt 15 1 5 11 0 Page 1D 16 Cylinder head cover bolt 10 1 0 7 0 Page 1D 18 Cam chain tension adjuster bolt 10 1 0 7 0 Page 1D 19 Cam chain tension adjuster spring holder bolt 8 0 8 6 0 Page 1D 19 Recoil starter mounting bolt 10 1 0 7 0 Page 1D 19 TDC plug 23 2 3 16 5 Page 1D 19 Spark plug 11 1 1 8 0 Page 1D 20 Rocker arm shaft bolt 28 2 8 20 Page 1D 20 Cylinder head cover bolt 10 1 0 7 3 ...

Page 144: ...e 1D 64 Page 1D 65 Material SUZUKI recommended product or Specification Note 09900 06107 09900 20101 Snap ring pliers Vernier calipers 1 15 mm 150 mm Page 1D 35 Page 1D 36 Page 1D 40 Page 1D 47 Page 1D 48 Page 1D 51 Page 1D 54 Page 1D 24 Page 1D 25 Page 1D 33 09900 20202 09900 20205 Micrometer 1 100 mm 25 50 mm Micrometer 0 25 mm Page 1D 28 Page 1D 21 Page 1D 25 Page 1D 29 Page 1D 33 Page 1D 34 09...

Page 145: ...Page 1D 29 Page 1D 58 Page 1D 58 09900 22302 09900 22403 Plastigauge 0 051 0 152 mm Small bore gauge 18 35 mm Page 1D 28 Page 1D 34 09910 32812 09913 50121 Crankshaft installer Oil seal remover Page 1D 44 Page 1D 50 Page 1D 63 Page 1D 60 Page 1D 62 09913 70210 09915 40610 Bearing installer set Oil filter wrench Page 1D 63 Page 1D 63 Page 1D 64 Page 1D 64 Page 1D 64 Page 1D 65 Page 1D 65 Page 1D 65...

Page 146: ...80 Valve guide reamer 5 0 mm Valve guide reamer 10 8 mm Page 1D 27 Page 1D 27 09916 44310 09916 84511 Valve guide remover installer Tweezers Page 1D 22 Page 1D 26 Page 1D 27 Page 1D 22 Page 1D 23 09920 13120 09921 20240 Crankcase separating tool Bearing remover set Page 1D 37 Page 1D 38 Page 1D 42 Page 1D 62 Page 1D 63 Page 1D 60 Page 1D 60 Page 1D 61 09930 10121 09930 30104 Spark plug wrench set ...

Page 147: ...D 73 09930 31921 09930 40113 Rotor remover Rotor holder Page 1D 41 Page 1D 43 Page 1D 36 Page 1D 40 Page 1D 47 Page 1D 54 09930 44541 09940 52861 Rotor holder Front fork oil seal installer Page 1D 41 Page 1D 53 Page 1D 44 ...

Page 148: ...IL COOLER OIL PUMP CYLINDER CAMSHAFT JOURNAL CENTER CRANKSHAFT JOURNAL BEARING L STARTER CLUTCH BEARING CONROD BIG END BEARING CYLINDER WALL PISTON STARTER SYSTEM RELATED GEARS ROCKER ARM SHAFT IN ROCKER ARM IN CAMSHAFT JOURNAL L CAMSHAFT JOURNAL R CAMSHAFT CAM FACES IN EX ROCKER ARM SHAFT EX VALVE SPRINGS STEMS CAM CHAIN AUTOMATIC DECOMP CYLINDER HEAD EX FOR CYLINDER HEAD COOLING OIL TEMP SWITCH ...

Page 149: ...CRANKSHAFT RIGHT END BEARING CLUTCH SHOE HOUSING BUSHING ONE WAY CLUTCH CLUTCH SHOE CYLINDER WALL PISTON STARTER SYSTEM RELATED GEARS ROCKER ARM SHAFT IN ROCKER ARM IN CAMSHAFT JOURNAL L CAMSHAFT JOURNAL R CAMSHAFT CAM FACES IN EX ROCKER ARM SHAFT EX VALVE SPRINGS STEMS CAM CHAIN CRANKSHAFT L CRANKSHAFT R AUTOMATIC DECOMP STARTER CLUTCH BEARING CYLINDER HEAD EX FOR CYLINDER HEAD COOLING OIL TEMP S...

Page 150: ...1E 3 Engine Lubrication System Cylinder Head Cooling System Chart Diagram B827H11502002 OIL SUMP FILTER ORIFICE OIL FILTER OIL COOLER OIL PUMP CYLINDER HEAD EX CYLINDER HEAD COOLING I827H1150003 01 ...

Page 151: ...in at 2 000 r min Winter 20 min at 2 000 r min 6 After warm up the engine increase the engine speed to 3 000 r min Observe the tachometer and read the oil pressure gauge If the oil pressure is lower or higher than the specification the following causes may be considered Oil pressure specification LT A400 F 110 150 kPa 1 1 1 5 kgf cm2 16 21 psi at 3 000 r min Oil temp at 60 C 140 F LT F400 F 60 100...

Page 152: ...tion 0B Page 0B 7 Engine Oil Level Inspection B827H11506002 Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 7 Oil Sump Filter Removal and Installation B827H11506003 Removal 1 Remove the engine protector Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Drain engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 7 3 Remove the oil sump...

Page 153: ...tall the oil jet in the reverse order of removal Pay attention to the following points Apply engine oil to the O ring CAUTION Use a new O ring to prevent oil leakage Oil Jet Inspection LT F400 F B827H11506006 Refer to Oil Jet Removal and Installation LT F400 F Page 1E 6 Make sure that the oil jet is not clogged If it is clogged clean the oil passage using a wire of the proper size or compressed ai...

Page 154: ...Remove the pin 5 washer 6 and oil pump 7 7 Remove the dowel pins Installation Install the oil pump and oil pump drive gear in the reverse order of removal Pay attention to the following points NOTE Be careful not to drop the parts into the crankcase Install the oil pump driven gear 1 as shown Install the new snap ring 2 CAUTION Never reuse the removed snap ring 1 2 A I827H1150013 01 3 I827H1150014...

Page 155: ...tch Shoe Removal and Installation in Section 5A Page 5A 16 Install the clutch cover LT F400 F Refer to Clutch Removal and Installation LT F400 F in Section 5C Page 5C 3 Oil Pump Inspection B827H11506008 Inspect the oil pump in the following procedures 1 Remove the oil pump Refer to Oil Pump Drive Gear Oil Pump Removal and Installation Page 1E 6 2 Rotate the oil pump by hand and check that it moves...

Page 156: ...inner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Inspect the oil cooler hoses for any damage and oil leakage If any defects are found replace the oil cooler hose with new ones 1 3 5 4 2 a a a a 5 5 5 FWD FWD I827H1150048 02 1 Oil cooler 10 N m 1 0 kgf m 7 0 lb ft 2 Oil cooler fin guard net Apply grease 3 Oil hose inlet Apply thread lock 4 Oil hose outlet Do n...

Page 157: ... engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 7 2 Remove the left inner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Remove the oil cooler hose bolts oil cooler side 4 Remove the oil cooler 1 5 Remove the oil cooler hoses 2 and 3 Installation Install the oil cooler hoses and oil cooler in the reverse order of removal Pay attention...

Page 158: ...cified torque Tightening torque Oil cooler hose bolt oil cooler side b 10 N m 1 0 kgf m 7 0 lb ft Pour engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 7 Oil Cooler Cleaning B827H11506021 Clean the oil cooler in the following procedures 1 Remove the oil cooler Refer to Oil Cooler Oil Cooler Hose Removal and Installation Page 1E 10 2 Blow out any foreign matter that is st...

Page 159: ...ed as shown in the figure If the fan motor does not turn replace the cooling fan assembly with a new one Refer to Cooling Fan Removal and Installation Page 1E 13 NOTE When making this test it is not necessary to remove the cooling fan The voltmeter is for making sure that the battery applies 12 V to the motor With the fan motor with electric motor fan running at full speed the ammeter should be in...

Page 160: ...ner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Disconnect the cooling fan thermo switch lead wire coupler 1 3 Place a rag under the switch and remove the cooling fan thermo switch 1 Installation Installation is in the reverse order of removal Pay attention to the following points Install new seal washer 1 Tighten the engine oil temperature switch to the speci...

Page 161: ... pan Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity Cooling fan thermo switch operating temperature Standard OFF ON Approx 120 C 248 F Standard ON OFF Approx 110 C 230 F 5 Reinstall the cooling fan thermo switch Refer to Cooling Fan Thermo switch Removal and Installation Page 1E 13 Engine Oil Temperature Switch Removal and Installation B827H11506017 Removal 1 R...

Page 162: ...bject it to strong blows or allow it to be dropped Do not contact the engine oil temperature switch 1 and the column thermometer 2 with the pan Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity Cooling fan thermo switch operating temperature Standard OFF ON Approx 160 C 320 F Standard ON OFF Approx 140 C 284 F 5 Reinstall the engine oil temperature switch Refer to...

Page 163: ...mperature OFF ON Approx 160 C 320 F ON OFF Approx 140 C 284 F Cooling fan thermo switch operating temperature OFF ON Approx 120 C 248 F ON OFF Approx 110 C 230 F Item Specification Note Engine oil type SAE 10 W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 2 900 ml 3 1 2 6 US lmp qt Filter change 3 100 ml 3 3 2 7 US lmp qt Overhaul 3 400 ml 3 6 3 0 US lmp qt Item Standard Limit Oil...

Page 164: ...ain oil gallery plug 23 2 3 16 5 Page 1E 5 Oil pump drive gear bolt 80 8 0 58 0 Page 1E 8 Oil cooler hose bolt engine side 10 1 0 7 0 Page 1E 11 Oil cooler hose bolt oil cooler side 10 1 0 7 0 Page 1E 11 Cooling fan thermo switch 20 2 0 14 5 Page 1E 13 Engine oil temperature switch 23 2 3 16 5 Page 1E 14 Oil pressure regulator 23 2 3 16 5 Page 1E 15 Material SUZUKI recommended product or Specifica...

Page 165: ...Engine Lubrication System 1E 18 09930 40113 Rotor holder Page 1E 7 Page 1E 8 ...

Page 166: ... System B827H11700001 WARNING Gasoline is highly flammable and explosive Extreme care must be taken Keep heat sparks and flames away from gasoline General Description I D No Location B827H11701002 Each carburetor has an I D number A printed on its body A I827H1170016 01 ...

Page 167: ...ts of a fuel tank fuel filter fuel valve vacuum hose fuel hose and carburetor assembly When there is negative pressure vacuum in the combustion chamber the fuel is able to flow from the fuel tank through the fuel valve and then to the carburetor assembly A B I827H1170033 01 A Vacuum B Fuel ...

Page 168: ...e pressure vacuum A is generated in the combustion chamber and reaches the diaphragm through a passage in the carburetor s main bore and the vacuum hose This negative pressure vacuum A is higher than the spring pressure which causes the diaphragm to force open the fuel valve 1 and allow fuel B to flow to the carburetor assembly 1 2 A B A B I827H1170034 01 1 Fuel valve A Vacuum A Fuel stop conditio...

Page 169: ...ragm chamber 2 through an orifice C provided in the piston valve 1 Rising negative pressure overcomes the spring 3 force causing the piston valve 1 to rise into the diaphragm chamber and prevent the air velocity from increasing Thus air velocity in the venturi passage is kept relatively constant for improved fuel atomization and the precise air fuel mixture A B 3 2 C A B 1 I827H1170035 02 1 Piston...

Page 170: ...air jet 4 This mixture rich with fuel then goes up through the passage to the pilot screw 5 Part of the mixture is discharged into the main bore through bypass ports 6 The mixture is metered by the pilot screw 5 and sprayed into the main bore through the pilot outlet port 7 6 3 2 4 C A B 7 5 1 I827H1170036 02 1 Throttle valve 3 slow jet 5 Pilot screw 7 Pilot outlet port B Fuel Air mixture 2 Float ...

Page 171: ...s an emulsion The emulsified fuel then passes through the clearance between the needle jet 5 and jet needle 7 and is discharged into the venturi A where it meets the main air stream being drawn by the engine Mixture proportioning is accomplished in the needle jet 5 The clearance through which the emulsified fuel must flow ultimately depends on throttle position 1 5 7 A 6 3 4 C A B 2 I827H1170037 0...

Page 172: ...ter plunger 4 and mixes again with the air coming through a passage extending from behind the diaphragm The two successive mixtures of the fuel with the air provide the proper air fuel mixture for starting This occurs when the mixture is sprayed through the starter outlet port 5 into the main bore NOTE A starter enricher system is operated almost the same way as a choke 3 1 2 5 5 3 4 1 2 C A B I82...

Page 173: ...ps proper fuel air mixture ratio But when the throttle valve is closed suddenly a large negative pressure generated on cylinder side works on to a diaphragm 3 The valve 4 on the diaphragm closes the air 1 therefore the fuel air mixture becomes rich with fuel This system is to keep the combustion condition constant by varying the fuel air mixture ratio by controlling air flow 1 2 C A B I827H1170043...

Page 174: ...ses and the needle valve 2 pushes up against the valve seat When this occurs no fuel enters the float chamber 3 As the fuel level falls the float 1 lowers and the needle valve 2 unseats itself admitting fuel into the float chamber 3 In this manner the needle valve 2 admits and shuts off fuel to maintain the appropriate fuel level inside the float chamber 3 3 2 1 A I827H1170039 02 1 Float 3 Float c...

Page 175: ...and Routing Diagram Carburetor Hose Routing Diagram B827H11702001 LH RH A LH RH B 1 3 2 3 2 3 2 UP A I827H1170040 02 1 Vacuum hose 3 Air vent hose A Intake pipe side 2 Fuel hose A Clamp end should face downward B Air cleaner side ...

Page 176: ...et port Clean Clogged bypass port Clean Starter enricher plunger not fully closed Adjust Improperly set pilot screw Adjust Incorrect float height Adjust Medium or high speed trouble Clogged main jet Clean Clogged main air jet Clean Clogged needle jet Clean Improperly working throttle valve Adjust Clogged fuel filter Clean or replace Incorrect float height Adjust Starter enricher plunger not fully ...

Page 177: ... 12 Repair Instructions Fuel Tank Construction B827H11706018 1 2 3 a a 4 3 3 4 I827H1170041 02 1 Fuel tank upper cover a 29 mm 1 14 in 2 Fuel tank 4 6 N m 0 46 kg f 3 5 lb ft 3 Fuel tank cushion Do not reuse 4 Frame ...

Page 178: ...fuel valve ON position A 4 Disconnect the fuel hose 3 and vacuum hose 4 5 Remove the fuel tank mounting bolts 6 Remove the fuel tank backward 7 Drain fuel completely Installation Remount the fuel tank in the reverse order of removal Fuel Valve Removal and Installation B827H11706019 Removal WARNING Gasoline is very explosive Extreme care must be taken 1 Remove the fuel tank Refer to Fuel Tank Remov...

Page 179: ... is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air 4 Reinstall the fuel valve Refer to Fuel Valve Removal and Installation Page 1G 13 5 Reinstall the fuel tank Refer to Fuel Tank Removal and Installation Page 1G 13 Fuel Level Gauge Removal and Installation B827H11706021 Removal WARNING Gasoline is very explosive...

Page 180: ...13 Starter Cable Removal and Installation B827H11706025 Removal 1 Remove the front fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Remove the left handlebar switch box Refer to Handlebars Removal and Installation in Section 6B Page 6B 3 3 Remove the starter cable as shown in the throttle cable routing diagram Refer to Throttle Cable Routing Diagram in Section 1D P...

Page 181: ...2 Spring retainer 10 Holder 18 Needle jet holder 25 Pilot screw 3 Jet needle 11 Cap 19 Main jet 26 O ring 4 Diaphragm 12 O ring 20 Slow jet 27 Float chamber body 5 Spring 13 Coasting enrichment valve 21 Starter jet 28 Vacuum hose 6 Air vent hose 14 Spring 22 Needle valve 29 Tampering plug P 33 only 7 Throttle lever cap 15 Cover 23 Float Apply grease 8 Starter plunger 16 Throttle stop screw 19 Main...

Page 182: ...he air cleaner box and intake pipe 7 Disconnect the starter cable 5 Installation Install the carburetor assembly in the reverse order of removal Pay attention to the following points Perform the following adjustments Engine idle speed Refer to Engine Idle Speed Inspection Page 1G 22 Throttle cable play Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Page 0B 13 Carburetor Disas...

Page 183: ...ragm 4 Remove the spring 9 spring retainer 10 spacer 11 jet needle 12 and diaphragm 13 5 Remove the float chamber body 14 6 Remove the O ring 15 7 Remove the throttle stop screw 16 8 Remove the float pin 17 float 18 and needle valve 19 8 I827H1170002 02 9 10 11 12 13 I827H1170003 03 14 I827H1170004 02 15 I827H1170005 02 16 I827H1170006 02 17 18 19 I827H1170007 02 ...

Page 184: ...s in the pilot system the pilot system components should be removed before cleaning 1 Use a 1 8 size drill bit 1 with a drill stop A to remove the pilot screw plug 2 2 Set the drill stop A 4 mm 0 16 mm from the end of the bit to prevent drilling into the pilot screw 3 3 Carefully drill through the plug 2 4 Thread a self tapping sheet metal screw into the plug 2 5 Pull on the screw head with pliers...

Page 185: ...l a new plug by tapping it into place with a punch For tampering plug type Check the float height Refer to Float Height Inspection and Adjustment Page 1G 21 Install a new O ring to the float chamber body properly CAUTION Replace the O ring with a new one Install the diaphragm NOTE When installing the diaphragm mark sure the tab of the diaphragm is aligned with the concave section of the carburetor...

Page 186: ...tor Assembly Page 1G 20 and Carburetor Disassembly Page 1G 17 Carburetor Parts Check the following items for any damage or clogging If they are clogged clean the fuel passage Slow jet Main jet Main air jet Slow air jet Needle jet holder air bleeding holes Float Jet needle Valve seat Piston valve Starter enricher jet O rings Throttle valve Diaphragm Pilot outlet and by pass ports Needle Valve Check...

Page 187: ...pe cleaning solution and allow them to soak Engine Idle Speed Inspection B827H11706033 Refer to Engine Idle Speed Adjustment in Section 0B Page 0B 13 Fuel Line Inspection B827H11706034 Refer to Fuel Line Inspection in Section 0B Page 0B 7 Air Cleaner Element Removal and Installation B827H11706035 Refer to Air Cleaner Element Removal and Installation in Section 1D Page 1D 5 Air Cleaner Element Insp...

Page 188: ...unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the Research Method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible P 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline type is recommended Others Fuel tank capacity incl...

Page 189: ...ke switch Ignition starter control relay Neutral switch Engine stop switch I827H1180007 01 Condition Possible cause Correction Reference Item Spark plug not sparking Damaged spark plug Replace Damaged spark plug cap Replace Fouled spark plug Clean or replace Wet spark plug Clean and dry or replace Defective ignition coil Replace Open or short in high tension cord Replace Defective CKP sensor Repla...

Page 190: ...CDI unit with the ignition switch in ON position Is the voltage OK Go to Step 3 Faulty ignition switch Faulty wire harness Broken wire harness or poor connection of related circuit couplers 3 Measure the ignition coil primary peak voltage Refer to Ignition Coil and Plug Cap Inspection Page 1H 3 NOTE This inspection method is applicable only with the multi circuit tester and peak voltage adaptor Is...

Page 191: ...o not cross thread or over tighten the spark plug or such an operation will damage the aluminum threads of the cylinder head Special tool 09930 10121 Spark plug wrench set Tightening torque Spark plug 11 N m 1 1 kgf m 8 0 lb ft Spark Plug Inspection and Cleaning B827H11806002 Refer to Spark Plug Inspection and Cleaning in Section 0B Page 0B 6 Ignition Coil and Plug Cap Inspection B827H11806003 Ref...

Page 192: ...imary peak voltage 180 V and more 7 After measuring the ignition coil primary peak voltage reinstall the removed parts Ignition Coil Resistance 1 Remove the left side cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Disconnect the spark plug cap 3 Disconnect the ignition coil lead wires 4 Measure the ignition coil resistance in both the primary and secondary coils I...

Page 193: ... the peak voltage adaptor as follows CAUTION Before using the multi circuit tester and peak voltage adaptor refer to the appropriate instruction manual Special tool A 09900 25008 Multi circuit tester set Tester knob indication Voltage 4 Measure the CKP sensor peak voltage in the following procedures a Shift the transfer to the neutral turn the ignition switch ON b Press the starter button and allo...

Page 194: ...itch OFF 2 Remove the left inner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Disconnect the handlebar switch coupler 1 Yellow 4 Inspect the engine stop switch for continuity with a tester If any abnormality is found replace the handlebar switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Page 6B 3 Special tool 09900 25008...

Page 195: ...ng Torque List LT A400 F in Section 0C Page 0C 9 Special Tools and Equipment Special Tool B827H11808001 1 I827H1180011 01 Item Specification Note Spark plug Type NGK CR7E DENSO U22ESR N Gap 0 7 0 8 0 028 0 031 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance 130 250 Ω Bl G CKP sensor peak voltage 4 0 V and more Bl G Ignition coil resistance Primary 0 1 1 0 Ω Terminal Ground Secondary 12...

Page 196: ...er relay B W Y B Neutral relay Starter button Engine stop switch Emergency switch E 17 Fuse Ignition switch Ignition starter control realy CDI Parking brake switch Neutral indicator light O Y Y G Battery Neutral switch To reverse indicator light Bl B Bl R W Reverse switch I827H1190001 02 Condition Possible cause Correction Reference Item Starter button is not effective Run down battery Repair or r...

Page 197: ...ire because a large amount of current flows Does the starter motor run Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal Faulty starter motor 3 Measure the starter relay voltage at the starter relay connectors between Y B and B W when the starter button is pushed Is the voltage OK Go to Step 4 Faulty ignition switch ...

Page 198: ...or Installation Install the starter motor in the reverse order of removal Pay attention to the following points Apply grease to the starter motor O ring Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Replace the O ring with a new one 1 Housing end outside 7 Washer set 3 5 N m 0 35 kgf m 2 5 lb ft 2 Brush holder 8 Armature Apply grease to sliding surface 3 Brush spring 9 Housing end...

Page 199: ...or Components Page 1I 3 Assembly Reassemble the starter motor in the reverse order of removal Pay attention to the following points CAUTION Replace the O rings with new ones to prevent oil leakage and moisture Apply grease to the lip of the oil seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply a small quantity of moly paste to the armature shaft Moly paste 99000 25140 SUZUKI Moly p...

Page 200: ...e Armature Coil Measure for continuity between each segment Measure for continuity between each segment and the armature shaft If there is no continuity between the segments or there is continuity between the segments and shaft replace the armature with a new one Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity set Oil Seal Check the seal lip for damage If any ...

Page 201: ...nce the relay coil may overheat and get damaged Special tool A 09900 25008 Multi circuit tester set Tester knob indication Continuity test 3 Measure the relay coil resistance between the terminals using the multi circuit tester If the resistance is not within the specified value replace the starter relay with a new one Special tool A 09900 25008 Multi circuit tester set Starter relay resistance 3 ...

Page 202: ...oval and Installation Page 1I 6 Neutral Switch Diode Inspection B827H11906009 Refer to Electrical Components Location in Section 0A Page 0A 6 Inspect the neutral switch diode in the following procedures 1 Remove the left inner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Disconnect the neutral switch diode 1 3 Measure the voltage between the A and B terminals u...

Page 203: ...trol relay with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity test 4 Install the ignition starter control relay in the reverse order of removal Parking Brake Switch Inspection B827H11906012 Inspect the parking brake switch in the following procedures 1 Remove the left inner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D...

Page 204: ...y with the tester If any abnormality is found replace the gear position switch with a new one Refer to Gear Position GP Switch Removal and Installation LT F400 F in Section 5B Page 5B 7 Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the gear position switch inspection reinstall the removed parts Starter Clutch Removal and Installation B827H119...

Page 205: ...uide 2 NOTE Be sure to seat the flange A of the one way clutch 1 to the guide 2 Install the guide to the generator rotor NOTE The arrow mark B must face the engine side Tighten the starter clutch bolts to the specified torque using the special tool Special tool A 09930 44541 Rotor holder Tightening torque Starter clutch bolt a 26 N m 2 6 kgf m 19 0 lb ft Install the generator rotor assembly onto c...

Page 206: ...ts Inspection B827H11906016 Refer to Starter Clutch Removal and Installation Page 1I 9 Starter Clutch 1 Install the starter driven gear onto the starter clutch 2 Turn the starter driven gear by hand to inspect the starter clutch for smooth movement The gear turns in one direction only If a large resistance is felt for rotation inspect the starter clutch or the starter clutch contacting surface on ...

Page 207: ...ect the handlebar switch coupler 1 Yellow 3 Measure the voltage between Y G and O lead wires Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery Recoil Starter Components B827H11906018 1 2 I827H1190034 02 Y G probe O probe ON 0 4 0 6 V OFF 1 4 V and more Tester s ba...

Page 208: ...e specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Recoil starter mounting bolt a 10 N m 1 0 kgf m 7 0 lb ft Recoil Starter Disassembly and Assembly B827H11906020 Refer to Recoil Starter Assembly Removal and Installation Page 1I 13 Disassembly WARNING Wear hand and eye protection when removing the reel since the spring may quickly unwind...

Page 209: ...ay quickly unwind and cause an injury When installing the spiral spring hook the spiral spring end A with the recoil starter case as shown in the figure Apply grease to the spiral spring Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Turn the rope on the reel properly After installing the spiral spring engage the part B of the reel with the spiral spring end C Hook the rope onto the hook p...

Page 210: ...e nut to the specified torque Tightening torque Recoil starter center nut a 12 N m 1 2 kgf m 8 5 lb ft Pull the rope and check that the ratchet is pushed out Recoil Starter Inspection B827H11906021 Ratchet Set Inspect the ratchet set for wear or damage If any defects are found replace the ratchet set with a new one 2 1 I831G1190058 02 I831G1190059 01 a I827H1190035 01 I831G1190060 02 I831G1190061 ...

Page 211: ...ial B827H11908001 I831G1190062 02 I831G1190063 01 Item Specification Note Starter motor brush length Standard 10 0 39 Limit 6 5 0 26 Starter relay resistance 3 5 Ω Fastening part Tightening torque Note N m kgf m lb ft Starter motor mounting bolt 10 1 0 7 0 Page 1I 4 Starter motor lead wire mounting nut 7 0 7 5 0 Page 1I 4 Starter motor housing bolt 3 5 0 35 2 5 Page 1I 4 Starter clutch bolt 26 2 6...

Page 212: ...mponents Page 1I 12 Special Tool B827H11908002 09900 20102 09900 25008 Vernier calipers 1 20 mm 200 mm Multi circuit tester set Page 1I 5 Page 1I 5 Page 1I 6 Page 1I 6 Page 1I 7 Page 1I 7 Page 1I 8 Page 1I 8 Page 1I 9 Page 1I 9 Page 1I 12 09913 70210 09930 44541 Bearing installer set Rotor holder Page 1I 11 Page 1I 11 Page 1I 10 Page 1I 10 ...

Page 213: ...circuited lead wires or loose lead connections Repair replace or connect properly Short circuited grounded or open generator coil Replace Short circuited or punctured regulator rectifier Replace Generator does charge but charging rate is below the specification Lead wires tend to get short or open circuited or loosely connected at terminals Repair or retighten Grounded or open circuited generator ...

Page 214: ...old climate for too long Replace the battery if badly sulfated Condition Possible cause Correction Reference Item Step Action Yes No 1 Check accessories which use excessive amounts of electricity Are accessories being installed Remove accessories Go to Step 2 2 Check the battery for current leakage Refer to Battery Current Leakage Inspection Page 1J 3 Is the battery for current leakage OK Go to St...

Page 215: ...ct the battery terminal and install the seat Regulated Voltage Inspection B827H11A06002 Inspect the regulated voltage in the following procedures 1 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Start the engine and keep it running about 5 000 r min with the ignition switch turned LIGHT position A and dimmer switch HI position 3 Measure the DC voltage be...

Page 216: ...r coil resistance 0 3 1 5 Ω Ω B Ground 5 After finishing the inspection reinstall the removed parts No load Performance 1 Remove the left side cover and left footrest mudguard Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Connect the tachometer to the spark plug high tension cord 3 Disconnect the generator lead wire coupler 1 4 Start the engine and keep it running at 5...

Page 217: ... Section 9D Page 9D 3 4 Remove the recoil starter assembly 1 5 Remove the starter cup nut with a suitable bar 6 Remove the starter cup 2 7 Disconnect the oil hose 3 8 Disengage the gearshift link arm 4 LT F400 F and transfer gearshift arm 5 9 Remove the speedometer gearbox 6 10 Remove the bolt spring and transfer gearshift cam stopper 7 LT F400 F 11 Disconnect the CKP sensor lead wire coupler 8 an...

Page 218: ...ol A 09930 44541 Rotor holder 15 Install the special tool attachment to the crankshaft end Special tool B 09930 31921 Rotor remover 16 Remove the generator rotor 12 with the special tool Special tool C 09930 30721 Rotor remover 17 Remove the key 13 and starter driven gear 14 I827H11A0013 01 11 I827H11A0014 01 A I827H11A0015 01 B I827H11A0016 01 C 12 I827H11A0017 02 13 14 I827H11A0018 01 ...

Page 219: ...f m 4 3 lb ft Degrease the tapered portion A of generator rotor assembly and B of the crankshaft Use nonflammable cleaning solvent to wipe off oily or greasy matter to make these surfaces completely dry Fit the key 2 in the key slot on the crankshaft Install the generator rotor assembly onto crankshaft Hold the generator rotor with the special tool and tighten the generator rotor nut to the specif...

Page 220: ...00 F Tighten the transfer gearshift cam stopper bolt to the specified torque LT F400 F Tightening torque Transfer gearshift cam stopper bolt d 22 N m 2 2 kgf m 16 0 lb ft Apply grease to the sliding part of the speedometer gearbox Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Fit new gasket 7 CAUTION Use new gasket to prevent oil leakage Apply thread lock to the bolt and tighten them to t...

Page 221: ...UPER GREASE A or equivalent CAUTION Replace the O ring with a new one Tighten the starter cup nut to the specified torque with a proper bar Tightening torque Starter cup nut f 38 N m 3 8 kgf m 27 5 lb ft Apply a small quantity of thread lock to the recoil starter mounting bolts and tighten to the specified torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening...

Page 222: ...ester as indicated in the following table If the voltage is not within the specified value replace the regulator rectifier with a new one NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V 5 Connect the regulator rectifier coupler and reinstall the removed p...

Page 223: ...he sealed areas B of the electrolyte container After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes 3 Insert the nozzles of the electrolyte container 3 into the electrolyte filler holes of the battery 4 Hold the electrolyte container firmly so that it does not fall NOTE Do not allow any of the electrolyte to spill 1 Anode plates 5 Stopper 2 Separat...

Page 224: ...e filler holes pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery s top cover CAUTION Once the caps are installed to the battery do not remove the caps Do not tap the caps with a hammer when installing them Charging For initial charging use the charger specially designed for MF battery CAUTION For charging the battery make sure to use the charger ...

Page 225: ...terior Parts Removal and Installation in Section 9D Page 9D 3 2 Remove the battery stay 1 3 Disconnect the battery lead wire 2 4 Disconnect the battery lead wire 3 NOTE Be sure to disconnect the battery lead wire 2 first then disconnect the battery lead wire 3 5 Remove the battery 4 Installation Install the battery in the reverse order of removal Pay attention to following point CAUTION Never use ...

Page 226: ...e is cold 65 V AC and more at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Fastening part Tightening torque Note N m kgf m lb ft Generator stator set bolt 11 1 1 8 0 Page 1J 7 CKP sensor mounting bolt 6 0 6 4 3 Page 1J 7 Generator lead wire clamp bolt 6 0 6 4 3 Page 1J 7 Generator rotor nut 140 14 0 101 0 Page 1J 7 Transfer gearshift cam stopper bolt 22 2 2 16 0 Page 1J 8 Speedometer g...

Page 227: ...Charging System 1J 15 09930 31921 09930 44541 Rotor remover Rotor holder Page 1J 6 Page 1J 6 Page 1J 7 ...

Page 228: ...at the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting Repair Instructions Exhaust System Components B827H11B06001 1 a 4 b 5 3 c 6 d 7 2 8 FWD FWD I827H11B0012 02 1 Exhaust pipe 6 Muffler connecting bolt 23 N m 2 3 kgf m 16 5 lb ft 2 Muffler 7 Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft 3 Connector 8 Spark arrester Do not reuse 4 Exhaus...

Page 229: ... muffler connecting bolt 1 4 Remove the muffler 2 NOTE Support the muffler to prevent it from falling 5 Remove the exhaust pipe 3 NOTE Support the exhaust pipe to prevent it from falling Installation Install the exhaust pipe muffler in the reverse order of removal Pay attention to the following points Install new exhaust pipe gasket 1 and connector 2 CAUTION Replace the removed gasket and connecto...

Page 230: ...ler connection for exhaust gas leakage and mounting condition If any defect are found replace the exhaust pipe assembly or muffler with a new one Check the exhaust pipe nuts 1 exhaust pipe mounting bolt 2 muffler connecting bolt 3 and muffler mounting bolts 4 are tightened to their specified torque Tightening torque Exhaust pipe nut a 18 N m 1 8 kgf m 13 0 lb ft Exhaust pipe mounting bolt b 23 N m...

Page 231: ... the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A400 F in Section 0C Page 0C 9 Fastening part Tightening torque Note N m kgf m lb ft Exhaust pipe nut 18 1 8 13 0 Page 1K 3 Page 1K 3 Exhaust pipe mounting bolt 2 3 2 3 16 5 Page 1K 3 Page 1K 3 muffler mounting bolt 2 3 2 3 16 5 Page 1K 3 Page 1K 3 Muffler connecting bolt 2 3 2 3 16 5 Page 1K 3 Page...

Page 232: ...1K 5 Exhaust System ...

Page 233: ...ng Knuckle End Removal and Installation 2B 10 Front Suspension Upper Lower Arm Bushing Removal and Installation 2B 11 Specifications 2B 12 Tightening Torque Specifications 2B 12 Special Tools and Equipment 2B 12 Recommended Service Material 2B 12 Special Tool 2B 13 Rear Suspension 2C 1 Repair Instructions 2C 1 Rear Suspension Components 2C 1 Rear Shock Absorber Removal and Installation 2C 2 Rear S...

Page 234: ...They must be tightened to the specified torque periodically and if the suspension effect is lost replace it with a new one CAUTION Never attempt to heat quench or straighten any suspension part Replace it with a new one or damage to the part may result NOTE The right and left suspension related parts shock absorbers suspension arms and knuckles are installed symmetrically and therefore the removal...

Page 235: ...ront suspension too stiff Bent front shock absorber shaft Replace Bent front upper or lower suspension arm Replace Front suspension too noisy Loose front suspension bolt nut Tighten Worn front suspension related bushings Replace Wobbly rear wheel Distorted wheel rim Replace Worn hub bearings Replace Defective or incorrect tire Replace Loose rear wheel set nut hub nut Tighten Worn rear suspension b...

Page 236: ...g 60 N m 6 0 kgf m 43 5 lb ft 2 Upper suspension arm 11 Knuckle end 65 N m 6 5 kgf m 47 0 lb ft 3 Bushing 12 Snap ring 50 N m 50 kgf m 36 0 lb ft 4 Steering knuckle 13 Front shock absorber mounting bolt Upper 29 N m 2 9 kgf m 21 0 lb ft 5 Inner dust seal 14 Front Shock absorber mounting nut Lower Apply grease 6 Spacer 15 Suspension arm pivot nut Apply thread lock to the thread part 7 Hub bearing 1...

Page 237: ...f washer faces outside 50 N m 5 0 kgf m 36 0 lb ft 3 Handlebar clamp bolt 12 Brake disc cover mounting bolt 60 N m 6 0 kgf m 43 5 lb ft 4 Steering shaft lower nut 55 N m 5 5 kgf m 60 0 lb ft 110 N m 11 0 kgf m 79 5 lb ft 5 Tie rod lock nut 60 N m 6 0 kgf m 43 5 lb ft 12 N m 1 2 kgf m 8 5 lb ft 6 Tie rod end nut 26 N m 2 6 kgf m 19 0 lb ft Apply thread lock to thread part 7 Suspension arm pivot nut...

Page 238: ... block 3 Remove the front shock absorber 1 Installation Install the front shock absorber in the reverse order of removal Pay attention to the following point Tighten the front shock absorber mounting bolt and nut to the specified torque Tightening torque Front shock absorber mounting bolt upper a 55 N m 5 5 kgf m 40 0 lb ft Front shock absorber mounting nut lower b 60 N m 6 0 kgf m 43 5 lb ft Fron...

Page 239: ...ve the steering knuckle 7 Installation Install the steering knuckle in the reverse order of removal Pay attention to the following points Apply grease to the lip of dust seals Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply thread lock to the steering knuckle pinch bolt and tighten them to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent ...

Page 240: ...equivalent Tightening torque Brake disc cover mounting bolt c 12 N m 1 2 kgf m 8 5 lb ft Apply grease to the spline of wheel hub and lip of dust seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the wheel hub washer 2 and front hub nut NOTE The conical side of washer 2 faces out side Refer to Front Suspension Assembly Construction Page 2B 2 Install the brake caliper Refer to Fron...

Page 241: ...amages are found replace the dust seal with a new one Front Wheel Hub Bearing Inspect the inner race play of the front wheel hub bearings by hand while they are in the steering knuckle Rotate the inner races by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the front hub bearing with a new one Steering Knuckle Dust Seal Front Wheel Hub Bearing Removal a...

Page 242: ...Apply grease to the bearings and the lip of the dust seals before installing them Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the wheel hub bearings using the special tool CAUTION Removed bearing must be replaced with a new one Special tool A 09913 70210 Bearing installer set NOTE Install the outer bearing 1 spacer 2 and then the inner bearing 3 Make sure the sealed side of the ...

Page 243: ...oval and Installation in Section 2D Page 2D 3 2 Remove the steering knuckle Refer to Front Wheel Hub Steering Knuckle Removal and Installation Page 2B 3 3 Remove the front drive shaft cover 1 LT A400F LT F400F 4 Remove the brake hose clamp 2 5 Remove the front shock absorber mounting bolt lower 3 6 Remove the suspension upper arm 4 by removing the pivot bolts 5 7 Remove the suspension lower arm 6 ...

Page 244: ...t to the specified torque Tightening torque Suspension arm pivot nut upper a 65 N m 6 5 kgf m 47 0 lb ft Suspension arm pivot nut lower b 65 N m 6 5 kgf m 47 0 lb ft Front shock absorber mounting nut lower c 60 N m 6 0 kgf m 43 5 lb ft 8 Install the brake hose Clamp Refer to Front Brake Hose Removal and Installation in Section 4A Page 4A 7 Front Suspension Arm Related Parts Inspection B827H1220601...

Page 245: ...for damage If any damages are found replace the drive shaft cover with a new one Steering Knuckle End Removal and Installation B827H12206012 Refer to Front Wheel Hub Steering Knuckle Removal and Installation Page 2B 3 and Front Suspension Upper Lower Arm Removal and Installation Page 2B 8 Removal 1 Remove the suspension arm Refer to Front Suspension Upper Lower Arm Removal and Installation Page 2B...

Page 246: ...n Upper Lower Arm Removal and Installation Page 2B 8 Front Suspension Upper Lower Arm Bushing Removal and Installation B827H12206014 Refer to Front Suspension Upper Lower Arm Removal and Installation Page 2B 8 Removal Remove the front suspension arm bushing using a hydraulic press and suitable tools Installation Install the front suspension arm bushing using a hydraulic press and suitable tools CA...

Page 247: ...ening torque Note N m kgf m lb ft Front shock absorber mounting bolt upper 55 5 5 40 0 Page 2B 3 Front shock absorber mounting bolt lower 60 6 0 43 5 Page 2B 3 Steering knuckle pinch bolt 50 5 0 36 0 Page 2B 4 Tie rod end nut 29 2 9 21 0 Page 2B 5 Brake disc cover mounting bolt 12 1 2 8 5 Page 2B 5 Front hub nut 110 11 0 79 5 Page 2B 6 Suspension arm pivot nut upper 65 6 5 47 0 Page 2B 9 Suspensio...

Page 248: ...13 50121 Snap ring pliers Oil seal remover Page 2B 10 Page 2B 11 Page 2B 6 09913 70210 09923 74511 Bearing installer set Bearing remover Page 2B 7 Page 2B 8 Page 2B 11 Page 2B 7 09930 30104 09942 72410 Rotor remover slide shaft Tie rod end remover Page 2B 7 Page 2B 4 ...

Page 249: ... a 4 2 3 3 b 5 c 6 I827H1230011 01 1 Rear shock absorber 5 Rear shock absorber mounting lower nut 102 N m 10 2 kgf m 74 0 lb ft 2 Swingarm 6 Swingarm pivot nut Apply thread lock to thread part 3 Bushing 35 N m 3 5 kgf m 25 5 lb ft Do not reuse 4 Rear shock absorber mounting upper nut 60 N m 6 0 kgf m 43 5 lb ft ...

Page 250: ...spection in Section 0B Page 0B 19 Rear Shock Absorber Inspection B827H12306005 Inspect the rear shock absorber for damage and oil leakage and absorber bushings for wear or damage If any defects are found replace the rear shock absorber with a new one Refer to Rear Shock Absorber Removal and Installation Page 2C 2 CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable Swi...

Page 251: ...llation Page 2C 2 Install the final gear assembly Refer to Final Gear Assembly Removal and Installation in Section 3B Page 3B 21 Install the rear wheels Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 3 Swingarm Inspection B827H12306018 Inspect the swingarm in the following procedures 1 Remove the swingarm Refer to Swingarm Removal And Installation Page 2C 2 2 Inspect the ...

Page 252: ... Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A400 F in Section 0C Page 0C 9 Special Tools and Equipment Recommended Service Material B827H12308001 NOTE Required service material is also described in the following Rear Suspension Components Page 2C 1 I827H1230009 01 I827H1230010 01 Fastening part Tightening torque Note N m kgf m l...

Page 253: ... improper tires or tires with improper or uneven air pressure may affect tire wear and loss of vehicle control Replace the wheel if find damage such as crack nick or scratch When tire replacement is necessary the original equipment type tire should be used Do not mix different types of tires on the same vehicle because handling may be seriously affected and may result in loss of control Replacemen...

Page 254: ... f I827H1240004 02 1 Front tire 6 Rear tire 23 N m 2 3 kgf m 16 5 lb ft 2 Cotter pin 7 Cotter pin 12 N m 1 2 kgf m 8 5 lb ft 3 Front wheel hub 8 Rear wheel hub 60 N m 6 0 kgf m 43 5 lb ft 4 Brake disc 60 N m 6 0 kgf m 43 5 lb ft 121 N m 12 1 kgf m 87 5 lb ft 5 Disc cover 110 N m 11 0 kgf m 79 5 lb ft Do not reuse ...

Page 255: ... point to the wheel rotation when remounting the wheel Tighten the wheel set nuts to the specified torque NOTE Tighten the wheel set nuts diagonally Tightening torque Wheel set nut Front and rear a 60 N m 6 0 kgf m 43 5 lb ft Tire Removal and Installation B827H12406003 1 Remove the wheel from vehicle Refer to Front Rear Wheel Removal and Installation Page 2D 3 2 After removing the air valve caps r...

Page 256: ... tires other than the standard may cause instability It is highly recommended to use the specified tire 3 Mount the tire on the rim by hand as shown in the figure 4 When installing each tire make sure the arrow A on the tire points in the direction of rotation Also make sure the outer side of the wheel rim is facing outward 5 Inflate the tire to seat the tire bead Maximum tire bead seat pressure F...

Page 257: ... on the sidewall The number of on the tire indications the maximum operating pressure Maximum operating pressure 25 kPa 0 25 kgf cm2 3 6 psi 35 kPa 0 35 kgf cm2 5 1 psi 45 kPa 0 45 kgf cm2 6 5 psi Specifications Service Data LT A400 F LT F400 F B827H12407001 Tire Tightening Torque Specifications B827H12407002 NOTE The specified tightening torque is also described in the following Front and Rear Wh...

Page 258: ...2D 6 Wheels and Tires ...

Page 259: ...400F LT F400F 3B 4 Front Drive Differential Assembly Removal and Installation LT A400F LT F400F 3B 4 Front Drive Differential Assembly Disassembly and Assembly LT A400F LT F400F 3B 5 Front Drive Differential Related Parts Inspection LT A400F LT F400F 3B 13 Universal Joint Bearing Pinion Gear Pilot Bearing Inspection 3B 14 Front Drive Differential Gear Shim Inspection and Selection LT A400F LT F400...

Page 260: ...Components LT F400 F 3C 20 Transfer Range Lever Removal and Installation 3C 20 Transfer Range Lever Disassembly and Assembly 3C 21 Shift Rod Length Adjustment 3C 21 Reverse Switch Inspection LT F400 F 3C 21 Specifications 3C 22 Service Data LT A400 F 3C 22 Service Data LT F400 F 3C 22 Tightening Torque Specifications 3C 22 Special Tools and Equipment 3C 23 Recommended Service Material 3C 23 Specia...

Page 261: ...xle Precautions Precautions Precautions for Driveline Axle B827H13000001 Refer to General Precautions in Section 00 Page 00 1 WARNING Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train ...

Page 262: ...ction Reference Item Noisy Drive Shaft Worn drive shaft joints Replace Worn wheel hub bearings Replace Loose wheel nuts Tighten 1 4 5 6 7 8 9 11 3 2 10 FWD FWD I827H1310024 01 1 Circlip 6 Differential side outer boot clamp 11 Drive shaft protector LT A400F LT F400F only 2 Differential side joint set 7 Differential side inner boot clamp Apply grease 3 Differential side boot set 8 Wheel side inner b...

Page 263: ...ine of the front drive shafts and install the front drive shafts to the front differential gear case Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Be careful not to damage the front differential gear case oil seals NOTE After installing the drive shaft make sure the circlip is seated properly by pulling inboard joint lightly Install the steering knuckle Refer to Front Wheel Hub St...

Page 264: ...an the inside and outside of the boots with a cloth Do not wash the boots in any commercially available degreaser such as gasoline or kerosene Washing in a degreaser causes deterioration of the boots 1 Fit a boot on the drive shaft end fitting the small diameter side of the boot to the shaft groove fix its end with a new boot band CAUTION Replace the boot band with a new one 2 Install the cage 1 o...

Page 265: ... ring with a new one Position the opening of stopper ring C so that it will not be lined up with a ball 6 After installing the boot on the outer race insert a screw driver into the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the figure 7 Fix the boot on the outer race wit...

Page 266: ... LT F400F B827H13106004 Inspect the front drive shaft in the following procedures 1 Remove the front drive shaft assembly Refer to Front Drive Shaft Assembly Removal and Installation LT A400F LT F400F Page 3A 2 2 Inspect the boots circlip and boot bands for wear or damage If any damages are found replace them with new ones 3 Install the front drive shaft assembly Refer to Front Drive Shaft Assembl...

Page 267: ...a 8 7 2 3 4 a 5 b 6 3 1 2 I827H1310025 02 1 Dust seal 6 Rear axle housing LH 55 N m 5 5 kgf m 40 lb ft 2 Snap ring 7 Rear axle RH 60 N m 6 0 kgf m 43 5 lb ft 3 Bearing 8 Rear axle LH Apply grease 4 Rear axle housing RH 9 Final gear case cover Do not reuse 5 O ring 10 Trailer towing ...

Page 268: ...move the rear wheel hub 1 for left axle housing removal a 1 b 2 b 2 c 3 c 3 c 4 c 4 d 5 d 5 c 6 e 7 c 6 e 7 f 8 I827H1310009 01 1 Swingarm pivot nut 8 Brake panel bolt Apply grease 2 Rear shock absorber nut Upper 102 N m 10 2 kgf m 74 0 lb ft Apply silicon grease 3 Rear shock absorber nut Lower 35 N m 3 5 kgf m 25 5 lb ft Apply thread lock to thread part 4 Rear axle housing mounting bolt Swingarm ...

Page 269: ...sing in the reverse order of removal Pay attention to the following points Apply grease to the rear axle shaft spline Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent NOTE Overall length of RH axle shaft is shorter than LH axle shaft Install new O ring to the rear drive gear case NOTE Before installing the O ring apply grease to it Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 2 2 4...

Page 270: ...ound replace the rear axle shaft with a new one Rear Axle Housing Inspect the rear axle housing for distortion or damages If any damages are found replace the rear axle housing with a new one Dust seal LH Only Inspect the dust seal lip for wear or damage If any damages are found replace the dust seal with a new one Hub Bearing Inspect the inner race play of the hub bearing by hand while it is in t...

Page 271: ...ng in reverse order of disassembly Pay attention to the following points Apply grease to the hub bearings and dust seal lip before installing them Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the hub bearings with the special tool Special tool A 09913 70210 Bearing installer set NOTE When installing the hub bearings to the rear axle housing the sealed cover of inner bering 1 must...

Page 272: ...ommended Service Material B827H13108001 NOTE Required service material is also described in the following Front Drive Shaft Components LT A400F LT F400F Page 3A 1 Rear Axle Components Page 3A 6 Rear Axle Construction Page 3A 7 Special Tool B827H13108002 A I827H1310023 01 Fastening part Tightening torque Note N m kgf m lb ft Rear axle housing mounting bolt Final gear case 55 5 5 40 0 Page 3A 9 Rear...

Page 273: ...Drive Chain Drive Train Drive Shaft 3A 12 09913 50121 09913 70210 Oil seal remover Bearing installer set Page 3A 10 Page 3A 10 Page 3A 11 09921 20240 Bearing remover set Page 3A 10 ...

Page 274: ...rom the engine to the front wheel Broken drive and driven bevel gear teeth Replace Worn or broken propeller shaft serration Replace Damaged coupling Replace Worn or damaged coupling joint serration Replace Broken or damaged front drive differential gear or pinion Replace Improperly operated front drive differential shifting motor Repair or replace Worn or damaged shifting sleeve shaft and fork of ...

Page 275: ...6 5 lb ft 2 Shim s RH 9 2WD 4WD shifting cable guide Apply grease 3 Front differential gear assembly 10 Bevel pinion gear Apply water resistant grease 4 Shim s LH 35 N m 3 5 kgf m 25 5 lb ft Apply bond 5 Front drive differential gear case cover 8 N m 0 8 kgf m 6 0 lb ft Apply thread lock to the thread part 6 2WD 4WD shifting fork 32 N m 3 2 kgf m 23 0 lb ft Apply hypoid gear oil 7 2WD 4WD shifting...

Page 276: ...400F B827H13206002 a 2 A 1 1 I827H1320001 02 1 Shim 23 N m 2 3 kgf m 16 5 lb ft Apply thread lock to the thread part 2 Front drive differential case cover bolt Apply grease Apply bond to mating surface A Mating surface Apply water resistance grease Apply hypoid gear oil ...

Page 277: ...front differential gear oil Refer to Front Differential Gear Oil Inspection LT A400F LT F400F in Section 0B Page 0B 9 2 Remove the inner fenders Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Remove the steering knuckles Refer to Front Wheel Hub Steering Knuckle Removal and Installation in Section 2B Page 2B 3 4 Hold the inboard joint 1 of the drive shaft and tug the dr...

Page 278: ...he front drive differential mounting bolts and tighten the nuts to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Front drive differential gear case mounting nut a 45 N m 4 5 kgf m 32 5 lb ft Pour the front differential gear oil Refer to Front Differential Gear Oil Inspection LT A400F LT F400F in Section 0B Page 0B 9 Front Drive Di...

Page 279: ...ly with a commercially available bearing puller NOTE If there is no abnormal condition the bearing removal is not necessary CAUTION Do not attempt to disassemble the front differential gear assembly The front differential gear is available only as an assembly 5 Remove the oil seals with the special tool Special tool B 09913 50121 Oil seal remover NOTE If there is no abnormal condition the oil seal...

Page 280: ... special tool Special tool B 09913 50121 Oil seal remover 9 Remove the snap ring 5 Special tool 09900 06108 Snap ring pliers 10 Remove the bearing NOTE Use the special tool if necessary Special tool B 09913 50121 Oil seal remover 11 Remove shifting sleeve 6 12 Remove the snap ring 7 Special tool 09900 06108 Snap ring pliers 13 Remove pinion gear 8 together with the bearing 4 I827H1320015 01 C D I8...

Page 281: ...e the C rings 9 from the universal joint 17 Remove the bearings by tapping with the special tool and hammer Special tool E 09913 70210 Bearing installer set 18 Remove the universal joint 10 NOTE If there is no abnormal condition the oil seal removal is not necessary 19 Remove the 2WD 4WD shifting fork 11 spring 12 and 13 by removing the E rings 14 and shaft 20 Remove the shifting fork shaft oil se...

Page 282: ...000 25010 SUZUKI SUPER GREASE A or equivalent Install the 2WD 4WD shifting fork springs shaft and E rings CAUTION Replace the E rings with new ones Install the bearing into the gear case with the special tool Special tool A 09913 70210 Bearing installer set CAUTION The removed bearing must be replaced with a new one Install the bearing onto the shaft with the special tool Special tool A 09913 7021...

Page 283: ...al tool A 09913 70210 Bearing installer set Install new oil seal into the gear case with the special tool Special tool A 09913 70210 Bearing installer set Apply grease to the seal lip groove Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply 4 5 gram of water resistance grease to the outside of seal lip groove Grease 99000 25160 Water resistance grease Apply grease to the bearings and du...

Page 284: ...er reassembling the universal joint check the joint moves smoothly If a large resistance is felt tap the bearing with a plastic mallet lightly Before installing the universal joint yoke assembly place the snap ring 4 between the shifting sleeve and splines of universal joint Install the universal joint yoke assembly by tapping it with a plastic mallet Fix the universal joint yoke assembly with the...

Page 285: ...rential gear with the special tool Special tool A 09913 70210 Bearing installer set CAUTION The removed bearing must be replace with a new one Install the shims 5 to the gear case and cover Install the front differential gear assembly to the gear case Apply bond to the mating surface of the case Sealant 99000 31140 SUZUKI BOND No 1207B or equivalent When installing the gear case cover align the sh...

Page 286: ... shifting fork is damaged inspect the groove of the shifting sleeve Also inspect the shifting fork shaft oil seal 2 for wear or damage 2WD 4WD Shifting Sleeve Inspect the 2WD 4WD shifting sleeve for wear or damage If any defects are found replace the 2WD 4WD shifting sleeve with new one Universal Joint Yoke Inspect the splines of universal joint for wear or damage If any wear or damage is found re...

Page 287: ...or damage is found replace the oil seal with a new one Pinion Gear Inspect the pinion gear for wear or damage Inspect the pinion gear bearing for abnormal noise and smooth rotation If any defects are found replace defective parts Universal Joint Bearing Pinion Gear Pilot Bearing Inspection B827H13206020 Check the bearings for wear or damage If any wear or damage is found replace the bearing with a...

Page 288: ... Page 3B 5 Backlash 1 Remove the front drive differential gear assembly from the frame 2 Make sure that the front drive differential case cover bolts are tightened to the specified torque Tightening torque Front drive differential gear case cover bolt a 23 N m 2 3 kgf m 16 5 lb ft 3 Remove the gear oil filler plug and measure the backlash of the differential ring gear using a horizontal type dial ...

Page 289: ... Side Shim Selection 1 Disassemble the front drive differential assembly Refer to Front Drive Differential Assembly Disassembly and Assembly LT A400F LT F400F Page 3B 5 2 Install the right side shim s and front drive differential gear assembly NOTE Do not install the left side shim s at this time 3 Put a few pieces of solder O D 1 2 1 5 mm 0 05 0 06 in x L 6 mm 0 24 in on the bearing outer race as...

Page 290: ...e to check the backlash after the tooth contact has been adjusted since it may have changed Adjust the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the pinion gear and final drive differential gear as a set 1 Remove the front drive differential gear assembly 2 Clean and degrease several tee...

Page 291: ...3 N m 2 3 kgf m 16 5 lb ft 5 Rotate the front drive differential gear several turns in each direction This will provide a contact pattern on the coated teeth of front drive differential gear 6 Remove the front drive differential gear and compare the coated teeth to the examples shown in A B and C If tooth contact is found to be incorrect example A and C the shim must be changed and the tooth conta...

Page 292: ...2 Shim s RH 9 Rear drive shaft Apply silicone grease 3 Final driven gear 10 Final gear coupling Apply water resistant grease 4 Shim s LH 23 N m 2 3 kgf m 16 5 lb ft Apply bond to matching surface 5 Washer 33 N m 3 3 kgf m 14 5 lb ft Apply thread lock to the thread part 6 Final gear case 10 N m 1 0 kgf m 7 0 lb ft Apply hypoid gear oil 7 Shim s 80 N m 8 0 kgf m 58 0 lb ft Do not reuse ...

Page 293: ...m 58 0 lb ft Apply silicone grease 2 Shim s RH 23 N m 2 3 kgf m 16 5 lb ft Apply water resistance grease 3 Final drive gear shim s 33 N m 3 3 kgf m 24 0 lb ft Apply hypoid gear oil 100 N m 10 0 kgf m 72 5 lb ft Apply bond to the mating surface Do not reuse a 2 3 1 b c d I827H1320063 04 ...

Page 294: ...on in Section 0B Page 0B 11 2 Remove the rear wheel Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 3 3 Disconnect the rear brake cables 1 and breather hose 2 4 Remove the rear axle housing mounting bolts from the swingarm 5 Remove the final gear assembly together with the axle housings 6 Remove the rear propeller shaft 3 and spring c b a I827H1320064 02 33 N m 3 3 kgf m 2...

Page 295: ...y grease to the spline of the axles Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply thread lock to the rear axle housing mounting bolts and tighten them to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Rear axle housing mounting bolt final gear case a 55 N m 5 5 kgf m 40 0 lb ft Apply water resistance grease to the sp...

Page 296: ...rake lever play Refer to Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment in Section 0B Page 0B 16 Pour the final gear oil Refer to Final Gear Oil Inspection in Section 0B Page 0B 11 Final Gear Assembly Disassembly and Assembly B827H13206017 Refer to Final Gear Assembly Removal and Installation Page 3B 21 Disassembly 1 Remove the O rings 1 2 Unlock the final gear coupling ...

Page 297: ... cover bolts diagonally and evenly 9 Pry up the final gear case cover with 5 mm screws A 10 Remove the final driven gear 4 shims and washer 5 11 Remove the oil seal out of the final gear case cover with the special tool Special tool B 09913 50121 Oil seal remover NOTE If there is no abnormal condition the oil seal removal is not necessary I827H1320078 01 C I827H1320079 01 3 I827H1320082 01 A I827H...

Page 298: ...4 Rotor remover slide shaft F 09941 64511 Bearing remover NOTE If there is no abnormal condition the bearing removal is not necessary 15 Remove the spacer and bearing from the final drive gear shaft with a commercially available bearing puller or hydraulic press NOTE If there is no abnormal condition the spacer and bearing removal is not necessary 16 Remove the final drive gear pilot bearing with ...

Page 299: ... installer set Install the spacer and bearing onto the shaft using a hydraulic CAUTION The removed bearing must be replaced with a new one Install new oil seals into the gear case and case cover with the special tool Apply gear oil to the new oil seal lips Special tool A 09913 70210 Bearing installer set Place the washer 1 and shim s 2 on the gear case bearing LH then install the final drive gear ...

Page 300: ...03 or equivalent Tightening torque Final gear case cover bolt a 23 N m 2 3 kgf m 16 5 lb ft NOTE After the backlash and tooth contact have been checked or adjusted apply thread lock to the final gear case cover bolts Install the shims final drive gear assembly Tighten new final drive gear lock nut to the specified torque with the special tool CAUTION Replace the removed lock nut with a new one Spe...

Page 301: ...iving gear coupling holder Tightening torque Final gear coupling nut b 100 N m 10 0 kgf m 72 5 lb ft Lock the final gear coupling nut with a center punch Final Gear Related Parts Inspection B827H13206018 Refer to Final Gear Assembly Removal and Installation Page 3B 21 and Final Gear Assembly Disassembly and Assembly Page 3B 23 Rear Drive Shaft Inspect the splines of rear drive shaft for wear or da...

Page 302: ...rive gear for wear or damage Inspect the final drive gear bearing for abnormal noise and smooth rotation If any defects are found replace defective parts Final Driven Gear Inspect the final driven gear for wear or damage If any defects are found replace the final driven gear with a new one Final Gear Coupling Inspect the final gear coupling for wear or damage If any defects are found replace the f...

Page 303: ...0 02 0 06 mm 0 0008 0 0024 in without gear cover specification Standard 0 08 0 13 mm 0 0031 0 0051 in Gear cover assembled specification 4 Measure the backlash with the dial gauge as shown Take backlash readings at several places while turning the final drive gear shaft in each direction and securely holding the final driven gear If the backlash is not within specification the shim must be changed...

Page 304: ...ith the micrometer Special tool 09900 20205 Micrometer 0 25 mm Shim thickness Compressed solder thickness 0 1 mm 0 004 in 5 Select the proper size of shim s from the table according as the compressed solder thickness List of shims for right side After selecting the proper size of shim s check or adjust the backlash and tooth contact Tooth Contact Remove the final driven gear Clean and degrease sev...

Page 305: ...e tooth contact should be re checked until the tooth contact is found to be correct example B CAUTION Make sure to check the backlash and shim thickness after the tooth contact has been adjusted since it may have changed Adjust the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the final driv...

Page 306: ...on 2 Remove the speedometer cover 1 from the steering head 3 Loosen the lock nut 2 4 Turn in the adjuster 3 fully so that the cable obtains enough play 5 Remove the transfer selection lever from the handlebars 6 Unscrew the cap nut 4 from the lever and disconnect the cable 7 Disconnect the cable from the front drive differential assembly side Refer to Front Drive Differential Assembly Removal and ...

Page 307: ...F in Section 0C Page 0C 9 Item Standard Limit Front drive differential gear backlash 0 05 0 10 0 0020 0 0040 Final gear backlash 0 08 0 13 0 0031 0 0051 Fastening part Tightening torque Note N m kgf m lb ft Front drive differential gear case mounting nut 45 4 5 32 5 Page 3B 5 Front drive differential gear case cover bolt 23 2 3 16 5 Page 3B 13 Page 3B 15 Page 3B 17 Page 3B 18 Rear axle housing mou...

Page 308: ...0 Page 3B 11 Page 3B 12 Page 3B 22 SUZUKI SILICONE GREASE or equivalent P No 99000 25100 Page 3B 27 Page 3B 28 Water resistance grease P No 99000 25160 Page 3B 5 Page 3B 10 Page 3B 22 Sealant SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 3B 12 Page 3B 27 Thread lock cement THREAD LOCK CEMENT SUPER 1303 or equivalent P No 99000 32030 Page 3B 5 Page 3B 22 Page 3B 23 Page 3B 27 09900 06108...

Page 309: ...B 12 Page 3B 25 Page 3B 26 Page 3B 26 Page 3B 8 09923 73210 09924 21920 Bearing remover Wheel hub remover Page 3B 25 Page 3B 7 09924 41830 09924 64510 Bearing retainer wrench Final driving gear coupling holder Page 3B 24 Page 3B 27 Page 3B 30 Page 3B 23 Page 3B 28 09930 30104 09941 64511 Rotor remover slide shaft Bearing remover Page 3B 7 Page 3B 8 Page 3B 25 Page 3B 25 Page 3B 25 ...

Page 310: ...Replace Worn bushing Replace Transfer will not shift back Broken gearshift cam Replace Distorted gearshift forks Replace Worn gearshift shaft Replace Improperly adjusted gearshift shaft Adjust Condition Possible cause Correction Reference Item Engine is noisy Noise seems to come from the transfer Worn down gears or shafts Replace Damage to bearings bushing Replace Transfer will not shift or shift ...

Page 311: ...g 16 Lock washer 29 Washer 4 Reverse idle gear shaft 17 Spacer 30 Transfer counter shaft 5 Spacer 18 Bearing 31 Bearing 6 Transfer input shaft 19 Low driven gear 32 Spacer 7 Washer 20 Washer 33 Transfer driven gear No 2 8 Reverse gear selecting dog 21 Snap ring 34 Snap ring 9 Reverse gear spacer 22 High Low gear selecting dog 35 Transfer output shaft assembly 10 Washer 23 High Low gear spacer 36 W...

Page 312: ... 13 14 16 FWD FWD 15 I827H1330002 03 1 Washer 7 Transfer selecting dog 13 Transfer idle gear 2 Transfer low gear 8 Washer 14 Washer 3 Bushing 9 Transfer high gear 15 Transfer output shaft 4 Bearing 10 Washer 16 Transfer driven gear 5 Washer 11 Spacer Do not reuse 6 Snap ring 12 Bearing ...

Page 313: ...2 and spacer 3 Special tool 09900 06107 Snap ring pliers 5 Remove the reverse idle gear 4 6 Remove the transfer input shaft 5 7 Remove the transfer countershaft assembly 6 reverse gearshift fork 7 and gearshift fork 8 8 Remove the transfer gearshift cam assembly 9 9 Remove the output shaft 10 Using a chisel unlock the drive bevel gear nut 11 Hold the transfer driven gear 10 with the special tool a...

Page 314: ...ear and transfer output shaft is available only as an assembly Installation Install the transfer in the reverse order of removal Pay attention to the following points CAUTION Apply engine oil to each gears and shafts Install the transfer output shaft assembly 1 with the plastic mallet Install the shim 2 drive bevel gear 3 and washer 4 11 12 13 I827H1330009 01 14 I827H1330010 01 1 I827H1330011 01 3...

Page 315: ...ssembly Install the gearshift fork 5 reverse gearshift fork 6 and transfer counter shaft assembly Refer to Transfer Construction LT A400 F Page 3C 8 NOTE Each gearshift fork has own embossed letters A or B Install the reverse idle gear assembly Refer to Transfer Construction LT A400 F Page 3C 8 Assemble the engine Refer to Engine Bottom Side Assembly in Section 1D Page 1D 43 Remount engine assembl...

Page 316: ...e washer and transfer selecting dog 5 7 Remove the snap ring 6 Special tool 09900 06107 Snap ring pliers 8 Remove the washer and transfer low gear 7 9 Remove the bushing 8 and washer 9 10 Remove the transfer gearshift cam assembly 10 and transfer gearshift shaft No 2 11 11 Remove the transfer driven gear 12 12 Remove the transfer output shaft if necessary Refer to Drive Bevel Gear Removal and Inst...

Page 317: ...t shaft assembly by aligning their punch marks Install the transfer driven gear NOTE Spline offset part A of the gear faces crankcase side Install the washer 1 Install the bushing by aligning its hole B with the hole C on the shaft Install the generator cover Refer to Generator Removal and Installation in Section 1J Page 1J 5 Transfer Construction LT A400 F B827H13306003 I827H1330024 03 A I827H133...

Page 318: ...tly engine oil to the counter shaft component parts Assemble the countershaft and reverse idle gear in the reverse order of disassembly Refer to Transfer Construction LT A400 F Page 3C 8 Transfer Idle Gear Bearing Removal and Installation LT F400 F B827H13306030 Removal 1 Remove the transfer idle gear Refer to Transfer Removal and Installation LT F400 F Page 3C 7 2 Remove the bearing from the tran...

Page 319: ...ft gear 11 Washer 20 Gearshift cam plate 3 Return spring 12 Circlip 21 Gearshift cam stopper 4 Transfer gearshift shaft No 2 13 Spring 22 Gearshift fork For reverse drive gears 5 Snap ring 14 Transfer gearshift cam For high low gears 23 Gearshift fork For high low gears 6 Washer 15 Snap ring Apply grease 7 Oil seal 16 Washer Apply thread lock 8 GP switch 17 Bearing Do not reuse 9 Washer 18 Washer ...

Page 320: ...330028 03 1 Transfer gearshift cam stopper set 8 OIl seal 15 Transfer gearshift shaft No 1 2 Gasket 9 Washer 16 Spring 3 Washer 10 Gearshift cam plate 17 Washer 4 Snap ring 11 Snap ring 18 Snap ring 5 Transfer gearshift shaft No 2 12 Snap ring 19 Washer 6 Snap ring 13 Washer Apply grease 7 Washer 14 Transfer gearshift cam Do not reuse ...

Page 321: ...tion LT A400 F B827H13306006 Gearshift System Construction LT F400 F B827H13306020 2 1 I827H1330029 01 1 Transfer gearshift shaft No 1 2 Transfer counter shaft 1 2 I827H1330030 01 1 Transfer gearshift shaft No 1 2 Reverse gearshift cam shaft ...

Page 322: ...T A400 F Page 3C 12 CAUTION Never reuse the circlip and snap ring After a circlip and the snap ring have been removed from the shaft they should be discarded and new ones must be installed When installing a new circlip and snap ring do not expand the end gap larger than required to slip the ring over the shaft After installing circlip and snap ring make sure that they are completely seated in thei...

Page 323: ...s The cross sectional view shows the correct position of the cam washers and snap rings Refer to Gearshift System Construction LT A400 F Page 3C 12 CAUTION Never reuse the snap rings After a snap rings has been removed from the shaft it should be discarded and a new snap ring must be installed When installing a new snap ring do not expand the end gap larger than required to slip the snap ring over...

Page 324: ...rnier calipers 1 20 mm 200 mm Gearshift fork groove width Standard Reverse Low High 5 5 5 6 mm 0 217 0 220 in Gearshift Fork Thickness Measure the gearshift fork thickness using the vernier calipers Special tool A 09900 20102 Vernier calipers 1 20 mm 200 mm Gearshift fork thickness Standard Reverse Low High 5 3 5 4 mm 0 209 0 213 in Transfer Related Parts Inspection LT F400 F B827H13306022 Refer t...

Page 325: ...n Gear Position GP Switch Inspection B827H13306012 Refer to Gear Position Switch Inspection in Section 1I Page 1I 8 Gear Position GP Switch Removal and Installation LT A400 F B827H13306013 Removal 1 Turn the ignition switch OFF 2 Remove the rear fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 3 Disconnect the gear position switch lead wire coupler 1 4 Remove the dri...

Page 326: ...osition GP Switch Removal and Installation LT F400 F B827H13306023 Refer to Gear Position GP Switch Removal and Installation LT F400 F in Section 5B Page 5B 7 Transfer Gearshift Shaft No 2 Gearshift Cam Plate Removal and Installation LT A400 F B827H13306014 Removal 1 Drain engine oil Refer to Engine Oil and Filter Replacement in Section 0B Page 0B 7 2 Remove the generator cover 1 Refer to Generato...

Page 327: ...ing torque Gearshift cam stopper nut a 10 N m 1 0 kgf m 7 0 lb ft Check the gearshift cam stopper moves smoothly Locate the gearshift cam in the neutral position Install the washer 2 and gearshift cam stopper plate 3 NOTE Align the gearshift cam pin A with the gearshift cam stopper plate hole B When installing the return spring position the stopper C of gearshift shaft No 2 and stopper D of shift ...

Page 328: ...the defective part s Gearshift Shaft Oil Seal Inspect the gearshift shaft oil seal lip for damage or wear If any defect are found replace the oil seal with a new one Gearshift Shaft Oil Seal Removal and Installation LT A400 F B827H13306016 Removal Remove the generator cover Refer to Generator Removal and Installation in Section 1J Page 1J 5 Remove the gearshift shaft oil seal 1 Installation Instal...

Page 329: ... reverse switch coupler 2 LT F400 F 5 Remove the transfer range lever assembly 3 by removing the bolts Installation Install the transfer range lever in the reverse order of removal Pay attention to the following points Apply grease to the lever pivot and spring Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 1 Shift knob 2 Transfer range lever assembly 3 Shift rod 1 Shift knob 2 Transfer ra...

Page 330: ...nts LT A400 F Page 3C 20 and Transfer Range Lever Components LT F400 F Page 3C 20 2 Install the transfer range lever assembly Refer to Transfer Range Lever Removal and Installation Page 3C 20 Shift Rod Length Adjustment B827H13306028 Adjust the shift rod length along each angle of the gearshift arm 1 Remove the front fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2...

Page 331: ...Limit Automatic transmission ratio Variable change 2 938 0 813 Secondary reduction ratio 2 730 42 19 x 21 17 Final reduction ratio Front 3 600 36 10 Rear 3 600 36 10 Transfer gear ratio Low 2 500 40 16 High 1 375 33 24 Reverse 2 125 34 16 Shift fork groove width High Low 5 50 5 60 0 217 0 220 Reverse 5 50 5 60 0 217 0 220 Shift fork thickness High Low 5 30 5 40 0 209 0 213 Reverse 5 30 5 40 0 209 ...

Page 332: ...t Cam Components LT F400 F Page 3C 11 Special Tool B827H13308002 Fastening part Tightening torque Note N m kgf m lb ft Drive bevel gear nut 100 10 0 72 5 Page 3C 6 Gearshift cam stopper nut 10 1 0 7 0 Page 3C 18 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 3C 20 Sealant SUZUKI BOND No 1207B or equivalent P No 99000 31140...

Page 333: ...ructions Front Output Shaft Components B827H13406001 LT A400 F FWD FWD 5 1 3 4 2 6 a a a I827H1340001 05 1 Front output shaft LT A400F 4 Shim s 100 N m 10 0 kgf m 72 5 lb ft 2 Rear output shaft 5 Driven bevel gear Apply grease 3 Drive bevel gear 6 Shim s Do not reuse ...

Page 334: ...afts LT F400 F FWD FWD 1 2 3 6 4 a a a 5 I827H1340003 02 1 Front output shaft LT F400F 4 Shim s 100 N m 10 0 kgf m 72 5 lb ft 2 Rear output shaft 5 Driven bevel gear Apply grease 3 Drive bevel gear 6 Shim s Do not reuse ...

Page 335: ...A400F LT F400F 1 and rear output shaft 2 5 Separate the front and rear output shafts LT A400F LT F400F Installation Install the front output shaft in the reverse order of removal Pay attention to the following points NOTE Apply engine oil to each rotating part before reassembling Align the bearing rings with their grooves in the crankcase Position the knock pin on the bearings to the pin grooves i...

Page 336: ...assembly and Assembly LT A400 F B827H13406016 Refer to Output Shaft Removal and Installation Page 3D 3 Disassembly 1 Using a chisel unlock the nut 2 With the rear output shaft held immovable with a vise remove the nut 3 Remove the washer driven bevel gear 1 and bearing 2 A LT A400F B LT F400F A LT A400F B LT F400F 1 A I827H1340013 02 1 B I827H1340014 02 A I827H1340015 01 B I827H1340016 01 I827H134...

Page 337: ...mmovable with a vise remove the nut 9 Remove the washer joint yoke 5 oil seal 6 bearing 7 and shim 8 Assembly Assemble the rear output shaft in the reverse order of disassembly Pay attention to the following points NOTE Apply engine oil to each rotating part before reassembling Install the shim 1 and bearing 2 NOTE The bearing knock pin A should be positioned shim side 3 3 4 I827H1340020 01 A I827...

Page 338: ...shaft nut 100 N m 10 0 kgf m 72 5 lb ft CAUTION Replace the removed nut with a new one After the backlash and tooth contact have been checked or adjusted stake the nut with a center punch Apply grease to the bearings and their dust seal lip Install the universal joint and bearings with the special tool Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Special tool A 09913 70210 Bearing instal...

Page 339: ...able with a vise tighten new nut to the specified torque Tightening torque Driven bevel gear nut a 100 N m 10 0 kgf m 72 5 lb ft CAUTION Replace the removed nut with a new one Stake the nut with a center punch Rear Output Shaft Disassembly and Assembly LT F400 F B827H13406017 Refer to Output Shaft Removal and Installation Page 3D 3 Disassembly 1 Using a chisel unlock the nut 2 With the rear output...

Page 340: ...tput shaft held immovable with a vise remove the nut 9 Remove the washer joint yoke 5 oil seal 6 bearing 7 and shim 8 Assembly Assemble the rear output shaft in the reverse order of disassembly Pay attention to the following points NOTE Apply engine oil to each rotating part before reassembling Install the shim 1 and bearing 2 NOTE The bearing knock pin A should be positioned shim side 1 2 I827H13...

Page 341: ...shaft nut 100 N m 10 0 kgf m 72 5 lb ft CAUTION Replace the removed nut with a new one After the backlash and tooth contact have been checked or adjusted stake the nut with a center punch Apply grease to the bearings and their dust seal lip Install the universal joint and bearings with the special tool Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Special tool A 09913 70210 Bearing instal...

Page 342: ...t a 100 N m 10 0 kgf m 72 5 lb ft CAUTION Replace the removed nut with a new one Stake the nut with a center punch Front Output Shaft Disassembly and Assembly LT A400F LT F400F B827H13406018 Refer to Output Shaft Removal and Installation Page 3D 3 Disassembly 1 Remove the oil seal 1 circlip 2 and snap ring 3 Special tool 09900 06107 Snap ring pliers 2 Remove the spacer 4 using a commercially avail...

Page 343: ...nt CAUTION Replace the removed oil seal with a new one NOTE The lip B of the oil seal should be positioned outside Install new snap ring 1 and circlip 2 CAUTION Replace the removed snap ring and circlip with new ones Rear Output Shaft Related Parts Inspection B827H13406019 Refer to Rear Output Shaft Disassembly and Assembly LT F400 F Page 3D 7 Rear Output Shaft Inspect the rear output shaft for we...

Page 344: ...r Output Shaft Bearing Inspect the rear output shaft bearings and rear driven bevel gear bearings for abnormal noise and smooth rotation If any defects are found replace the bearing with a new one Universal Joint Inspect the universal joint and outer surface of the bearings for scuffing wear and damage If any defects are found replace the bearings and universal joint as a set A LT A400 F B LT F400...

Page 345: ...ce the oil seal that shows indications of leakage Front Output Shaft Bearing LT A400F LT F400F Inspect the front output shaft bearing for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Drive Bevel Gear Removal and Installation LT A400 F B827H13406021 Removal 1 Remove the engine assembly from the frame Refer to Engine Assembly Removal in Section 1D Page 1D 6 2 R...

Page 346: ...Apply engine oil to each rotating part before reassembling Install the transfer output shaft assembly 1 with a plastic mallet Install the shim 2 drive bevel gear 3 and washer 4 Hold the transfer driven gear with the special tool and tighten the drive bevel gear nut to the specified torque CAUTION The removed drive bevel gear nut must be replaced with a new one Special tool A 09920 53740 Clutch sle...

Page 347: ...tion 1D Page 1D 34 4 Using a chisel unlock the nut 5 Hold the output shaft with the special tool and a vice Special tool A 09930 73190 Output shaft holder 6 Remove the drive bevel gear nut 7 Remove the washer 1 and drive bevel gear 2 8 Remove the shim 3 9 Remove the transfer output shaft 4 with a plastic mallet Installation Install the drive bevel gear in the reverse order of removal Pay attention...

Page 348: ...t a 100 N m 10 0 kgf m 72 5 lb ft After the backlash and tooth contact have been checked or adjusted stake the nut with a center punch Driven and Drive Bevel Gear Shim Inspection and Adjustment B827H13406009 Refer to Output Shaft Removal and Installation Page 3D 3 Backlash 1 Place the rear output shaft on the left crankcase half and hold bearings with the special tool Special tool A 09921 21910 Be...

Page 349: ... 022 in 24945 03G50 058 0 575 mm 0 023 in 24945 03G50 060 0 600 mm 0 024 in 24945 03G50 063 0 625 mm 0 025 in 24945 03G50 065 0 650 mm 0 026 in 24945 03G50 068 0 675 mm 0 027 in 24945 03G50 070 0 700 mm 0 028 in 24945 03G50 073 0 725 mm 0 029 in 24945 03G50 075 0 750 mm 0 030 in 24945 03G50 078 0 775 mm 0 031 in 24945 03G50 080 0 800 mm 0 031 in 24945 03G50 083 0 825 mm 0 032 in 24945 03G50 085 0 ...

Page 350: ...f machinist s layout dye or paste to several teeth of the driven bevel gear 3 Install the rear output shaft 4 Rotate the rear output shaft several turns in both directions 5 Remove the rear output shaft and inspect the coated teeth of the drive bevel gear The tooth contact pattern should be correct as shown in example 2 If tooth contact is found to be incorrect examples 1 and 3 the shim thickness ...

Page 351: ...0335 in Part No Shim thickness 24935 03G50 055 0 550 mm 0 0217 in 24935 03G50 058 0 575 mm 0 0226 in 24935 03G50 060 0 600 mm 0 0236 in 24935 03G50 063 0 625 mm 0 0246 in 24935 03G50 065 0 650 mm 0 0256 in 24935 03G50 068 0 675 mm 0 0266 in 24935 03G50 070 0 700 mm 0 0276 in 24935 03G50 073 0 725 mm 0 0285 in 24935 03G50 075 0 750 mm 0 0295 in 24935 03G50 078 0 775 mm 0 0305 in 24935 03G50 080 0 8...

Page 352: ... Bevel Gear Shim Adjustment Information B827H13406023 LT A400 F a 1 2 b c I827H1340082 01 1 Driven bevel gear shim 100 N m 10 0 kgf m 72 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 2 Drive bevel gear shim 100 N m 10 0 kgf m 72 5 lb ft Do not reuse ...

Page 353: ...eller Shafts 3D 21 LT F400 F a 1 2 b c I827H1340083 01 1 Driven bevel gear shim 100 N m 10 0 kgf m 72 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 2 Drive bevel gear shim 100 N m 10 0 kgf m 72 5 lb ft Do not reuse ...

Page 354: ...e Material B827H13408001 NOTE Required service material is also described in the following Front Output Shaft Components Page 3D 1 Special Tool B827H13408002 Item Standard Limit Front rear output shaft bevel gear backlash 0 03 0 15 0 001 0 006 Fastening part Tightening torque Note N m kgf m lb ft Rear output shaft nut 100 10 0 72 5 Page 3D 6 Page 3D 9 Driven bevel gear nut 100 10 0 72 5 Page 3D 7 ...

Page 355: ...0210 Magnetic stand Bearing installer set Page 3D 17 Page 3D 5 Page 3D 6 Page 3D 8 Page 3D 9 09920 53740 09921 21910 Clutch sleeve hub holder Bearing holder Page 3D 13 Page 3D 14 Page 3D 16 09930 73190 Output shaft holder Page 3D 15 Page 3D 16 ...

Page 356: ...3D 24 Propeller Shafts ...

Page 357: ...pecifications 4A 14 Special Tools and Equipment 4A 14 Recommended Service Material 4A 14 Special Tool 4A 14 Front Brakes 4B 1 Precautions 4B 1 Precautions for Front Brakes 4B 1 Repair Instructions 4B 1 Front Brake Components 4B 1 Front Brake Pad Inspection 4B 2 Front Brake Pad Replacement 4B 2 Front Brake Caliper Removal and Installation 4B 3 Front Brake Caliper Disassembly and Assembly 4B 4 Front...

Page 358: ...on and Adjustment 4D 1 Parking Rear Brake Lever Removal and Installation 4D 1 Parking Rear Brake Cable Removal and Installation 4D 3 Specifications 4D 3 Tightening Torque Specifications 4D 3 Special Tools and Equipment 4D 3 Recommended Service Material 4D 3 ...

Page 359: ...st servicing or which has been stored for a long period of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean...

Page 360: ...ke hose No 2 C Fix the brake hose to its guide firmly 5 Front brake caliper RH D After the brake hose guide has contacted the speedometer bracket tighten the bolt 6 Front brake caliper LH E Face the black mark on the brake hose to forward 7 Brake hose guide F Check that there is at least 6 mm 0 2 in of clearance between the brake hose and steering shaft 8 Clamp G After the hose clamp stopper has c...

Page 361: ...to the concave side of the transfer lever holder LT A400F LT F400F 5 Parking brake cable B Pass the starter cable and rear brake cable to inside of the guide 6 Starter cable C Pass the parking brake cable to outside of the throttle cable 7 Clamp D Fix the rubber of throttle cable to the cable guide 8 Brake adjuster nut E Pass the speedometer cable to inside of the center hole 9 Spring F Pass the t...

Page 362: ...Adjust Brake squeaking Carbon adhesion on pad surface Repair surface with sandpaper Carbon adhesion on lining surface Repair surface with sandpaper Tilted pad Correct pad fitting or replace Damaged hub bearing Replace Loosen wheel axle Tighten to specified torque Worn pads and linings Replace Foreign material in brake fluid Replace brake fluid Clogged return port of master cylinder Disassemble and...

Page 363: ...continuity with a tester If any abnormality is found replace the rear brake light switch with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 Connect the rear brake light switch lead coupler 1 5 Reinstall the left side cover and seat Rear Brake Light Switch Inspection and Adjustment B827H14106004 Inspection Check the rear brake light switch 1 so that...

Page 364: ...rake Fluid Circuit B827H14106009 Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering the danger to which such trapped air expose...

Page 365: ...e Tightening torque Front brake air bleeder valve 6 N m 0 6 kgf m 4 5 lb ft 8 Fill the reservoir with brake fluid to the upper mark of the reservoir 9 Reinstall the reservoir cap Brake Fluid Replacement B827H14106010 CAUTION Make sure that the vehicle is holded securely Handle brake fluid with care the fluid reacts chemically with paint plastic rubber materials etc 1 Remove the brake fluid reservo...

Page 366: ...gram Refer to Front Brake Hose Routing Diagram Page 4A 1 2 Tighten the brake flare nut 1 to the specified torque Tightening torque Brake pipe flare nut a 16 N m 1 6 kgf m 11 5 lb ft 3 Bleed air from the front brake system Refer to Air Bleeding from Front Brake Fluid Circuit Page 4A 5 Rear Brake Cable Removal and Installation B827H14106012 Removal 1 Remove the right footrest mudguard Refer to Exter...

Page 367: ...emoval and Installation in Section 6B Page 6B 3 3 Disconnect the front brake light switch lead coupler 1 1 2 3 4 5 6 a 7 b c 10 c 9 FWD FWD FWD FWD 8 I827H1410039 02 1 Reservoir cap 7 Brake hose union bolt 6 N m 0 6 kgf m 4 5 lb ft 2 Diaphragm 8 Brake lever Apply silicone grease 3 Plate 9 Brake lever pivot bolt Apply brake fluid 4 Separator 10 Brake lever pivot bolt lock nut Do not reuse 5 Master ...

Page 368: ...Master cylinder holder bolt Upper and Lower a 10 N m 1 0 kgf m 7 0 lb ft Set the brake hose union as shown in the front brake hose routing diagram Refer to Front Brake Hose Routing Diagram Page 4A 1 After setting the brake hose union to the stopper tighten the union bolt 3 to the specified torque CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage Tightening torq...

Page 369: ...p 7 Piston 8 Primary cup 9 Spring 10 Assembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning so...

Page 370: ...rake lever pivot bolt lock nut 6 N m 0 6 kgf m 4 5 lb ft Front Brake Master Cylinder Parts Inspection B827H14106016 Refer to Front Brake Master Cylinder Brake Lever Disassembly and Assembly Page 4A 10 Master Cylinder Inspect the master cylinder bore for any scratches or other damage Piston Inspect the piston surface for any scratches or other damage Rubber Parts Inspect the primary cup secondary c...

Page 371: ...in Section 9D Page 9D 3 2 Remove the cotter pin 1 washer 2 and pin 3 3 Remove the brake light switch spring 4 and brake pedal spring 5 Special tool 09920 20310 Clutch spring hook a 5 6 1 2 3 4 1 I827H1410037 03 1 Rear brake pedal 4 Brake light switch spring 12 N m 1 2 kgf m 8 5 lb ft 2 Rear brake light switch 5 Rear brake pedal pivot nut Apply grease 3 Brake pedal spring 6 O ring Do not reuse 1 3 ...

Page 372: ...Install the brake pedal spring and brake light switch spring correctly Refer to Rear Brake Pedal Construction Page 4A 12 Special tool 09920 20310 Clutch spring hook After installing the rear brake pedal check the rear brake pedal free travel Refer to Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment in Section 0B Page 0B 16 Specifications Service Data LT A400 F LT F400 F B8...

Page 373: ...ction Page 4A 12 Special Tool B827H14108002 Fastening part Tightening torque Note N m kgf m lb ft Front brake air bleeder valve 6 0 6 4 5 Page 4A 6 Page 4A 7 Brake pipe flare nut 16 1 6 11 5 Page 4A 7 Master cylinder holder bolt Upper and Lower 10 1 0 7 0 Page 4A 9 Brake hose union bolt 23 2 3 16 5 Page 4A 9 Brake lever pivot bolt 6 0 6 4 5 Page 4A 11 Brake lever pivot bolt lock nut 6 0 6 4 5 Page...

Page 374: ...that for the other side Repair Instructions Front Brake Components B827H14206001 FWD FWD c 8 b 1 2 3 d 7 4 b 5 c 6 a I827H1420026 02 1 Front brake caliper 7 Brake caliper mounting bolt Apply thread lock to the thread part 2 Piston seal 8 Front brake disc Apply thread lock to the thread part 3 Dust seal 6 N m 0 6 kgf m 4 5 lb ft Apply thread lock to the thread part 4 Piston 18 N m 1 8 kgf m 13 0 lb...

Page 375: ...he brake caliper 4 Remove the brake pads by removing the pad mounting pin NOTE When removing the pads push the piston all the way into the brake caliper 5 Clean up the caliper especially around the caliper piston 6 Install the new brake pads CAUTION Replace the brake pads as a set otherwise braking performance will be adversely affected 7 Apply a small quantity of thread lock to the brake pad moun...

Page 376: ...er several times to check for proper brake operation and then check the brake fluid level 12 Install the front wheel assembly Front Brake Caliper Removal and Installation B827H14206004 Removal 1 Remove the front wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 3 2 Drain brake fluid Refer to Brake Fluid Replacement in Section 4A Page 4A 6 3 Remove the brake ho...

Page 377: ...ke system after installing the caliper Refer to Air Bleeding from Front Brake Fluid Circuit in Section 4A Page 4A 5 Install the front wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 3 Check the brake fluid leakage and brake operation WARNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose j...

Page 378: ... fluid Particularly wash the dust seal groove and piston seal groove BF Brake fluid DOT 4 CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvent such as...

Page 379: ... the caliper holder 6 to the brake caliper 7 Install the brake pads Refer to Front Brake Pad Replacement Page 4B 2 Front Brake Caliper Parts Inspection B827H14206006 Refer to Front Brake Caliper Disassembly and Assembly Page 4B 4 Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks scratches or other damage If any damage is found replace the caliper with a new one Brake Caliper...

Page 380: ...ove the front wheel assembly Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 3 2 Remove the front wheel hub Refer to Front Wheel Hub Steering Knuckle Removal and Installation in Section 2B Page 2B 3 3 Remove the brake disc 1 by removing the brake disc bolts 2 Installation Install the front brake disc in the reverse order of removal Pay attention to the following points Mak...

Page 381: ...brake caliper Refer to Front Brake Caliper Removal and Installation Page 4B 3 2 Measure the runout using the dial gauge Replace the disc if the runout exceeds the service limit Special tool A 09900 20607 Dial gauge 1 100 mm 10 mm B 09900 20701 Magnetic stand Brake disc runout Service limit 0 30 mm 0 012 in 3 Remount the front brake caliper Refer to Front Brake Caliper Removal and Installation Page...

Page 382: ...2 6 19 0 Page 4B 3 Page 4B 4 Front brake pad mounting pin 18 1 8 13 0 Page 4B 3 Front brake hose union bolt 23 2 3 16 5 Page 4B 4 Caliper holder slide pin nut 23 2 3 16 5 Page 4B 6 Caliper holder pin 18 1 8 13 0 Page 4B 6 Brake disc bolt 23 2 3 16 5 Page 4B 7 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Page 4B 5 Page 4B 5 Grease SUZUKI SILICONE GREASE or equivalent ...

Page 383: ...side Outside 1 2 4 6 H G 1 2 C 1 B I827H1430033 03 1 Rear brake breather hose B White marking 2 Clamp C Set the breather hose firmly 3 Clip D Pass the breather hose to the hole of the fuel tank upper cover 4 Parking brake cable E Pass the breather hose outside of the parking brake cable 5 Brake cable plate F Pass the breather hose outside of the frame 6 Rear brake cable G Be careful not to contact...

Page 384: ...1 Rear hub 7 Brake anchor panel 6 N m 0 6 kgf m 4 5 lb ft 2 O ring 8 Brake cam lever Apply grease 3 Dust seal 9 Rear brake drain plug Apply silicone grease 4 Drum cover A Apply soap water to the O ring Apply thread lock to the thread part 5 Brake drum 11 N m 1 1 kgf m 8 0 lb ft Do not reuse 6 Brake shoe 32 N m 3 2 kgf m 23 0 lb ft ...

Page 385: ...d Installation in Section 2D Page 2D 3 2 Remove the cotter pin 1 3 Remove the rear axle nut 2 by applying the rear brake 1 2 4 d 3 c 5 A b 10 9 3 3 a 3 8 7 6 I827H1430034 02 1 Drum cover 8 Brake anchor panel 60 N m 6 0 kgf m 43 5 lb ft 2 Brake drum 9 Brake camshaft Apply grease 3 O ring 10 Brake cam lever Apply silicone grease 4 Dust seal A Apply soap water Apply bond to the mating surface 5 Rear ...

Page 386: ... If there are wear or damage remove the dust seal 7 Refer to Rear Brake Related Parts Inspection Page 4C 8 9 Remove the O ring 8 from the brake drum 10 Remove the brake drum 9 11 Remove the brake shoes and springs NOTE If reinstalling the removed brake shoes mark the brake shoes with direction leading and trailing of installation before removing them 3 I827H1430002 01 4 I827H1430003 01 I827H143000...

Page 387: ...Remove the brake cam lever 14 and spring 15 17 Remove the brake camshaft 16 and O rings 17 Assembly Assemble the rear brake in the reverse order of disassembly Pay attention to the following points Apply grease to the O rings and brake camshaft CAUTION Replace the O rings with new ones Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 10 I827H1430009 02 11 I827H1430010 03 12 I827H1430011 02 1...

Page 388: ... water to it CAUTION Replace the O ring 5 with a new one Apply bond to the mating surface of the brake panel Sealant 99000 31230 SUZUKI BOND No 1216B or equivalent Install the new O ring 6 onto the rear axle housing CAUTION Replace the O ring 6 with a new one Install the brake anchor panel 7 to the rear axle housing Apply thread lock to the bolts and tighten them to the specified torque Thread loc...

Page 389: ...eading or trailing NOTE Make sure that brake shoe spring s end faces the brake panel as shown Install the brake drum 8 Install the new O rings 9 to the brake drum 8 CAUTION Replace the O rings 9 with new ones Apply grease to the spline on the rear axle Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the new dust seal 10 to the drum cover 11 by using the removed dust seal 12 Apply gr...

Page 390: ...tallation in Section 2D Page 2D 3 After installing the rear brake adjust the following items Brake pedal free travel Refer to Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment in Section 0B Page 0B 16 Brake lever play Refer to Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment in Section 0B Page 0B 16 Rear Brake Related Parts Inspection B827H14306006 ...

Page 391: ...ons B827H14307002 NOTE The specified tightening torque is also described in the following Rear Brake Components Page 4C 2 Rear Brake Construction Page 4C 3 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A400 F in Section 0C Page 0C 9 I827H1430037 01 I827H1430038 01 Item Standard Limit Rear brake lever play 3 5 0 1 0 2 Rear brake ped...

Page 392: ...ke Construction Page 4C 3 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 4C 5 Page 4C 7 Page 4C 7 SUZUKI SILICONE GREASE or equivalent P No 99000 25100 Page 4C 7 Sealant SUZUKI BOND No 1216B or equivalent P No 99000 31230 Page 4C 6 Thread lock cement THREAD LOCK CEMENT SUPER 1360 or equivalent P No 99000 32130 Page 4C 6 ...

Page 393: ... B827H14406007 Refer to Parking Brake Switch Inspection in Section 1I Page 1I 8 Ignition Starter Control Relay Parking Brake Relay Inspection B827H14406006 Refer to Ignition Starter Control Relay Inspection in Section 1I Page 1I 8 Parking Rear Brake Lever Inspection and Adjustment B827H14406001 Refer to Rear Brake Pedal Rear Brake Parking Brake Lever Inspection and Adjustment in Section 0B Page 0B...

Page 394: ... Pay attention to the following points Apply grease to the brake lever pivot bolt Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the pivot bolt and lock nut to the specified torque Tightening torque Brake lever pivot bolt 6 N m 0 6 kgf m 4 5 lb ft Brake lever pivot bolt lock nut 6 N m 0 6 kgf m 4 5 lb ft Apply grease to the brake cable end Grease 99000 25010 SUZUKI SUPER GREASE A o...

Page 395: ...justment in Section 0B Page 0B 16 3 Install the side cover and seat Specifications Tightening Torque Specifications B827H14407001 NOTE The specified tightening torque is also described in the following Parking Rear Brake Lever Components Page 4D 1 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A400 F in Section 0C Page 0C 9 Special ...

Page 396: ...4D 4 Parking Brake ...

Page 397: ...ion Symptom Diagnosis LT F400 F 5B 1 Repair Instructions 5B 2 Transmission Components LT F400 F 5B 2 Transmission Removal and Installation LT F400 F 5B 3 Transmission Construction 5B 4 Countershaft Gear Driveshaft Gear Disassembly and Assembly LT F400 F 5B 5 Transmission Reverse Gearshift Cam Disassembly and Assembly LT F400 F 5B 6 Transmission Related Parts Inspection LT F400 F 5B 7 Gear Position...

Page 398: ...5 ii Table of Contents Specifications 5C 10 Service Data LT F400 F 5C 10 Tightening Torque Specifications 5C 10 Special Tools and Equipment 5C 11 Recommended Service Material 5C 11 Special Tool 5C 11 ...

Page 399: ...Precautions 5 1 Transmission Transaxle Precautions Precautions Precautions for Transmission Transaxle B827H15000001 Refer to General Precautions in Section 00 Page 00 1 ...

Page 400: ... Routing Diagram Drive Train Operation LT A400 F B827H15102001 High Gear I827H1510001 01 1 Conrod 4 Transfer input shaft 7 Output drive gear 2 Crankshaft 5 High driven gear 8 Output driven gear Drive bevel gear 3 Drive V belt 6 High Low gear selection dog 9 Driven bevel gear Output shaft ...

Page 401: ... 2 Low Gear I827H1510002 01 1 Conrod 4 Transfer input shaft 7 Output drive gear 2 Crankshaft 5 Low driven gear 8 Output driven gear Drive bevel gear 3 Drive V belt 6 High Low gear selection dog 9 Driven bevel gear Output shaft ...

Page 402: ...e Gear I827H1510003 01 1 Conrod 5 Reverse idle gear 9 Output driven gear Drive bevel gear 2 Crankshaft 6 Reverse driven gear 10 Driven bevel gear Output shaft 3 Drive V belt 7 Reverse gear dog 4 Transfer input shaft 8 Output drive gear ...

Page 403: ...ssive engine noise Gear worn or abnormal contact Replace Spline worn Replace Bearing worn or burned Replace V belt slipping V belt slipping Replace Pulley face worn Replace Clutch slipping Clutch shoe worn Replace Centrifugal weight operation failure Repair or replace V belt worn Replace Clutch dragging Clutch shoe spring fatigued Replace Movable driven face distorted Replace ...

Page 404: ...lutch 14 Movable driven plate 26 Oil seal 3 Clutch wheel 15 Damper 27 Drive V belt 4 Bearing 16 Oil seal 28 Fixed driven face 5 Oil seal 17 Snap ring 150 N m 15 0 kgf m 108 5 lb ft 6 O ring 18 Bearing 115 N m 11 5 kgf m 83 0 lb ft 7 Collar 19 Spring plate 100 N m 10 0 kgf m 72 5 lb ft 8 Fixed drive face 20 Spring 115 N m 11 5 kgf m 83 0 lb ft 9 Oil seal 21 Spring seat Apply grease 10 Movable drive...

Page 405: ...val and Installation in Section 1E Page 1E 13 3 Loosen the clamp screws and remove the inlet cooling duct 1 and connector 2 4 Remove the rear fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 5 Loosen the clamp screws and remove the connector 3 and outlet belt cooling duct 4 5 4 1 2 3 I827H1510005 02 1 Inlet cooling duct connector 3 Induction box 5 Outlet cooling duct...

Page 406: ... the right footrest mudguard Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Remove the right footrest Refer to Footrest Removal and Installation in Section 9E Page 9E 2 3 Remove the brake pedal Refer to Rear Brake Pedal Removal and Installation in Section 4A Page 4A 12 4 Remove the V belt outer cover 1 5 Remove the gasket 2 and dowel pins Movable drive face 1 Remove the...

Page 407: ...ce drive V belt Install the drive V belt 1 as low as possible between the movable driven face and fixed driven face by tapping it with a plastic mallet CAUTION The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turning direction The drive belt contact surface of the driven face should be thoroughly cleaned Apply grease in the groove of fixed drive...

Page 408: ...9930 40113 Rotor holder Tighten the movable driven face nut to the specified torque with the special tool Tightening torque Movable driven face nut a 115 N m 11 5 kgf m 83 0 lb ft Special tool A 09930 40113 Rotor holder NOTE Turn the fixed drive face until the belt is seated in and driven faces will move together smoothly without slip V belt Outer Cover Install the dowel pins and new gasket 1 CAUT...

Page 409: ...l removal is not necessary Assembly 1 Install the oil seals with the special tool Special tool A 09913 70210 Bearing installer set NOTE The removed oil seal must be replaced with a new one 2 Apply grease to the lip of oil seals and inside grease groove A of the movable drive face Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Wipe off any excess grease thoroughly Take care not to a...

Page 410: ...loosen the movable driven face ring nut with the special tool WARNING Do not remove the movable driven face ring nut before attaching the clutch spring compressor Special tool A 09917 23711 Ring nut wrench B 09924 54520 Fixed driven face holder 2 Set the special tool to the movable driven face assembly 1 and compress the movable driven face assembly by turning in the special tool handle NOTE Make ...

Page 411: ...se the movable driven face to come off abruptly 4 Loosen the special tool handle slowly and remove the special tool 5 Remove the spring plate 3 and spring 4 6 Remove the spring seat 5 7 Remove the O rings 6 pins and rollers 7 8 Remove the movable driven face 8 C 1 I827H1510030 01 B 2 A I827H1510031 01 3 4 I827H1510032 01 5 I827H1510033 01 6 7 I827H1510034 01 8 I827H1510035 01 ...

Page 412: ...en face Apply grease to the oil seal lips O rings and inside groove of movable driven face CAUTION Replace the O rings 1 with new ones Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Wipe off any excess grease thoroughly Take care not to apply grease to the contact surface of the drive V belt Install the movable driven face 2 to the fixed driven face 3 Apply grease to the pin groove...

Page 413: ...d E into the slot F of the special tool as shown in the figure Tighten the movable driven face ring nut 7 temporarily Remove the special tool from the movable driven face assembly Tighten the movable driven face ring nut to the specified torque with the special tools Tightening torque Movable driven face ring nut 100 N m 10 0 kgf m 72 5 lb ft Special tool C 09917 23711 Ring nut wrench D 09924 5452...

Page 414: ...Drive Face Parts Inspection B827H15106009 Movable Fixed Drive Face Inspect the drive faces for any abnormal conditions such as stepped wear or discoloration caused by burning If any damages are found replace the drive faces with new ones Roller Inspect each roller and their sliding surface for wear or damage If any defects are found replace the rollers as a set NOTE The rollers must always be chan...

Page 415: ...length Service limit 204 3 mm 8 04 in O ring and Oil Seal Inspect the O rings and oil seals for wear or damage If any defects are found replace the O rings and oil seals with new ones Clutch Shoe Removal and Installation B827H15106011 Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation Page 5A 7 Removal 1 Drain the engine oil Refer to Engine Oil and Filter Re...

Page 416: ...ly thread lock to the clutch shoe nut and tighten it to the specified torque with the special tool Tightening torque Clutch shoe nut a 150 N m 15 0 kgf m 108 5 lb ft Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Special tool A 09930 40113 Rotor holder CAUTION The clutch shoe nut has left hand thread Apply molybdenum oil solution to the one way clutch 1 M O Molybdenum o...

Page 417: ...mission Removal and Installation Page 5A 7 V belt Outer Cover Bearing Removal and Installation B827H15106021 Removal 1 Remove the V belt outer cover Refer to V belt Type Continuously Variable Automatic Transmission Removal and Installation Page 5A 7 2 Remove the oil seal 1 3 Remove the snap ring 2 Special tool 09900 06108 Snap ring pliers 4 Remove the bearing with the special tool Special tool A 0...

Page 418: ...th the special tool CAUTION The removed snap ring and oil seal must be replaced with new ones Special tool A 09913 70210 Bearing installer set Apply grease to the rip of the oil seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent V belt Inner Cover Disassembly and Assembly B827H15106012 Refer to Clutch Shoe Removal and Installation Page 5A 16 Disassembly 1 Remove the clutch wheel 1 from V ...

Page 419: ...embly Pay attention to the following points Install the oil seal with the special tool CAUTION The removed oil seal must be replaced with a new one The marked side of the oil seal must face the fixed drive face side Special tool A 09913 70210 Bearing installer set Install the bearing with the special tool Special tool A 09913 70210 Bearing installer set CAUTION The removed bearing must be replaced...

Page 420: ...heel rotates smoothly Clutch Related Parts Inspection B827H15106013 Refer to V belt Inner Cover Disassembly and Assembly Page 5A 19 Clutch Shoe Inspect the boss and centrifugal weight fulcrum sections for looseness damage and operation Inspect the clutch shoe for damage and fouling with oil on the surface If any defects are found replace the clutch shoe assembly with a new one Check the depth of t...

Page 421: ...sure that the OUTSIDE letter A in the one way clutch faces to the clutch wheel Install the clutch shoe 2 into the clutch wheel and turn the clutch shoe by hand to inspect the one way clutch for a smooth movement The clutch shoe turns one direction only If a large resistance is felt to rotation inspect the one way clutch for damage or one way clutch contacting surface of the clutch shoe for wear or...

Page 422: ...Secondary reduction ratio 2 730 42 19 x 21 17 Final reduction ratio Front and rear 3 600 36 10 Transfer gear ratio Low 2 500 40 16 High 1 375 33 24 Reverse 2 125 34 16 Item Standard Limit Drive V belt width 28 4 1 12 27 4 1 08 Movable driven face spring free length 215 0 8 46 204 3 8 04 Fastening part Tightening torque Note N m kgf m lb ft Movable drive face nut 115 11 5 83 0 Page 5A 9 Movable dri...

Page 423: ...nstaller set Ring nut wrench Page 5A 10 Page 5A 13 Page 5A 19 Page 5A 19 Page 5A 20 Page 5A 20 Page 5A 20 Page 5A 20 Page 5A 11 Page 5A 14 09921 20240 09922 31430 Bearing remover set Clutch spring compressor Page 5A 18 Page 5A 11 Page 5A 14 09924 54520 09930 40113 Fixed driven face holder Rotor holder Page 5A 11 Page 5A 14 Page 5A 7 Page 5A 7 Page 5A 9 Page 5A 9 Page 5A 17 Page 5A 17 ...

Page 424: ...t shift Broken gearshift cam Replace Distorted gearshift forks Replace Worn gearshift shaft Replace Worn or damage clutch release mechanical Adjust or replace Improperly adjusted gearshift rod Adjust Transmission will not shift back Broken reverse gearshift shaft cam Replace Shift shafts are rubbing or sticky Repair Distorted or worn gearshift forks Replace Broken or damaged gearshift lever return...

Page 425: ... 13 15 14 FWD FWD I827H1520031 02 1 Reverse gear dog 7 2nd driven gear 13 2nd drive gear 2 Reverse driven gear 8 Driveshaft 14 Reverse idle gear 3 1st driven gear 9 Countershaft 15 Reverse idle shaft 4 4th driven gear 10 4th drive gear Do not reuse 5 3rd driven gear 11 3rd drive gear 6 5th driven gear 12 5th drive gear ...

Page 426: ...ion reverse gearshift cam 2 gearshift cam 3 and gearshift forks 6 Remove the driveshaft assembly 4 and countershaft assembly 5 Installation Install the transmission related parts in the reverse order of removal Pay attention to the following points Install the gearshift forks 1 2 3 and 4 as shown in the figure NOTE Each fork has own embossed letters Face the letters upward to the right side 1 I827...

Page 427: ...nstall the snap ring 6 washer 7 and spacer 8 Special tool 09900 06107 Snap ring pliers Install the reverse idle gear 9 and washer 10 Transmission Construction B827H15206004 8 7 6 5 I827H1520007 01 9 10 I827H1520008 01 1 2 I827H1520009 07 1 Countershaft 2 Driveshaft ...

Page 428: ... press Assembly Assemble the transmission in the reverse order of disassembly Pay attention to the following points NOTE Before installing the gears coat lightly engine oil to the shafts and gears CAUTION Never reuse a snap rings After a snap rings has been removed from a shaft it should be discarded and a new snap ring must be installed When installing a new snap ring care must be taken not to ex...

Page 429: ...ft cam assembly as shown in the figure Assembly When assembling the reverse gearshift cam pay attention to the following points CAUTION Never reuse a snap ring After a snap ring has been removed from a shaft it should be discarded and a new snap ring must be installed When installing a snap ring care must be taken not to expand the end gap larger than required to slip the snap ring over the shaft ...

Page 430: ...gearshift fork groove width using the vernier calipers Special tool A 09900 20102 Vernier calipers 1 20 mm 200 mm Gearshift fork groove width Standard Transmission 4 50 4 60 mm 0 178 0 181 in Standard Reverse 5 00 5 10 mm 0 197 0 201 in Gearshift Fork Thickness Measure the gearshift fork thickness using the vernier calipers Special tool A 09900 20102 Vernier calipers 1 20 mm 200 mm Gearshift fork ...

Page 431: ...cover Refer to Generator Removal and Installation in Section 1J Page 1J 5 Gear Position GP Switch Removal and Installation LT A400 F B827H15206020 Refer to Gear Position GP Switch Removal and Installation LT A400 F in Section 3C Page 3C 16 Gearshift Lever Removal and Installation LT F400 F B827H15206017 Removal 1 Remove the left footrest mudguard Refer to Exterior Parts Removal and Installation in...

Page 432: ... Adjustment LT F400 F Page 5B 9 Gearshift Lever Height Inspection and Adjustment LT F400 F B827H15206014 Inspect and adjust the gearshift lever height in the following procedures 1 Inspect the gearshift lever height a between the pedal top face and footrest Adjust the gearshift lever height if necessary Gearshift lever height a Standard 0 10 mm 0 0 0 4 in 2 Remove the left footrest mudguard Refer ...

Page 433: ...e Apply thread lock to thread part 2 Gearshift fork for 1st driven 3rd driven gear 8 Gearshift cam Apply thread lock to thread part 3 Gearshift fork for 2nd driven gear 9 Gear position switch Do not reuse 4 Gearshift spring 10 Gearshift shaft 10 N m 1 0 kgf m 7 0 lb ft 5 Gearshift cam stopper 11 Return spring 10 N m 1 0 kgf m 7 0 lb ft 6 Gearshift cam plate guide Apply grease 19 N m 1 9 kgf m 13 5...

Page 434: ...er 4 6 Remove the spring 5 and gearshift cam stopper 6 Installation Installation is in the reverse order of removal Pay attention to the following points Apply a small quantity of thread lock to the thread of gearshift cam stopper bolt Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tighten the nut 1 to the specified torque NOTE Hook the return spring end to the stopper ...

Page 435: ... properly Install the gearshift shaft assembly while aligning the spring ends with the gearshift shaft stopper Install the clutch cover Refer to Clutch Removal and Installation LT F400 F in Section 5C Page 5C 3 Gearshift Linkage Inspection LT F400 F B827H15206021 Refer to Gearshift Shaft Gearshift Cam Plate Removal and Installation LT F400 F Page 5B 11 Gearshift Shaft Check the gearshift for bend ...

Page 436: ...nstallation in Section 1J Page 1J 5 Specifications Service Data LT F400 F B827H15207001 Drive train Unit mm in Except ratio 1 I827H1520041 01 A I827H1520042 01 Item Standard Limit Primary reduction ratio 2 392 67 28 Secondary reduction ratio 1 133 17 15 Final reduction ratio Front 3 600 36 10 Rear 3 600 36 10 Transmission gear ratio Low 3 083 37 12 2nd 1 933 29 15 3rd 1 388 25 18 4th 1 095 23 21 T...

Page 437: ...Page 5B 10 Special Tool B827H15208002 Fastening part Tightening torque Note N m kgf m lb ft Gearshift cam stopper nut 10 1 0 7 0 Page 5B 11 Gearshift shaft stopper 19 1 9 13 5 Page 5B 12 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 5B 9 Sealant SUZUKI BOND No 1207B or equivalent P No 99000 31140 Page 5B 8 Thread lock cem...

Page 438: ...Worn teeth of clutch plates Replace Distorted clutch plates driven and drive Replace Clutch dampers weakened Replace Slipping clutch Clutch control out of adjustment or loss of play Adjust Weakened clutch springs Replace Worn clutch shoes Replace Worn or distorted pressure plate Replace Distorted clutch plates driven and drive Replace Dragging clutch Clutch control out of adjustment or too much pl...

Page 439: ...827H1530001 01 1 Bearing 7 Clutch driven plate 13 Clutch wheel 2 Clutch release plate 8 Clutch pressure plate 100 N m 10 0 kgf m 72 5 lb ft 3 Clutch spring 9 Collar 145 N m 14 5 kgf m 105 0 lb ft 4 Washer 10 Primary driven gear assembly Apply engine oil 5 Clutch sleeve hub 11 Clutch shoe assembly 6 Clutch drive plate 12 One way clutch ...

Page 440: ...juster cap 1 4 Remove the clutch cover 5 Remove the dowel pins and gasket 2 6 Remove the washer 3 clutch release arm 4 and clutch release roller guide 5 7 Remove the clutch release plate 6 and springs 8 Hold the clutch sleeve hub with the special tool and remove the clutch shoe nut CAUTION The clutch shoe nut has left hand threads Special tool A 09920 53730 Clutch sleeve hub holder 1 I827H1530002 ...

Page 441: ...sembly 8 12 Remove the thrust washer 9 thrust washer 10 and spacer 11 Installation Install the clutch components in the reverse order of removal Pay attention to the following points Install the clutch drive plates and driven plates one by one onto the clutch sleeve hub 1 Install the clutch pressure plate 2 I827H1530008 01 A I827H1530009 01 7 8 I827H1530010 01 9 10 11 I827H1530011 01 1 I827H153001...

Page 442: ...b ft Special tool A 09920 53730 Clutch sleeve hub holder Stake the clutch sleeve hub nut with a center punch Install the one way clutch with the OUT SIDE letters A outside Install the clutch shoe assembly Install the washer NOTE The convex side of the washer faces outside Apply engine oil to the clutch shoe nut and install it Hold the clutch shoe with the special tool and tighten the clutch shoe n...

Page 443: ...w lock nut 2 d 23 N m 2 3 kgf m 16 5 lb ft Apply grease to the O ring and install the clutch adjuster cap Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Clutch Related Parts Inspection LT F400 F B827H15306018 Refer to Clutch Removal and Installation LT F400 F Page 5C 3 Clutch Drive and Driven Plate NOTE Wipe off the engine oil from the drive and driven plates with a clean rag Measure the t...

Page 444: ... tool A 09900 20102 Vernier calipers 1 20 mm 200 mm Clutch spring free length Service limit 35 6 mm 1 40 in Clutch Sleeve Hub and Primary Driven Gear Assembly Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates If necessary replace it with a new one Clutch Shoe Inspect the boss and centrifugal weight fulcrum sections for loosene...

Page 445: ... faces to the clutch shoe side 2 Install the clutch shoe 3 onto the clutch wheel and turn the clutch shoe by hand to inspect the one way clutch for a smooth movement The clutch shoe turns one direction only If a large resistance is felt to rotation inspect the one way clutch for damage or one way clutch contacting surface of the clutch shoe for wear or damage If any defects are found replace them ...

Page 446: ...points Install the bearing with the special tool Special tool A 09913 70210 Bearing installer set Install the snap ring with the special tool Special tool 09900 06108 Snap ring pliers CAUTION Removed snap ring must be replaced with a new one Fit the adjusting screw as shown Tighten the lock nuts temporarily Adjust the clutch release roller after installing the clutch cover to the engine Refer to C...

Page 447: ... this section refer to Tightening Torque List LT A400 F in Section 0C Page 0C 9 I827H1530034 01 Item Standard Limit Clutch release screw 1 16 1 8 turns back Drive plate thickness 2 92 3 08 0 115 0 121 2 62 0 103 Drive plate claw width 13 85 13 95 0 545 0 549 13 05 0 514 Drive plate distortion 0 10 0 004 Clutch spring free length 37 44 1 47 35 6 1 40 Clutch wheel I D 140 0 140 2 5 512 5 520 140 5 5...

Page 448: ...UKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 5C 6 09900 06108 09900 20102 Snap ring pliers Vernier calipers 1 20 mm 200 mm Page 5C 9 Page 5C 9 Page 5C 6 Page 5C 7 Page 5C 7 09900 20803 09913 70210 Thickness gauge Bearing installer set Page 5C 7 Page 5C 9 09920 53730 09921 20240 Clutch sleeve hub holder Bearing remover set Page 5C 3 ...

Page 449: ...6B 1 Repair Instructions 6B 1 Steering Handlebars Components 6B 1 Steering Assembly Construction 6B 2 Handlebars Removal and Installation 6B 3 Handlebars Inspection 6B 5 Steering Shaft Tie rod Removal and Installation 6B 5 Steering Parts Inspection 6B 10 Specifications 6B 11 Service Data LT A400 F LT F400 F 6B 11 Tightening Torque Specifications 6B 11 Special Tools and Equipment 6B 12 Recommended ...

Page 450: ...6 1 Precautions Steering Precautions Precautions Precautions for Steering B827H16000001 Refer to General Precautions in Section 00 Page 00 1 ...

Page 451: ...tending to seize Replace Linkage connections tending to seize Repair or replace Wobbly Handlebars Unequally inflated tires Regulate Loose front wheel hub nuts Tighten Damaged or worn front wheel hub bearings Replace Worn or loose tie rod ends Replace or tighten Defective or incorrect front tires Replace Damaged or worn wishbone arms and related bushings Replace Distorted front wheels Replace Loose...

Page 452: ... I827H1620049 02 1 Handlebars 6 Steering shaft 11 Dust seal 23 N m 2 3 kgf m 16 5 lb ft 2 Handle grip 7 Steering shaft bushing 12 Tie rod end 49 N m 4 9 kgf m 35 5 lb ft 3 Handlebar holder 8 Dust seal 13 Tie rod 29 N m 2 9 kgf m 21 0 lb ft 4 Steering shaft holder 9 O ring A Apply handle grip bond Apply grease 5 Dust seal 10 Washer 26 N m 2 6 kgf m 19 0 lb ft Do not reuse ...

Page 453: ...5 I827H1620001 03 1 Steering shaft 6 O ring 49 N m 4 9 kgf m 35 5 lb ft 2 Tie rod 7 Cotter pin 26 N m 2 6 kgf m 19 0 lb ft 3 Tie rod end nut 8 Handlebar clamp bolt Apply grease 4 Tie rod lock nut 9 Drive shaft protector LT A400F LT F400F Do not reuse 5 Steering shaft lower nut 29 N m 2 9 kgf m 21 0 lb ft ...

Page 454: ...front brake master cylinder upside down 3 Remove the transfer lever assembly 4 LT A400F LT F400F LT A400F LT F400F 4 Remove the clamps 5 Remove the left switch box 5 and rear brake lever holder clamp bolt 6 6 Remove the handlebar clamp bolts 7 Remove the handlebar holders 7 8 Remove the left grip 8 starter lever 9 and rear brake lever holder 10 from the handlebars 11 1 3 2 I827H1620002 01 4 I827H1...

Page 455: ... the mating surface of the left handlebar holder Tighten the handlebar clamp bolts 3 to the specified torque NOTE First tighten the handlebar clamp bolts 3 front ones to the specified torque Tightening torque Handlebar clamp bolt a 26 N m 2 6 kgf m 19 0 lb ft Connect the starter cable 4 to the starter lever Insert the projection D of the left switch box into the hole of the handlebars Align the pu...

Page 456: ...tion B827H16206004 Refer to Handlebars Removal and Installation Page 6B 3 Inspect the handlebars for distortion or damage If any defects are found replace the handlebars with a new one Steering Shaft Tie rod Removal and Installation B827H16206005 Removal 1 Remove the front wheels Refer to Front Rear Wheel Removal and Installation in Section 2D Page 2D 3 2 Remove the front fender Refer to Exterior ...

Page 457: ...nd 2 from the tie rod 4 Steering Shaft 1 Remove the speedometer and handlebars Refer to Speedometer Removal and Installation in Section 9C Page 9C 2 and Handlebars Removal and Installation Page 6B 3 2 Remove the cotter pin and steering shaft lower nut 3 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 13 4 Remove the steering shaft holder bolts I827H1620019 01...

Page 458: ...ge remove the steering shaft bushing 8 Refer to Steering Parts Inspection Page 6B 10 Special tool A 09924 84521 Bearing installer set B 09930 31921 Rotor remover Installation Install the steering shaft tie rod in the reverse order of removal Pay attention to the following points Steering Shaft Install the steering bushing 1 using the special tool Special tool A 09924 84521 Bearing installer set 1 ...

Page 459: ...quivalent Apply grease to the dust seals before installing the steering shaft Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Apply grease to the steering shaft holders before installing the shaft holders Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION To prevent the entry of dirt the dust seal end A must face rearward when installing the dust seals to steering shaft Tighten ...

Page 460: ...outside Tighten the tie rod end nuts to the specified torque Tightening torque Tie rod end nut a 29 N m 2 9 kgf m 21 0 lb ft Install the new cotter pins CAUTION Replace the cotter pins with new ones Push the tie rod to tie rod lock nut tightening direction Tighten the lock nuts to the specification CAUTION When tightening the lock nuts hold the tie rod end with a open end wrench NOTE The lock nuts...

Page 461: ...spection B827H16206007 Refer to Steering Shaft Tie rod Removal and Installation Page 6B 5 Dust Seal Inspect the dust seals for wear or damage If any defects are found replace the dust seals with new ones Tie rod Inspect the tie rods for distortion or damage If any defects are found replace the tie rod with new ones Tie rod End Inspect the tie rod ends for smooth movement If there are any abnormali...

Page 462: ...described in the following Steering Handlebars Components Page 6B 1 Steering Assembly Construction Page 6B 2 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A400 F in Section 0C Page 0C 9 I827H1620046 01 I827H1620047 01 Item Standard Limit Steering angle 47 right left Turning radius 3 1 m 10 2 ft Toe in with 75 kg 165 lbs 10 4 mm 0 3...

Page 463: ...nstruction Page 6B 2 Special Tool B827H16208002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Page 6B 5 Page 6B 8 Page 6B 8 Page 6B 8 Page 6B 8 Page 6B 8 Handle grip bond Handle Grip Bond commercially available Page 6B 4 09924 84521 09930 31921 Bearing installer set Rotor remover Page 6B 7 Page 6B 7 Page 6B 7 09942 72410 Tie r...

Page 464: ...6B 13 Steering Handlebar ...

Page 465: ...ls and Equipment 9B 7 Special Tool 9B 7 Combination Meter Fuel Meter Horn 9C 1 Repair Instructions 9C 1 Speedometer Components 9C 1 Speedometer Removal and Installation 9C 2 Speedometer Disassembly and Assembly 9C 3 Speedometer light bulb Indicator light bulb Replacement 9C 3 Ignition Switch Inspection 9C 3 Ignition Switch Removal and Installation 9C 3 Horn Inspection For P 17 24 9C 4 Horn Removal...

Page 466: ...ectrical System B827H19000001 Refer to General Precautions in Section 00 Page 00 1 and Precautions for Electrical Circuit Service in Section 00 Page 00 2 Component Location Electrical Components Location B827H19003001 Refer to Electrical Components Location in Section 0A Page 0A 6 ...

Page 467: ...Wiring Systems 9A 1 Body and Accessories Wiring Systems Schematic and Routing Diagram Wiring Diagram B827H19102001 Refer to Wire Color Symbols in Section 0A Page 0A 4 ...

Page 468: ...Bl W Bl B W B W B B W B W B Bl B Bl B W B W B B B R B W B W O W B W B Bl Bl B R B R O Y O Y Bl W Bl W B W B W Gr Gr Y Bl Y Bl W Bl W Bl O Bl O Bl O Y O Y O W O W Y G Y G Bl Bl R W B Bl Bl Bl B Bl B B Bl B Bl B R B R Bl R Bl R O Bl O Bl W Y Y Bl Y Bl W Bl W Bl Gr Gr O Y O Y B O B O O O W O W Y G Y G B Bl B Bl O Y O Y Y B Y B B W B W O Y O Y B O G G B W B W O Bl W Bl W B W B W B W B W B R B R B R B ...

Page 469: ...R W O Bl O Bl Y O O Y O Y W B W B W Bl W Bl B W B W B B W B W B Bl B Bl B W B W B B B R B W B W O W B W B Bl Bl B R B R O Y O Y Bl W Bl W B W B W Gr Gr Y Bl Y Bl W Bl W Bl O Bl O Bl O R O R O W O W Y G Y G Bl Bl R W B Bl Bl Bl B Bl B B Bl B Bl B R B R Bl R Bl R O Bl O Bl W Y Y Bl Y Bl W Bl W Bl Gr Gr O Y O Y B O B O O O W O W Y G Y G B Bl B Bl O Y O Y Y B Y B B W B W O Y O Y B O G G B W B W O Bl W...

Page 470: ...Bl O Bl Y O O Y O Y W B W B W Bl W Bl B W B W B B W B W B Bl B Bl B W B W B B B R B W B W O W B W B Bl Bl B R B R O Y O Y Bl W Bl W B W B W Gr Gr Y Bl Y Bl W Bl W Bl O Bl O Bl O Y O Y O W O W Y G Y G Bl Bl R W B Bl Bl Bl B Bl B B Bl B Bl B R B R Bl R Bl R O Bl O Bl W Y Y Bl Y Bl W Bl W Bl Gr Gr O Y O Y B O B O O O W O W Y G Y G B Bl B Bl O Y O Y Y B Y B B W B W O Y O Y B O G G B W B W O Bl W Bl W ...

Page 471: ... R W R W O Bl O Bl Y O O Y O Y W B W B W Bl W Bl B W B W B B W B W B Bl B Bl B W B W B B B R B W B W O W B W B Bl Bl Bl R Bl R O Y O Y Bl W Bl W B W B W Gr Gr Y Bl Y Bl W Bl W Bl O Bl O Bl O Y O Y O W O W Y G Y G Bl Bl B Bl Bl Bl B Bl B B Bl B Bl O Bl O Bl W Y Y Bl Y Bl W Bl W Bl Gr Gr O Y O Y B O B O O O W O W Y G Y G B Bl B Bl O Y O Y Y B Y B B W B W O Y O Y B O G G B W B W O Bl W Bl W B W B W B...

Page 472: ... R W O Bl O Bl Y O O Y O Y W B W B W Bl W Bl B W B W B B W B W B Bl B Bl B W B W B B B R B W B W O W B W B Bl Bl Bl R Bl R O Y O Y Bl W Bl W B W B W Gr Gr Y Bl Y Bl W Bl W Bl O Bl O Bl O R O R O W O W Y G Y G Bl Bl B Bl Bl Bl B Bl B B Bl B Bl O Bl O Bl W Y Y Bl Y Bl W Bl W Bl Gr Gr O Y O Y B O B O O O W O W Y G Y G B Bl B Bl O Y O Y Y B Y B B W B W O Y O Y B O G G B W B W O Bl W Bl W B W B W B W B...

Page 473: ...Y B Y O R W R W O Bl O Bl Y O O Y O Y W B W B W Bl W Bl B W B W B B W B W B Bl B Bl B W B W B B B R B W B W O W B W B Bl Bl Bl R Bl R O Y O Y Bl W Bl W B W B W Gr Gr Y Bl Y Bl W Bl W Bl O Bl O Bl O Y O Y O W O W Y G Y G Bl Bl B Bl Bl Bl B Bl B B Bl B Bl O Bl O Bl W Y Y Bl Y Bl W Bl W Bl Gr Gr O Y O Y B O B O O O W O W Y G Y G B Bl B Bl O Y O Y Y B Y B B W B W O Y O Y B O G G B W B W O Bl W Bl W B ...

Page 474: ...ness cooling fan motor lead wire and starter cable with the clamp 3 Clamp Bind the right headlight lead wire and mud protector P 24 with the clamp 18 High tension cord 4 Power source terminal lead wire 19 Clamp Bind the wiring harness GP switch lead wire and generator lead wire with the clamp 5 Horn lead wire P 17 24 20 CDI unit 6 Clamp P 28 33 21 Clamp Bind the rear combination light lead wire re...

Page 475: ...er the hook of air cleaner box 13 Clamp Bind the handlebar switch lead wire ignition switch lead wire indicator light lead wire speedometer cable reverse switch lead wire LT F400 F and horn lead wire P 17 24 with the clamp F Pass the wiring harness and cooling fan motor lead wire inside the cooling fan bracket and starter cable outside 14 Reverse switch lead wire LT F400 F G Move the tube on the r...

Page 476: ...outing Diagram Page 9A 8 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List LT A400 F in Section 0C Page 0C 9 4 Magneto lead wire b 45 A When tightening the starter motor mounting bolts tighten the rear one first c Within 45 10 N m 1 0 kgf m 7 0 lb ft Item Specification Note Fuse size Headlight HI 10 A LO 10 A Brake light 10 A Ignition 10 ...

Page 477: ...Lighting Systems 9B 1 Body and Accessories Lighting Systems Repair Instructions Headlight Construction B827H19206001 1 Headlight housing 2 Grommet 3 Yellow tape LH White tape RH 2 3 1 I827H1920001 02 ...

Page 478: ...9B 2 Lighting Systems Front Side Reflector Construction B827H19206015 2 1 a b I827H1920003 01 1 Front side reflector P 28 only 1 8 N m 0 18 kgf m 1 5 lb ft 2 Bracket stopper 3 3 N m 0 33 kgf m 2 5 lb ft ...

Page 479: ...ts B827H19206002 Headlight Removal and Installation B827H19206003 Removal 1 Disconnect the headlight coupler 1 2 Remove the headlight with the housing 2 1 1 I827H1920004 01 1 Headlight bulb 12 V 35 35 W x2 1 I827H1920005 01 2 I827H1920006 03 ...

Page 480: ...emature bulb failure Do not use bulb other than those with predetermined wattage Remove the bulb when it gets cool since it may be heated to an extremely high temperature when the headlight is turned ON 1 Remove the headlight housing cover 1 2 Remove the socket cover 2 and disconnect the socket 3 3 Replace the headlight bulb 4 by unhooking the bulb holder spring 5 4 Reinstall the removed parts NOT...

Page 481: ...206009 Rear Combination Light Removal and Installation B827H19206010 Removal 1 Remove the rear combination light coupler 1 2 Remove the rear combination light assembly 2 1 I827H1920002 01 1 Brake light Taillight bulb 12 V 21 5 W 1 I827H1920011 01 2 I827H1920012 01 ...

Page 482: ...ulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Do not use bulb other than those with predetermined wattage 1 Remove and the reversing light lens 1 2 Push the bulb in and turn it to counterclockwise 3 Replace the bulb 4 Reinstall the removed parts Reversing Light Relay Inspection For P 17 B827H19206013 First check the ins...

Page 483: ...nob indication Continuity 5 After finishing the dimmer switch inspection reinstall the removed parts Specifications Service Data LT A400 F LT F400 F B827H19207001 Wattage Unit W Tightening Torque Specifications B827H19207002 NOTE The specified tightening torque is also described in the following Front Side Reflector Construction Page 9B 2 Reference For the tightening torque of fastener not specifi...

Page 484: ...and Accessories Combination Meter Fuel Meter Horn Repair Instructions Speedometer Components B827H19306001 1 2 3 4 5 I827H1930001 01 1 Speedometer 3 Speedometer light bulb 12V 1 7 W 5 Indicator light bulb 12V 3 4 W 2 Damper 4 Speedometer bracket ...

Page 485: ...nect the speedometer cable 4 5 Remove the speedometer 5 from the bracket by removing the clips 6 6 Disconnect the speedometer light socket 7 and remove the speedometer 7 Remove the indicator light harness by disconnecting the coupler 8 Black 8 Remove the speedometer cable from the engine side Refer to Generator Removal and Installation in Section 1J Page 1J 5 1 2 I827H1930002 01 3 I827H1930003 01 ...

Page 486: ...r Removal and Installation Page 9C 2 Ignition Switch Inspection B827H19306012 Inspect the ignition switch in the following procedures 1 Remove the left inner fender Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Disconnect the ignition switch coupler 1 Green 3 Inspect the ignition switch for continuity with a tester If any abnormality is found replace the ignition switc...

Page 487: ...n connectors as shown in the wiring harness routing diagram Refer to Wiring Harness Routing Diagram in Section 9A Page 9A 8 2 Connect a 12 V battery to the terminals If the sound is not heard from the horn replace the horn with a new one 3 Connect the horn connectors Horn Removal and Installation For P 17 24 B827H19306015 Removal 1 Disconnect the horn connectors and remove the horn by removing the...

Page 488: ...y and Accessories Exterior Parts Repair Instructions Rear Fender Heat Shield Construction B827H19406002 1 2 A a I827H1940003 02 1 Rear fender heat shield A Do not cover the hole with the heat shield 2 Rear fender a 0 mm 0 in ...

Page 489: ...fastener all the way into the installation hole 3 Push in the head of center piece until it becomes flush with the fastener outside face Type B Removal 1 Pry up the head of fastener center piece 1 with a screw driver 2 Pull out the fastener A Installation 1 Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation ho...

Page 490: ...2 Remove the side cover 1 LH RH Installation Installation is in the reverse order of removal Fuel Tank Upper Cover Refer to Fuel Tank Removal and Installation in Section 1G Page 1G 13 Footrest Mudguard Removal 1 Remove the side cover 2 Remove the footrest mudguard 1 LH RH Installation Installation is in the reverse order of removal I827H1940004 01 I827H1940005 01 1 I827H1940006 01 1 I827H1940007 0...

Page 491: ...llowing screw and fasteners Installation Installation is in the reverse order of removal Front Under Cover Removal Remove the front under cover 1 Installation Installation is in the reverse order of removal I827H1940010 01 1 I827H1940011 01 1 I827H1940012 01 I827H1940013 02 1 I827H1940014 02 ...

Page 492: ...er cover 6 Disconnect the power source terminal coupler 1 7 Disconnect the headlight couplers 2 8 Remove the front fender with the headlight assemblies 9 Remove the headlight assemblies from the front fender Refer to Headlight Removal and Installation in Section 9B Page 9B 3 Installation Installation is in the reverse order of removal Pay attention to the following point Check the headlight beam a...

Page 493: ...footrest mudguards 5 Remove the battery 2 Refer to Battery Removal and Installation in Section 1J Page 1J 13 6 Remove the starter relay 3 Refer to Starter Relay Removal and Installation in Section 1I Page 1I 5 7 Disconnect the fuse box 4 from the bracket 8 Remove the air cleaner duct 5 9 Remove the rear fender 6 Installation Installation is in the reverse order of removal 1 I827H1940023 01 3 4 5 2...

Page 494: ...nstruction B827H19506002 2 3 1 FWD FWD a b I827H1950001 03 1 Frame 3 Battery plate 28 N m 2 8 kgf m 20 0 lb ft 2 Engine mounting upper bracket 28 N m 2 8 kgf m 20 0 lb ft b b a a FWD FWD 1 2 I827H1950002 03 1 Footrest RH 55 N m 5 5 kgf m 40 0 lb ft Apply thread lock to the thread part 2 Footrest LH 25 N m 2 5 kgf m 18 0 lb ft ...

Page 495: ... of removal Pay attention to the following point Install the gearshift lever assembly to the footrest LT F400 F LH Refer to Gearshift Lever Removal and Installation LT F400 F in Section 5B Page 5B 8 Apply thread lock to the footrest mounting bolts M10 and tighten them to the special torque Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tightening torque Footrest mountin...

Page 496: ... Body Structure Carrier Construction B827H19506004 1 Front carrier 28 N m 2 8 kgf m 20 0 lb ft Apply thread lock to the thread part 2 Rear carrier 28 N m 2 8 kgf m 20 0 lb ft 2 1 FWD FWD a b I827H1950005 04 ...

Page 497: ...ier Removal and Installation B827H19506006 Removal Remove the rear carrier 1 by removing the bolts and screw Installation Install the rear carrier in the reverse order of removal Pay attention to the following points Apply thread lock to the rear carrier mounting bolts Thread lock cement 99000 32110 THREAD LOCK CEMENT SUPER 1322 or equivalent Tighten the rear carrier mounting bolts to the specifie...

Page 498: ...827H19506008 Removal 1 Remove the front under cover Refer to Exterior Parts Removal and Installation in Section 9D Page 9D 3 2 Remove the front grip bar 1 by removing the bolts 1 a b I827H1950006 03 1 Front grip bar 28 N m 2 8 kgf m 20 0 lb ft 28 N m 2 8 kgf m 20 0 lb ft 1 I827H1950013 01 I827H1950014 01 ...

Page 499: ...t Trailer Towing Removal and Instruction B827H19506010 Removal Remove the trailer towing 1 by removing the bolts Installation Apply thread lock to the rear axle housing mounting bolts and tighten them to the specified torque Thread lock cement 99000 32030 THREAD LOCK CEMENT SUPER 1303 or equivalent Tightening torque Rear axle housing mounting bolt final gear case a 55 N m 5 5 kgf m 40 0 lb ft a a ...

Page 500: ...ed service material is also described in the following Footrest Construction Page 9E 1 Carrier Construction Page 9E 3 Fastening part Tightening torque Note N m kgf m lb ft Footrest mounting bolt M10 55 5 5 40 0 Page 9E 2 Footrest mounting bolt M8 25 2 5 18 0 Page 9E 2 Front carrier mounting bolt 28 2 8 20 0 Page 9E 4 Rear carrier mounting bolt 28 2 8 20 0 Page 9E 4 Front grip bar mounting bolt 28 ...

Page 501: ...Prepared by December 2007 Part No 99500 43070 01E Printed in Japan 504 ...

Page 502: ...Printed in Japan K8 9 9 5 0 0 4 3 0 7 0 0 1 E K8 ...

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