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13-2 LT-A450XK9 (’09-MODEL)

SPECIFICATIONS (LT-A450XK9)

DIMENSIONS AND CURB MASS

Overall length ......................................................................................

2 115 mm (83.3 in) ........... P-28, 33
2 135 mm (84.1 in) ........... P-17, 24

Overall width .......................................................................................

1 210 mm (47.6 in) ........... P-28, 33
1 250 mm (49.2 in) ........... P-17, 24

Overall height ......................................................................................

1 215 mm (47.8 in)

Wheelbase ..........................................................................................

1 280 mm (50.4 in)

Ground clearance................................................................................

260 mm (10.2 in)

Seat height. .........................................................................................

860 mm (33.9 in)

* Curb mass ........................................................................................

305 kg (672 lbs) .......... P-28, 33
307 kg (676 lbs) .......... P-17, 24

Front track ...........................................................................................

930 mm (36.6 in)

Rear track............................................................................................

940 mm (37.0 in)

ENGINE

Type.....................................................................................................

4-stroke, liquid-cooled, OHC

Number of cylinders ............................................................................

Bore ....................................................................................................

84.0 mm (3.0307 in)

Stroke..................................................................................................

82.0 mm (3.228 in)

Displacement ......................................................................................

454 cm

(27.7 cu. in)

Compression ratio ...............................................................................

10.0 : 1

Fuel system.........................................................................................

Fuel injection

Air cleaner ...........................................................................................

Non-woven fabric element

Starter system.....................................................................................

Electric & recoil starter

Lubrication system ..............................................................................

Wet sump

Idle speed ...........................................................................................

1 500 ± 100 r/min

DRIVE TRAIN

Clutch ..................................................................................................

Wet shoe, automatic, centrifugal type

Transmission .......................................................................................

Automatic variable ratio (V-belt)

Transfer ...............................................................................................

2-speed forward with reverse

Gearshift pattern, Transmission .........................................................

Automatic

Transfer .................................................................

L-H-N-R (Hand operated)

Primary reduction ratio (Automatic drive)............................................

2.902 – 0.779 (Variable change)

Secondary reduction ratio ...................................................................

2.733 (41/19 × 19/15)

Final reduction ratio (Front & Rear).....................................................

3.600 (36/10)

Transfer gear ratio, Low ......................................................................

2.562 (41/16)

High .....................................................................

1.240 (31/25)

Reverse................................................................

2.000 (32/16)

Drive system .......................................................................................

Shaft drive

CHASSIS

Front suspension.................................................................................

Independent, double wishbone, coil spring, oil damped

Rear suspension .................................................................................

Independent, double wishbone, coil spring, oil damped

Front wheel travel ................................................................................

180 mm (7.1 in)

Rear wheel travel. ...............................................................................

200 mm (7.9 in)

Caster .................................................................................................

1.6°

Trail......................................................................................................

3.4 mm (0.13 in)

Toe-out ................................................................................................

12 mm (0.47 in)

Camber ...............................................................................................

0.64°

Steering angle.....................................................................................

46° (right & left)

Turning radius .....................................................................................

3.1 m (10.2 ft)

Front brake ..........................................................................................

Disc brake, twin

Rear brake ..........................................................................................

Sealed oil-bathed multi-disc

Front tire size ......................................................................................

AT25 × 8-12

✩✩

, tubeless

Rear tire size .......................................................................................

AT25 × 10-12

✩✩

, tubeless

ELECTRICAL

Ignition type.........................................................................................

Electronic ignition (CDI)

Ignition timing. .....................................................................................

7° B.T.D.C. at 1 500 r/min

Spark plug...........................................................................................

NGK CR6E or DENSO U20ESR-N

Battery.................................................................................................

12V 43.2kC (12Ah)/10HR

Generator ............................................................................................

Three-phase A.C. generator

Main fuse ............................................................................................

30 A

Fuse ....................................................................................................

10/10/10/10/15/15 A

Headlight .............................................................................................

12 V 35/35 W × 2

Brake light/Taillight ..............................................................................

12 V 21/5 W

Reversing light ....................................................................................

12 V 21 W ...... P-17

Speedometer light ...............................................................................

LED

Coolant temperature/Fi indicator light .................................................

LED

Neutral indicator light ..........................................................................

LED

High beam indicator light ....................................................................

LED................ P-17

Reverse indicator light.........................................................................

LED

Difflock indicator light ..........................................................................

LED

CAPACITIES

Fuel tank

..........................................................................................

17.5 L (4.6/3.8 US/Imp gal)

Engine oil, Oil change.........................................................................

2 500 ml (2.6/2.2 US/Imp qt)

With filter change ..............................................................

2 700 ml (2.9/2.4 US/Imp qt)

Overhaul. ..........................................................................

3 200 ml (3.4/2.8 US/Imp qt)

Differential gear oil ..............................................................................

500 ml (16.9/17.6 US/lmp oz)

Final gear oil .......................................................................................

770 ml (26.0/27.1 US/lmp oz)

Coolant

..........................................................................................

2.5 L (2.6/2.2 US/lmp qt)

Summary of Contents for LT-A450X

Page 1: ...ou can assure your customers of fast and reli able service This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the con tent 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 repr...

Page 2: ...SUPPLEMENTS LT A450XK9 09 MODEL LT A450XK8 12 13 WIRING DIAGRAM 14 ...

Page 3: ...DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example 1 Handlebar 2 Handlebar upper clamp 3 Steering shaft 4 Steering shaft holder 5 Dust seal 6 Bush 7 Dust seal 8 O ring 9 Tie rod 0 Tie rod end A Handleber upper clamp bolt B Handleber holder nut ...

Page 4: ...SUPER 1360 99000 32130 Apply hypoid gear oil Apply or use brake fluid Apply molybdenum oil solution mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Measure in voltage range Apply SUZUKI SUPER GREASE A or equivalent grease 99000 25010 Measure in resistance range Apply SUZUKI SILICONE GREASE 99000 25100 Measure in current range Apply SUZUKI MOLY PASTE 99000 25140 Measure in diode test ...

Page 5: ... DIFF LOCK Relay Differential Lock Relay DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light DTC Diagnostic Trouble Code E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS F FI Fuel Injection Fuel Injector FP Fuel Pump FPR Fuel Pressure Regulator FP Relay Fuel Pump Relay G GEN Gene...

Page 6: ...N NOX Nitrogen Oxides O OHC Over Head Camshaft P PCV Positive Crankcase Ventilation Crankcase Breather R REC Rectifier REG Regulator RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System T TO Sensor Tip Over Sensor TOS TP Sensor Throttle Position Sensor TPS ...

Page 7: ... G Generator Ground I Idle Speed Control Ignition Control Module Intake Air Temperature M Malfunction Indicator Lamp Manifold Absolute Pressure ACL B CKP Sensor DLC DTM DTC EI ECM ECL ECT RPM FC FP GEN GND IC ICM IAT MIL MAP Air Cleaner Air Cleaner Box Battery Voltage B Crankshaft Position Sensor CKPS Crank Angle Dealer Mode Coupler Diagnostic Code Malfunction Code Engine Control Module ECM FI Con...

Page 8: ...ly Memory R Random Access Memory Read Only Memory T Throttle Body Throttle Body Fuel Injection Throttle Position Sensor V Voltage Regulator OBD PROM RAM ROM TB TBI TP Sensor VR Self Diagnosis Function Diagnostic ROM Throttle Body TB Throttle Body Fuel Injection TBI TP Sensor TPS Voltage Regulator ...

Page 9: ... PRECAUTIONS 1 2 SUZUKI LT A450XK7 07 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION 1 5 FUEL FOR USA AND CANADA 1 5 FUEL FOR OTHER COUNTRIES 1 5 ENGINE OIL FOR USA 1 5 ENGINE OIL FOR OTHER COUNTRIES 1 5 FRONT DIFFERENTIAL GEAR OIL 1 5 REAR DRIVE FINAL GEAR OIL 1 5 BRAKE FLUID 1 5 ENGINE COOLANT 1 6 BREAK IN PROCEDURES 1 7 INFORMATION LABELS 1 8 SPECIFICATIONS 1 9 ...

Page 10: ...ood judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of each other...

Page 11: ...d nu ts tig hten the la rger si zes firs t Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever y ou r emove oi l sea ls ga skets packing O rings l ocking was hers sel f locking nuts cotter pins circlips and certain other parts as specified be sure to re place them with new ones Also before installing these new parts be sure t...

Page 12: ...arkets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number 1 is stamped on the left side of the front frame pipe The engine serial number 2 is located on the right side of the crankcase These numbers are required especially for registering the machine and ordering spare parts RIGHT SIDE LEFT SIDE ...

Page 13: ...IES 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 engine oil is not available select an alternative accord ing to the right chart FRONT DIFFERENTIAL GEAR OIL Use hypoid gear oil that meets the API grade GL 5 or SAE 75W 90 and...

Page 14: ...not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator LIQUID AMOUNT OF WATER ENGINE COOLANT Solution capacity total Approx 2 450 ml 2 6 2 1 US Imp qt For engine coolant mixture information refer to cooling system section in page 7 2 Mixing of anti freeze engine co...

Page 15: ...jecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Brake in engine speeds Initial 500 km 300 miles Less than 1 2 throttle Upon reaching an odometer reading of 500 km 300 miles you can subject the vehicle to full throt...

Page 16: ...label A 8 General warning label A For E 28 9 Warning no passenger label A 0 AGE 16 label A For E 28 A Manual notice label A For E 33 B Max AMP caution label A Except for E 28 C Max AMP caution label A For E 28 D Fuel caution label A For E 24 E Front carrier warning label A For E 24 33 F Front carrier warning label A For E 17 28 G Rear carrier warning label A For E 24 33 H Rear carrier warning labe...

Page 17: ... in Stroke 82 0 mm 3 228 in Displacement 454 cm 27 7 cu in Compression ratio 10 0 1 Fuel system Fuel injection Air cleaner Nonwoven fabric element Starter system Electric and recoil starter Lubrication system Wet sump Idle speed 1 500 100 r min DRIVE TRAIN Clutch Wet shoe automatic centrifugal type Transmission Automatic variable ratio V belt Transfer 2 speed forward with reverse Gearshift pattern...

Page 18: ...in Spark plug NGK CR6E or DENSO U20ESR 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 15 15 A Headlight 12 V 35 35 W 2 Brake light Taillight 12 V 21 5 W Reversing light 12 V 21 W E 17 Speedometer light LED Coolant temperature FI warning light LED Neutral indicator light LED High beam indicator light LED E 17 Reverse indicator light LED Diff l...

Page 19: ...L GEAR OIL 2 12 THROTTLE CABLE PLAY 2 13 THROTTLE BODY 2 13 ENGINE COOLANT 2 14 RADIATOR 2 15 RADIATOR HOSES 2 15 DRIVE BELT 2 16 DRIVE SHAFT BOOTS 2 20 BRAKES 2 21 REAR BRAKE PLATES 2 23 BRAKE FLUID 2 24 BRAKE HOSES 2 26 TIRES 2 26 STEERING 2 27 SUSPENSIONS 2 27 CHASSIS NUTS AND BOLTS 2 28 GENERAL LUBRICATION 2 31 COMPRESSION PRESSURE CHECK 2 32 COMPRESSION TEST PROCEDURE 2 32 OIL PRESSURE CHECK ...

Page 20: ...itial 200 Every 1 000 Every 2 000 miles Initial 100 Every 600 Every 1 200 months 1 3 6 Air cleaner element I I Exhaust pipe nuts and muffler mounting bolts T T T Valve clearance I I Spark plug I Replace every 6 000 km 4 000 miles Spark arrester C Fuel line I I Replace every 4 years Engine oil and oil filter R R Front differential gear oil I Replace every 2 years Final gear oil I Replace every year...

Page 21: ... Left mud guard 8 9 Right mud guard 8 10 Left inner fender 8 10 Right inner fender 8 10 Front grill 8 6 Front carrier 8 6 Front fender 8 9 Rear carrier 8 14 Rear fender 8 15 AIR CLEANER ELEMENT If the air cleaner element is clogged with dust intake resistance will be increased with a resultant decrease in power output and increase in fuel consumption Check and clean the air cleaner element in the ...

Page 22: ...sed a ir i s applied to t he outside dirt will be forc ed in to th e p ores of th e a ir cleaner el ement r estricting ai r flow t hrough the ai r cleaner element Inspect the air cleaner element for tears A torn ele ment must be replaced In driving under du sty co nditions cl ean th e ai r cleaner element more frequently The surest way to accelerate engine wear is to operate the engine with out th...

Page 23: ... 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 REMOVAL Remove the right inner fender 8 10 Remove the right side cover 8 10 Remove the left upper mud guard 8 9 Remove the valve clearance inspection caps 3 12 ...

Page 24: ...irection The spark plug should be removed Turn the generator rotor until the TDC line A on the genera tor rotor is aligned with the index mark B of the generator cover Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm If the clearance is out of specification bring it into the speci fied range with the special tool 09900 20803 Thickness gauge 09917 13210 ...

Page 25: ...e is extremely worn or burnt replace the spark plug with a new one Also replace the spark plug if it has a broken insulator dam aged threads etc SPARK PLUG INSTALLATION Insert the spark plug and tighten it to the cylinder head by hand then tighten it to the specified torque Spark plug 11 N m 1 1 kgf m 8 0 lb ft Replace every 6 000 km 4 000 miles Standard Cold type NGK CR6E CR7E DENSO U20ESR N U22E...

Page 26: ... by brush Reinstall the spark arrester pipe 2 FUEL LINE Remove the front fender 8 9 Remove the rear fender 8 15 Remove the air cleaner box 6 10 Inspect the fuel feed hose for damage and fuel leakage If any damages are found replace it with a new one Clean every 2 000 km 1 200 miles 6 months Inspect every 1 000 km 600 miles 3 months Replace every 4 years ...

Page 27: ...5 L 2 6 US qt 2 2 lmp qt of oil Use an engine oil that meets the API service classifica tions SF or SG and that has a viscosity rating of SAE 10W 40 Engine oil drain plug 20 5 N m 2 05 kgf m 15 0 lb ft Make sure that the engine is cooled Place the vehicle on level ground and hold it vertically Install the oil filler cap 2 Start the engine and allow it to run for three minutes at idling speed Turn ...

Page 28: ...only Oil filter 2 N m 0 2 kgf m 1 5 lb ft Pour the new engine oil through the oil filler hole When per forming the oil filter change the engine will hold about 2 7 L 2 9 US qt 2 4 Imp qt of oil Check the oil level 2 9 Add new engine oil and check the oil level 2 9 Engine oil capacity Oil change 2 5 L 2 6 US qt 2 2 lmp qt Oil and filter change 2 7 L 2 9 US qt 2 4 lmp qt Engine overhaul 3 2 L 3 4 US...

Page 29: ...the front differential gear oil by removing the oil drain plug 1 oil filler plug and oil level plug Tighten the oil drain plug 1 to the specified torque and pour fresh oil through the oil filler hole until it overflows from the oil level hole Tighten the oil level plug and oil filler plug to the specified torque Install the front under cover Differential gear oil specification Hypoid gear oil SAE ...

Page 30: ... Place an oil pan below the final gear case Drain the final gear oil by removing the oil drain plug 1 and oil filler plug Tighten the oil drain plug 1 to the specified torque and pour fresh oil through the oil filler hole until the oil level reaches the bottom tip of the thread Tighten the oil filler plug securely Install the rear under cover Final gear oil specification Mobil fluid 424 or equival...

Page 31: ...3 5 mm 0 12 0 20 in After adjusting the throttle cable play tighten the lock nut 1 THROTTLE BODY Remove the right and left side cover 8 9 Inspect the throttle body for dart or mud If any dirt or mud is found clean it Inspect ini tially at 2 00 km 1 00 mi les 1 mo nth an d every 1 000 km 600 miles 3 months thereafter Inspect every 1 00 0 k m 600 miles 3 months a nd every 2 000 km 1 200 miles 6 mont...

Page 32: ...ecessary Tighten the drain plug 4 to the specified torque Engine coolant drain plug 12 5 N m 1 25 kgf m 9 0 lb ft Pour the specified engine coolant into the reservoir tank Engine coolant Use and antifreeze designed for aluminum radiators mixed with distilled water only Water antifreeze mixture ratio 50 50 40 60 NOTE For engine coolant information refer to page 7 2 Replace the engine coolant every ...

Page 33: ...mp qt RADIATOR Inspect the radiator for damage and engine coolant leakage If any damages are found replace it with a new one RADIATOR HOSES Inspect the radiator hoses for damage and engine coolant leak age If any damages are found replace them with new ones Repeat the above procedure several times and make sure the rad iator is filled with en gine coolant to the upper line of the engine coolant re...

Page 34: ...er 8 10 Remove the right mud guard 8 10 Remove the rear brake cable clamp 1 Remove the right footrest 2 Remove the clutch cover and clutch cover gasket Remove the cap 3 Remove the movable drive face cover 4 Remove the dowel pins 5 Inspect every 2 000 km 1 200 miles 6 months ...

Page 35: ...930 40113 Rotor holder Remove the movable drive face 8 Remove the movable driven face bolt with the special tool Remove the movable driven face assembly 9 and drive belt 0 09930 40113 Rotor holder INSPECTION Inspect the drive belt for wear and damage If any defects are found replace it with a new one ...

Page 36: ...able driven face bolt 110 N m 11 0 kgf m 79 5 lb ft 09930 40113 Rotor holder Install the movable drive face assembly 3 The drive belt should be installed so that the arrows on the drive belt periphery point in the normal turn ing direction The dr ive b elt co ntact surface of t he d riven f ace should be thoroughly cleaned Pull the center area A of upper and lower belt lines to be close to eac h o...

Page 37: ...pecified torque with the special tool Movable drive face bolt 110 N m 11 0 kgf m 79 5 lb ft 09930 40113 Rotor holder NOTE Turn the fixed drive face until the belt is seated in and both the drive and driven faces will move together smoothly without slip Install the dowel pins 6 Install the movable drive face cover 7 and tighten the bolts securely Install the cap 8 ...

Page 38: ... 5 7 lb ft DRIVE SHAFT BOOTS Inspect the drive shaft boots for wear or damage If any defects are found replace it with a new one The removed c lutch c over g asket must b e replaced with a new one Tighten the clutch cover bolts A first and then other ones diagonally Inspect initially at 20 0 k m 100 miles 1 month a nd every 1 000 km 600 miles 3 months thereafter ...

Page 39: ...ine is out of the limit replace the friction plate as a set 8 73 REAR BRAKE PEDAL AND LEVER The procedure for adjusting the rear brake pedal and brake lever is as follows NOTE First adjust the brake pedal and then adjust the brake lever REAR BRAKE PEDAL HEIGHT Turn the adjuster 1 in or out until the pedal height A to the specification after loosening the lock nut 2 Make sure to tighten the lock nu...

Page 40: ...essure is felt Rear brake pedal free travel A 20 30 mm 0 8 1 2 in MINOR ADJUSTMENT Loosen the lock nut 2 Turn adjuster nut 3 so the rear brake pedal has 20 30 mm 0 8 1 2 in free travel at the rear brake pedal end before pressure is felt Tighten the lock nut 2 Rear brake pedal Free travel A 20 30 mm 0 8 1 2 in Adjust the rear brake light switch so that the brake light will come on just before press...

Page 41: ...MENT Loosen the lock nut 2 Turn adjuster 3 so the rear brake lever has 6 8 mm 0 2 0 3 in play at the rear brake lever end before pressure is felt Tighten the lock nut 2 Rear brake lever play A 6 8 mm 0 2 0 3 in After adjusting the play check that the rear wheels roll freely without applying the brake the transfer in neutral and the rear wheels off the ground Readjust the rear brake lever if the re...

Page 42: ... 600 miles 3 months Replace every 2 years The brake system of this vehicle is filled with a gly col based br ake f luid Do no t u se or mi x di fferent types of flu id s uch as si licone based a nd petro leum based fluids Do not use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from the last servicing or stored for a long period of time Brake fluid i...

Page 43: ...e and insert the free end of the hose into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handle bar grip reaching bottom of the st...

Page 44: ...in tain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows Cold inflation tire pressure Front 35 kPa 0 35 kgf cm 5 1 psi Rear 30 kPa 0 3 kgf cm 4 4 psi VEHICLE LOAD CAPACITY LIMIT 172 kg 380 lbs Inspect every 2 000 km 1 200 miles 6 months Replace every 4 years Inspect every 1 000 km 600 miles 3 months To mi nimize t he possibility o f t...

Page 45: ...n adjust the tie rod to the right or left until the toe out is within the specified range B A Toe out Toe out 10 4 mm 0 39 0 16 in If the toe out is out of specification bring it into the specified valve 8 65 SUSPENSIONS Support the vehicle with a jack and wooden blocks Remove the front and rear wheels 8 18 Inspect the wishbone arm and bearing for scratches wear or damage If any defects are found ...

Page 46: ... rear 60 6 0 43 5 0 Steering knuckle end nut upper and lower 29 2 9 21 0 A Tie rod end nut 29 2 9 21 0 B Tie rod lock nut 45 4 5 32 5 C Front shock absorber mounting bolt upper 55 5 5 40 0 D Front shock absorber mounting nut lower 60 6 0 43 5 E Front brake air bleeder valve 6 0 0 6 4 3 F Front brake caliper mounting bolt 26 2 6 19 0 G Brake disk plate mounting bolt 23 2 3 16 5 H Front brake hose u...

Page 47: ...PERIODIC MAINTENANCE 2 29 ...

Page 48: ...2 30 PERIODIC MAINTENANCE ...

Page 49: ...pline Grease 2 Brake lever holder and throttle lever 6 Drive belt cover bearing inner race 3 Brake pedal 4 Propeller shaft joint spline NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the vehicle has been operated under wet or rainy conditions L...

Page 50: ...oes below specification check the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque and the valves are properly adjusted Warm up the engine before testing Make sure that the battery is fully charged Remove the related parts and test the compression pressur...

Page 51: ...ssage Combination of the above items OIL PRESSURE TEST PROCEDURE Connect the tachometer onto the spark plug high tension cord Remove the right inner fender 8 10 Remove the cooling duct Remove the main oil gallery plug 1 Install the oil pressure gauge and adaptor into the main oil gallery Warm up the engine as follows Summer 10 minutes at 2 000 r min Winter 20 minutes at 2 000 r min After warming u...

Page 52: ... train Perform the following Warm up the engine INITIAL ENGAGEMENT INSPECTION Connect the tachometer or the multi circuit tester onto the spark plug high tension cord Start the engine Shift the range lever to the High position Slowly open the throttle and note the engine speed r min when the vehicle begins to move forward 09900 26006 Tachometer or 09900 25008 Multi circuit tester set Engagement sp...

Page 53: ...and rear brakes as firmly as possible Fully open the throttle for a brief period and note the maxi mum engine speed sustained during the test cycle Lock up speed 3 750 4 250 r min If the lock up speed r min does not coincide with the standard range inspect the following items for any abnormalities Clutch shoe 3 57 Clutch housing 3 57 Movable drive and driven face 3 52 and 3 55 Do not apply f ull p...

Page 54: ... engine failure to be determined Also in the case of a customer vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master STD comparison between the same models helps facilitate the troubleshooting Set up the SDS tool 5 22 09904 41010 SDS set tool 99565 01010 009 CD ROM Ver 9 ...

Page 55: ...PERIODIC MAINTENANCE 2 37 Data at 3 000 r min under no load Data at the time of racing 3 000 r min Check the manifold absolute pressure XXX kPa XXX mmHg Throttle Quick wide open Throttle Slowly open ...

Page 56: ...saved under the same condition then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring With DTC not output if the value of engine coolant temperature is found to be lower than the data saved previously the possible cause may probably lie in a sensor circuit shorted to ground or influence of internal resistance value etc Unstable engin...

Page 57: ...IDE 3 42 CYLINDER 3 42 PISTON AND PISTON RING 3 43 CONROD 3 45 CRANKSHAFT 3 46 CRANK BALANCER BALANCER DRIVEN GEAR AND DRIVE GEAR 3 47 STARTER CLUTCH 3 47 STARTER IDLE GEAR NO 1 AND NO 2 3 49 MOVABLE DRIVE FACE AND DRIVEN FACE 3 50 DRIVE BELT 3 57 CLUTCH SHOE 3 57 CLUTCH HOUSING 3 57 OIL PUMP 3 58 OIL SUMP FILTER 3 58 TRANSFER 3 59 GEARSHIFT FORK AND GEAR 3 62 GEARSHIFT CAM 3 63 GEARSHIFT SHAFT 3 ...

Page 58: ...TION Recoil starter 3 11 3 113 Water pump 3 16 3 106 Starter cup 3 16 3 106 Speed sensor 3 82 3 84 PARTS REMOVAL INSTALLATION Clutch cover 3 21 3 100 Movable drive driven face 3 21 3 99 Movable drive face 3 22 3 98 Drive belt 3 22 3 98 Fixed drive face 3 22 3 98 Gear position switch 3 23 3 97 PARTS REMOVAL INSTALLATION Starter motor 3 3 3 114 Cam chain tensioner 3 31 3 39 Cylinder head cover 3 12 ...

Page 59: ...eat 8 6 Disconnect the battery lead wires Remove the front fender 8 9 Remove the rear fender 8 15 Remove the right and left mud guard 8 9 and 8 10 Remove the right and left inner fenders 8 10 Remove the speak plug cap 2 7 Remove the rear propeller shaft 4 40 Disconnect the starter motor lead wire 1 and ground lead wire 2 Disconnect the inlet hose 3 and outlet hose 4 When disconnecting the battery ...

Page 60: ...r 5 Remove the throttle body assembly 6 11 Remove the transfer gear shift lever assembly 8 97 Remove the transfer gear shift shaft lever 6 Disconnect the speed sensor coupler and clamp 7 Disconnect the generator coupler 8 CKP sensor coupler 9 and gear position sensor coupler 0 ...

Page 61: ...INE 3 5 Remove the belt cooling ducts Intake A and outlet B Loosen the muffler connect bolt C Remove the exhaust pipe D Remove the muffler E Remove the rear brake cable clamp F Remove the right footrest G ...

Page 62: ...INE Remove the rear brake pedal assembly 10 29 Remove the front drive train differential gear case mounting bolts nuts Slide the front differential assembly H forward Remove the front propeller shaft spring I ...

Page 63: ...ENGINE 3 7 Remove the engine mounting nuts Remove the engine from the right side ...

Page 64: ...he engine in the reverse order of engine removal Pay attention to the following points Tighten the engine mounting nuts to the specified torque Engine mounting nut 60 N m 6 0 kgf m 43 5 lb ft ITEM N m kgf m lb ft A 60 6 0 43 5 B 60 6 0 43 5 ...

Page 65: ...er 1 keep that the clearance A and B are equal Apply a small quantity of THREAD LOCK SUPER 1303 to the front differential gear mounting nuts Tighten the front differential gear mounting nuts to the speci fied torque 99000 32030 THREAD LOCK SUPER 1303 Front drive train differential gear case mounting nut 50 N m 5 0 kgf m 36 0 lb ft When installing the gearshift shaft lever align the both serra tion...

Page 66: ... 5 0 kgf m 40 0 lb ft Install the rear brake cable clamp 2 Tighten the muffler mounting bolts to the specified torque Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Install the exhaust pipe gasket and tighten the exhaust pipe nuts 3 and muffler connect bolt 4 to the specified torque Exhaust pipe nut 23 N m 2 3 kgf m 16 5 lb ft Muffler connect bolt 23 N m 2 3 kgf m 16 5 lb ft The removed gasket ...

Page 67: ...e starter motor 1 SPARK PLUG Remove the spark plug 09930 10121 Spark plug wrench set WATER HOSE Remove the water bypass hose RECOIL STARTER Remove the recoil starter 1 CAM CHAIN TENSION ADJUSTER Remove the cam chain tension adjuster cap bolt 1 and gas ket ...

Page 68: ...rewdriver until the push rod locked Remove the cam chain tension adjuster 2 and gasket 3 CYLINDER HEAD COVER Remove the valve clearance inspection caps 1 Remove the cylinder head cover bolts and washers Remove the cylinder head cover 2 Remove the dowel pins ...

Page 69: ...til the TDC line A on the genera tor rotor is aligned with the index mark B of the generator cover NOTE At the above condition the piston is at TDC of compression stroke and also the engraved lines C on the camshaft is parallel with the mating surface of the cylinder head cover Flatten the lock washer tongues 4 and remove the camshaft sprocket bolts ...

Page 70: ...ut the camshaft 6 from the camshaft sprocket Remove the camshaft sprocket 7 OIL FILTER Remove the oil filter with special tool 09915 40610 Oil filter wrench CYLINDER HEAD Remove the cylinder head base nuts 1 Remove the cylinder head bolts M8 2 ...

Page 71: ...t CYLINDER Remove the cylinder head gasket 1 and dowel pins 2 Remove the cam chain guide 3 Remove the cylinder 4 NOTE It the cylinder dose not come off easily lightly tap it using a plas tic mallet Remove the cylinder gasket 5 and dowel pins 6 PISTON Place a clean lag over the cylinder base to prevent the piston pin circlip from dropping in to the crankcase Remove the piston pin circlip 1 ...

Page 72: ... remove the piston 3 WATER PUMP Remove the water pump 1 GENERATOR COVER Remove the starter cup nut 1 with a suitable bar 2 Remove the starter cup 3 Remove the generator cover 4 and clamps 5 Remove the generator cover gasket 6 and dowel pins 7 ...

Page 73: ... 1 and shaft 2 Remove starter idle gear No 2 3 and shaft 4 GEARSHIFT SHAFT Remove the and washers 1 and gearshift shaft 2 Remove the gearshift cam stopper plate 3 by removing its bolt 4 Remove the gearshift cam stopper bolt 5 gearshift cam stopper 6 washer 7 and return spring 8 ...

Page 74: ...p ring 2 Remove the spacer 3 STARTER CLUTCH AND GENERATOR ROTOR Remove the generator rotor nut 1 Install the special tool to the crankshaft end 09930 31921 Rotor remover attachment Remove the generator rotor 2 with the special tool 09930 30721 Rotor remover Remove the key 3 and starter driven gear 4 ...

Page 75: ...ch sleeve hub holder 09920 31020 Extension handle Remove the crank balancer driven gear bolt 2 and crank bal ancer drive gear 3 Remove the oil pump drive gear 4 and key 5 Unlock the crank balancer drive gear nut with a chisel Remove the crank balancer drive gear nut with the special tools 09920 53740 Clutch sleeve hub holder 09924 52460 Socket wrench 52 mm 09920 31020 Extension handle ...

Page 76: ...k balancer drive gear 7 Remove the pin 8 Remove the spacer 9 OIL PUMP Remove the snap ring 1 Remove the oil pump driven gear 2 Remove the pin 4 and washer 5 Remove the oil pump 6 CLUTCH COVER Remove the clutch cover 1 and clutch cover gasket ...

Page 77: ... the cap 2 MOVABLE DRIVE FACE Remove the movable drive face cover 1 Remove the dowel pins 2 Remove the movable drive face bolt 3 and collar 4 with the special tool 09930 40113 Rotor holder Remove the movable drive face 5 ...

Page 78: ... the special tool Remove the movable driven face assembly 1 and drive belt 2 09930 40113 Rotor holder FIXED DRIVE FACE Remove the fixed drive face 1 Remove the clutch inner cover 2 and clutch inner cover gas ket Remove the cushions 3 GEAR POSITION SWITCH Remove the gear position switch 1 ...

Page 79: ... 2 and springs 3 CLUTCH HOUSING CASE Remove the clutch housing case 1 together with the clutch housing 2 Remove the dowel pins 3 and clutch housing case gasket 4 Remove the oil jet 5 Remove the clutch housing 6 from the clutch housing case ...

Page 80: ...ut has left hand thread 09930 40113 Rotor holder 09930 40120 Rotor holder attachment A Remove the washer 3 Remove the clutch shoe with the special tool 09930 30104 Sliding shaft 09920 33540 Clutch shoe remover CRANKCASE Remove the right crankcase bolts M6 and clamp 1 Remove the right crankcase bolts M8 NOTE Loosen the crankcase bolts diagonally with the smaller sizes first ...

Page 81: ... tool to the right crankcase so that the tool plate is paralleled with the end of the crankcase 09920 13120 Crankcase and shaft remover Remove the collar 2 Remove the dowel pins 3 OIL SUMP FILTER Remove the oil sump filter 1 REAR OUTPUT SHAFT Remove the rear output shaft 1 Remove the C ring 2 ...

Page 82: ...3 Remove the transfer output shaft assembly 4 and reverse idle gear 5 Install a suitable washer 6 and the removed movable drive face bolt 7 to the transfer input shaft Remove the transfer input shaft with a plastic mallet REAR OUTPUT SHAFT DRIVE BEVEL GEAR Unlock the drive bevel gear nut 1 with a chisel ...

Page 83: ...older Remove the washer 3 and rear output shaft drive bevel gear 4 Remove the shim 5 Install the removed drive bevel gear nut to the transfer output driven gear 6 Remove the transfer output driven gear with a plastic mallet CRANK BALANCER Remove the crank balancer 1 CRANKSHAFT Install the removed generator cover 1 and tighten the bolts ...

Page 84: ...3 28 ENGINE Remove the crankshaft with the special tool 09920 13120 Crankcase and shaft remover Remove the generator cover ...

Page 85: ... distortion with a thickness gauge Check points are shown in Fig Cylinder head cover distortion Service Limit 0 05 mm 0 0027 in 09900 20803 Thickness gauge If the distortion exceeds the limit replace the cylinder head cover ROCKER ARM SHAFT O D Measure the diameter of the rocker arm shafts Rocker arm shaft O D Standard IN EX 11 973 11 984 mm 0 4713 0 4718 in 09900 20205 Micrometer 0 25 mm Identify...

Page 86: ...EASSEMBLY Reassemble the cylinder head cover in the reverse order of dis assembly Pay attention to the following points Apply engine oil to the rocker arm shafts Install the wave washers 1 rocker arms 2 and shafts 3 Install the gaskets 4 and rocker arm shaft bolts 5 Tighten the rocker arm shaft bolts 5 to the specified torque Rocker arm shaft bolt 27 5 N m 2 75 kgf m 20 0 lb ft The r emoved ga ske...

Page 87: ... and gasket 7 from the cylinder head Using the special tools compress the valve spring and remove the two cotter halves 8 from the valve stem 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers Identify the position of each removed part Organize the pa rts in th eir re spective gro ups i e in take or exhaust so that they can be installed in their original locations ...

Page 88: ...ove the valve spring retainer 9 and valve spring 0 Pull out the valve A from the combustion chamber side Remove the oil seal B and valve spring seat C Remove the other valves in the same manner as described previously ...

Page 89: ... Magnetic stand 09900 21304 V block set 100 mm VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout If it measures more than the service limit replace the valve Valve head radial runout Service Limit 0 03 mm 0 001 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm VALVE FACE WEAR The...

Page 90: ...the guide should be replaced with a new one Valve stem deflection IN EX Service Limit 0 35 mm 0 014 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM WEAR If the valve stem is worn down to the limit as measured with a micrometer replace the valve If the stem is within the limit then replace the guide After replacing valve or guide be sure to recheck the deflection Valve stem...

Page 91: ... freezer for about one hour and heat the cylinder head to 100 150 C 212 302 F with a hot plate Apply engine oil to the valve guide hole Drive the valve guide into the hole using the valve guide installer 1 and attachment 2 09916 44310 Valve guide remover installer 1 09916 53370 Attachment 2 NOTE Install the valve guide until the attachment contacts with the cyl inder head 3 When refinishing o r r ...

Page 92: ...ve seat width on each valve face If the valve face has worn abnormally replace the valve Coat the valve seat with a red lead Prussian Blue and set the valve in place Rotate the valve with light pressure Inspect that the transferred red lead Prussian Blue on the valve face is uniform all around and in center of the valve face 09916 10911 Valve lapper set If the seat width W measured exceeds the sta...

Page 93: ...things that could prevent the valve from sealing INTAKE EXHAUST seat angle 15 45 15 45 seat width 0 9 1 1 mm 0 035 0 043 in 0 9 1 1 mm 0 035 0 043 in valve diameter 30 6 mm 1 20 in 27 mm 1 06 in valve guide I D 5 000 5 012 mm 0 1968 0 1973 in 5 000 5 012 mm 0 1968 0 1973 in The valve seat contact area must be inspected after each cut Do no t us e lapping compound a fter the fin al cut is made The ...

Page 94: ...th Service limit IN EX 38 8 mm 1 52 in 09900 20102 Vernier calipers Valve spring tension Standard IN EX 182 210 N 18 6 21 4 kgf 31 5 mm 41 0 47 2 lbs 1 24 in REASSEMBLY Install the valve spring seat Apply a small quantity of engine oil to the oil seal 1 and press fit it into position Insert the valve with its stem coated with MOLYBDENUM OIL SOLUTION all around and along the full stem length with o...

Page 95: ... manner as described previously 2 Valve spring retainer 3 Valve cotter Install the thermostat thermostat case and engine mounting damper plate 7 14 Install the cam chain tensioner 4 washer 5 and cam chain tensioner bolt 6 Tighten the cam chain tensioner bolt to the specified torque Cam chain tensioner bolt 13 N m 1 3 kgf m 9 5 Ib ft Install the ECT sensor 7 12 Apply SUZUKI SUPER GREASE A to the O ...

Page 96: ...he camshaft assembly CAMSHAFT CAM WEAR Inspect the camshaft for wear or damage Measure the cam height H with a micrometer Cam height H Service Limit IN 33 15 mm 1 3051 in EX 33 17 mm 1 3059 in 09900 20202 Micrometer 25 50 mm CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place Use the plastigauge t...

Page 97: ... the camshaft journal oil clearance measured exceeds the limit measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal Replace the camshaft or the cylinder head depending upon which one exceeds the specification Camshaft journal holder I D Standard 17 512 17 525 mm 0 6894 0 6899 in 22 012 22 025 mm 0 8666 0 8671 in 09900 20602 Dial gauge 1 1000 1 mm ...

Page 98: ...e cam chain tensioner 3 31 Visually inspect the contacting surface of the cam chain ten sioner 1 and cam chain guide 2 If any defects are found replace it with a new one Install the cam chain tensioner 3 39 CYLINDER CYLINDER DISTORTION Inspect the gasket surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places indicated If the larg...

Page 99: ...Using a micrometer measure the piston outside diameter at 15 mm 0 6 in A from the piston skirt end If the measurement is less than the limit replace the piston Piston diameter Service Limit 83 880 mm 3 3023 in at 15 mm 0 6 in from the skirt end 09900 20204 Micrometer 75 100 mm PISTON TO CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter above If the piston to cylinder ...

Page 100: ...pin O D Service Limit 18 980 mm 0 7472 in 09900 20205 Micrometer 0 25 mm PISTON RING TO GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the clearances exceeds the limit replace both the piston and piston rings Piston ring to groove clearance Service Limit 1st 0 180 mm 0 007 in 2nd 0 150 mm 0 006 in Piston ring groove width Standard 1...

Page 101: ...3 Small bore gauge 18 35 mm CONROD DEFLECTION AND BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also be used to check the extent of wear on the parts of the conrod big end Conrod deflection Service Limit 3 0 mm 0 12 in 09900 20701 Magnetic stand 09900 20607 Dial gauge 1 100 mm 09900 21304 V block set 1...

Page 102: ... as shown REASSEMBLY Measure the width between the crankshaft webs a referring to the figure when rebuilding the crankshaft Crank web to web width Standard 70 9 71 1 mm 2 79 2 78 in 1 Crankshaft R 5 Washer 2 Washer 6 Crank pin 3 Conrod 7 Crankshaft L 4 Bearing a ...

Page 103: ...BALANCER DRIVEN GEAR AND DRIVE GEAR INSPECTION Inspect the crank balancer 1 crank balancer drive gear 2 and crank balancer driven gear 3 for wear or damage If any defects are found replace the defective part STARTER CLUTCH INSPECTION Install the starter driven gear 1 onto the starter clutch and turn the starter driven gear by hand to inspect the starter clutch for a smooth movement The gear turns ...

Page 104: ...of THREAD LOCK SUPER 1303 to the starter clutch bolt 99000 32030 THREAD LOCK SUPER 1303 Hold the rotor and tighten the bolts Starter clutch bolt 25 5 N m 2 55 kgf m 18 5 lb ft STARTER DRIVEN GEAR BEARING INSPECTION Inspect the starter driven gear bearing for any damages If any defects are found replace the starter drive gear bearing with a new one STARTER DRIVEN GEAR BEARING REPLACEMENT Remove the...

Page 105: ...earing installer set 37 STARTER IDLE GEAR NO 1 AND NO 2 INSPECTION Inspect the starter idle gear No 1 1 No 2 2 starter idle gear shafts 3 and 4 for wear or damage If any defects are found replace the defective part The rem oved be aring must be replaced w ith a new one ...

Page 106: ...r 4 pcs 4 Roller 8 pcs D O ring 2 pcs 5 Oil seal 2 pcs E Spring seat 6 Movable drive face F Spring 7 Drive belt G Spring plate ITEM N m kgf m lb ft 8 Fixed drive face A Movable drive face bolt A 110 11 0 79 5 9 Fixed driven face B Movable driven face bolt B 110 11 0 79 5 0 Oil seal 2 pcs C Movable driven face ring nut C 110 11 0 79 5 ...

Page 107: ... abnormal conditions the oil seals removal are not necessary ROLLER INSPECTION 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 changed as a set DAMPER INSPECTION Inspect the dampers for wear or damage If any defects are found replace the dampers with new ones ...

Page 108: ...UZUKI SUPER GREASE A to the lip of oil seals and inside grease groove of the movable drive face 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Position the eight rollers 1 on the movable drive face 2 Mount the dampers 3 on the movable drive face plate 4 Position the movable drive face plate on the movable drive face Install the spacer 5 NOTE When inserting the spacer press down the movable...

Page 109: ...turning in the special tool handle NOTE Make sure to insert the spring end A into the slot B of the spe cial tool as shown 09922 31430 Movable driven face spring compressor Remove the movable driven face ring nut 1 Loosen the special tool handle slowly and remove the special tool Remove the spring plate 2 and spring 3 Do not remove the movable driven face ring nut before attaching the clutch sprin...

Page 110: ...m the movable driven face NOTE If there are abnormal conditions the oil seals removal are not necessary MOVABLE DRIVEN FACE SPRING INSPECTION Measure the spring free length with the vernier calipers If the length is shorter than the service limit replace the spring with a new one Movable driven face spring free length Service Limit 204 3 mm 8 04 in ...

Page 111: ...s and movable driven face inside grease groove 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the movable driven face 2 to the fixed driven face 3 Apply SUZUKI SUPER GREASE A to the O rings and pin grooves of the movable driven face 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the rollers 4 and pins 5 The r emoved o il s eals m ust be replaced wit h ne w ones Wipe...

Page 112: ...ial tool 09922 31430 Movable driven face spring compressor Tighten the movable driven face ring nut 9 temporarily Remove the special tool from the movable driven face assem bly Tighten the movable driven face ring nut to the specified torque with the special tool Movable driven face ring nut 110 N m 11 0 kgf m 79 5 lb ft 09917 23711 Ring nut socket wrench 09924 52450 Fixed driven face holder ...

Page 113: ...on Inspect the clutch shoe for damage and fouling with oil on the surface If any defects are is found replace the clutch shoe assembly with a new one Measure the thickness of the clutch shoe at the center position If the thickness is less than the service limit replace the clutch shoe assembly with a new one Clutch shoe thickness Service Limit No groove at any part CLUTCH HOUSING INSPECTION Inspec...

Page 114: ...e resistance is felt to rotation inspect the one way clutch for damage or inspect the one way clutch contacting surface of the clutch shoe for wear or damage If any defects are found replace them with new ones OIL PUMP INSPECTION Rotate the oil pump by hand and inspect that it moves smoothly If it does not move smoothly replace the oil pump assembly Inspect the oil pump driven gear for wear and da...

Page 115: ...ft E Dog Q Counter shaft 4 Spacer F Spacer R Bearing 5 Oil seal G Reverse driven gear S Spacer 6 Spacer H Reverse drive gear bush T Transfer drive gear 7 O ring I Lock washer U Snap ring 8 Bearing J Washer V Bearing 9 Transfer input shaft K Dog W Transfer output drive gear 0 Bearing L Spacer X Spacer A Bearing M High driven gear Y Bearing B Washer N High driven gear bush Z Oil seal ...

Page 116: ...put shaft and posi tion it so it fits into the groove A Fit the lock washer 2 onto the washer 1 Never reuse a snap ring After a snap ring has been removed from a sh aft it should be discarded and a new snap ring must be installed When installing a new snap ring do not expand the end g ap l arger t han r equired t o s lip the sn ap r ing over the shaft After installing a snap ring make sure that it...

Page 117: ...ENGINE 3 61 Install the reverse drive gear bush 3 and low driven gear bush 4 When installing t he bu sh o nto t he t ransfer output shaft align the shaft oil hole B with the bush oil hole C ...

Page 118: ...o groove clearance Standard 0 10 0 30 mm 0 004 0 012 in Service Limit 0 50 mm 0 020 in 09900 20803 Thickness gauge GEARSHIFT FORK GROOVE WIDTH Measure the gearshift fork groove width using the vernier cali pers Shift fork groove width Standard Reverse 5 50 5 60 mm 0 217 0 220 in High 5 50 5 60 mm 0 217 0 220 in 09900 20101 Vernier calipers GEARSHIFT FORK THICKNESS Measure the gearshift fork thickn...

Page 119: ...If any defects are found replace the defective part with a new one 1 Gear position switch 7 Washer C Gearshift fork for Reverse 2 O ring 8 Spring D Gearshift fork for High Low 3 Gearshift shaft 9 Dog for High Low E Gearshift fork shaft 4 Snap ring 0 Snap ring F Gearshift shaft 5 Dog for Reverse A Bearing G Gearshift lever 6 Snap ring B Gearshift cam ...

Page 120: ...3 64 ENGINE REASSEMBLY Install the dogs 1 and 2 as shown NOTE Align the punched marks A of the dog with the punched mark B on the shaft ...

Page 121: ...t for bend or damage Inspect the return spring for damage or fatigue Replace the defective parts with a new one if necessary REASSEMBLY Reassemble the gearshift shaft in the reverse order of disas sembly Pay attention to the following points NOTE When installing the gearshift shaft return spring position the stopper A of the gearshift shaft between the shaft return spring ends B ...

Page 122: ...ONSTRUCTION REMOVAL AND DISASSEMBLY Remove the front output shaft 1 from the right case Remove the C ring 2 and snap ring 3 1 Bearing 4 Shim S 2 Front output shaft 5 Oil seal 3 Front output shaft housing 6 Front drive collar assembly ...

Page 123: ... 7 with special tool 09913 70210 Bearing installer set Remove the O ring 8 Remove the oil seal 9 with the special tool 09913 50121 Oil seal remover Remove the O ring 0 Remove the snap ring A and washer B Remove the bearing with the special tool 09921 20240 Bearing remover set NOTE If there is no abnormal noise the bearing removed is not neces sary ...

Page 124: ...rs as a set BEARING INSPECTION Rotate the inner race by finger to inspect for abnormal play noise and smooth rotation If there is anything unusual replace the bearing with a new one REASSEMBLY AND INSTALLATION Install the bearing to the front output shaft housing with the special tool 09913 70210 Bearing installer set Install the washer 1 and snap ring 2 Install the O ring 3 The removed snap ring ...

Page 125: ...ive collar Apply SUZUKI SUPER GREASE A to the O ring 9900 25010 SUZUKI SUPER GREASE A or equivalent grease Install the output shaft housing 8 and front drive collar assembly 9 to the front output shaft Install the snap ring 0 and C ring A Install the front output shaft to the right case Tighten the front output shaft bolts to the specified torque Front output shaft bolt 10 N m 1 0 kgf m 7 0 lb ft ...

Page 126: ...d shim s 2 1 Rear output shaft drive bevel gear 7 Bearing 2 Shim s 8 Oil seal 3 Rear output shaft driven bevel gear A Drive bevel gear nut ITEM N m kgf m lb ft 4 Front output shaft drive gear B Rear output shaft nut A 100 10 0 72 5 5 Rear output shaft C Output shaft nut B 100 10 0 72 5 6 Shim s C 100 10 0 72 5 ...

Page 127: ...ortion is found replace the rear output shaft with a new one GEAR INSPECTION Inspect the rear output shaft drive bevel gear 2 front output shaft drive gear 3 and rear output shaft driven bevel gear 4 for wear or damage If any defects are found replace the drive and driven bevel gears as a set BEARING INSPECTION Rotate the inner race by finger to inspect for abnormal play noise and smooth rotation ...

Page 128: ... B should be positioned inside Install the universal joint 4 43 With the rear output shaft held immovable with a vise tighten the rear output shaft nut to the specified torque Rear output shaft nut 100 N m 10 0 kgf m 72 5 lb ft Stake the collar of the rear output shaft nut into the notch in the shaft TRANSFER OUTPUT DRIVE DRIVEN GEAR INSPECTION Inspect the transfer output drive 1 driven 2 gear for...

Page 129: ...nstall the rear output shaft drive bevel gear 3 93 Place the rear output shaft on the left crankcase half and hold bearings with the special tool 09921 21910 Bearing holder Set a dial gauge on the rear output shaft drive bevel gear as shown ...

Page 130: ...03G50 075 24945 03G50 078 24945 03G50 080 24945 03G50 083 24945 03G50 085 0 550 mm 0 022 in 0 575 mm 0 023 in 0 600 mm 0 024 in 0 625 mm 0 025 in 0 650 mm 0 026 in 0 675 mm 0 027 in 0 700 mm 0 028 in 0 725 mm 0 029 in 0 750 mm 0 030 in 0 775 mm 0 031 in 0 800 mm 0 031 in 0 825 mm 0 032 in 0 850 mm 0 033 in 24945 03G50 088 0 875 mm 0 034 in 24945 03G50 090 0 900 mm 0 035 in 24945 03G50 093 0 925 mm...

Page 131: ...s found to be incorrect examples 1 and 3 the shim thickness between the rear output shaft drive bevel gear and bearing must be changed and the tooth contact re checked until correct Make sure to check the backlash after the tooth con tact 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 b ...

Page 132: ...G50 060 24935 03G50 058 24935 03G50 055 24935 03G50 083 0 700 mm 0 0276 in 0 725 mm 0 0285 in 0 750 mm 0 0295 in 0 775 mm 0 0305 in 0 800 mm 0 0315 in 0 825 mm 0 0325 in 24935 03G50 080 24935 03G50 078 24935 03G50 075 24935 03G50 073 24935 03G50 070 24935 03G50 098 0 850 mm 0 0335 in 0 875 mm 0 0344 in 0 900 mm 0 0354 in 0 925 mm 0 0364 in 0 950 mm 0 0374 in 0 975 mm 0 0384 in 24935 03G50 095 2493...

Page 133: ... oil seal with the special tool 09913 50121 Oil seal remover Remove the snap ring 1 Remove the oil seals 2 and 3 with the special tool 09913 50121 Oil seal remover OIL SEAL INSTALLATION Install the oil seal 1 with the special tool NOTE The plate side of the oil seal faces to the inside 09913 70210 Bearing installer set 47 The removed oil seal must be replaced with a new one ...

Page 134: ...he snap ring 3 BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase If there is anything unusual replace the bearing with a new one LEFT CRANKCASE BEARING REMOVAL NOTE If there is no abnormal noise the bearing removal is not neces sary Remove the bearing retainers The removed oil seal must be repla...

Page 135: ...nt Bearing 6 68 Attachment LEFT CRANKCASE BEARING INSTALLATION Press the bearings with the special tool 09913 70210 Bearing installer set Bearing 1 52 Attachment Bearing 2 42 Attachment Bearing 3 80 Attachment Bearing 4 40 Attachment Bearing 5 62 Attachment Bearing 6 68 Attachment Apply a small quantity of THREAD LOCK SUPER 1303 to the bearing retainer screws and tighten them securely 09900 32030 ...

Page 136: ...s Remove the bearings with the special tool 09921 20240 Bearing remover set Bearing 1 2 Remover 20 Remove the oil seals 3 77 Remove the bearings with the special tool 09913 70210 Bearing installer set Bearing 3 42 Attachment Bearing 4 55 Attachment Remove the bearing 5 with the special tools 09923 74511 Bearing remover 09930 30104 Sliding shaft ...

Page 137: ... 30 Attachment Bearing 2 42 Attachment Bearing 3 75 Attachment Bearing 4 55 Attachment Bearing 5 35 Attachment Apply a small quantity of THREAD LOCK SUPER 1303 to the bearing retainer screws and tighten them securely 09900 32030 THREAD LOCK SUPER 1303 Install the oil seals 3 77 The re moved bearings m ust be rep laced with n ew ones ...

Page 138: ...ith the special tool 09913 50121 Oil seal remover Remove the generator stator 4 CKP sensor 5 bracket 6 and grommet 7 Remove the snap ring 8 Remove the bearings 9 and 0 with the special tool 09921 20240 Bearing remover set 25 NOTE If there is no abnormal noise the bearing removal is not neces sary ...

Page 139: ...properly Generator starter bolt 11 N m 1 1 kgf m 8 0 lb ft CKP sensor mount bolt 6 N m 0 6 kgf m 4 3 lb ft Bracket bolt 6 N m 0 6 kgf m 4 3 lb ft Install the oil seals 4 and 5 with the special tool 09913 70210 Bearing installer set Oil seal 4 42 Attachment Oil seal 5 20 Attachment Apply SUZUKI SUPER GREASE A to the lip of the oil seals 09900 25010 SUZUKI SUPER GREASE A or equivalent grease The re ...

Page 140: ...torque Speed sensor bolt 10 N m 1 0 kgf m 7 0 lb ft CLUTCH HOUSING CASE DISASSEMBLY Remove the oil seal 1 with the special tool 09913 50121 Oil seal remover Remove the bearing retainers Remove the bearing 2 with the special tool 09921 20240 Bearing remover set 25 NOTE If there is no abnormal noise the bearing removal is not neces sary The removed O ring must be replaced with a new one ...

Page 141: ...ER 1303 to the bearing retainer screws and tighten them securely 09900 32030 THREAD LOCK SUPER 1303 Install the oil seal 2 with the special tool 09913 70210 Bearing installer set 55 Apply SUZUKI SUPER GREASE A to the lip of the oil seal 99000 25010 SUZUKI SUPER GREASE A or equivalent grease MOVABLE DRIVE FACE COVER DISASSEMBLY Remove the oil seal 1 with the special tool 09913 50121 Oil seal remove...

Page 142: ...Press the bearing 1 with the special tool 09913 70210 Bearing installer set 42 Install the snap ring 2 Install the oil seal 3 with the special tool 09913 70210 Bearing installer set 47 Apply SUZUKI SUPER GREASE A to the lip of oil seal 99000 25010 SUZUKI SUPER GREASE A or equivalent grease The r emoved bea ring mu st be r eplaced w ith a new one The removed oil seal must be replaced with a new one...

Page 143: ...RECOIL STARTER DISASSEMBLY Remove the nut 1 and friction plate 2 Remove the ratchet guide 3 ratchet 4 and ratchet pin 5 1 O ring 5 Reel 2 Starter cup 6 Spiral spring 3 Starter cup nut 7 Rope assembly 4 Ratchet set ...

Page 144: ...e knob 0 Untie a knot at the rope Hook the rope to groove A of the reel A Turn the rope on the reel A properly Remove the reel A Remove the spiral spring B RATCHET SET INSPECTION Inspect the ratchet set for wear or damage If any defects are found replace the ratchet set with a new one ...

Page 145: ...of disassem bly Pay attention to the following points When installing the spiral spring hook the spiral spring end 1 with the recoil starter case 2 Apply SUZUKI SUPER GREASE A to the spiral spring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Turn the rope on the reel properly After installing the spiral spring engage the part A of the reel with the spiral spring end 3 Wear hand and eye p...

Page 146: ...wise five or six times with the rope Install the ratchet pin spacer spring cover ratchet and ratchet guide NOTE Apply SUZUKI SUPER GREASE A to the shaft and ratchet guide 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Pull the rope and check that the ratchet is pushed out ...

Page 147: ... its left end into the crankcase with the special tool 09910 32812 Crankshaft installer 09940 52861 Front fork oil seal installer CRANK BALANCER Install the crank balancer shaft 1 REAR OUTPUT SHAFT DRIVE BEVEL GEAR Install the transfer output driven gear 1 with a plastic mallet Always keep the drive belt drive face and driven face away from any greasy matter Never fit the crankshaft into the crank...

Page 148: ...h sleeve hub holder Tighten the rear output shaft drive bevel gear nut to the speci fied torque Drive bevel gear nut 100 N m 10 0 kgf m 72 5 lb ft Stake the collar of the drive bevel gear nut into the notch in the shaft of the transfer output gear TRANSFER Install the transfer input shaft 1 with a plastic mallet The r emoved d rive b evel ge ar nu t mu st be r eplaced with a new one ...

Page 149: ...verse idle gear 3 Install the gearshift forks 4 Install the gearshift cam 5 and gearshift fork shaft 6 REAR OUTPUT SHAFT Install the C ring 1 Install the rear output shaft 2 NOTE Be sure to fit the bearing knock pin A on the bearing into the groove of the crankcase ...

Page 150: ...10 SUZUKI BOND 1215 or equivalent bond NOTE Use of SUZUKI BOND 1215 is as follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and assemble the crankcases within few minutes Take extreme care not to apply any BOND 1215 to the oil hole oil groove and bearing Apply to distorted surfaces as it forms a comparatively thick film Ti...

Page 151: ...r equivalent grease Install the collar 1 CLUTCH SHOE Install the clutch shoe 1 and washer 2 Apply a small quantity of THREAD LOCK SUPER 1303 to the clutch shoe nut 3 99000 32030 THREAD LOCK SUPER 1303 NOTE Install the washer 2 as shown Install the clutch shoe nut 3 The removed O ring must be replaced with a new one to prevent oil leakage Clutch shoe side Clutch shoe nut side ...

Page 152: ... as shown NOTE When installing the one way clutch onto the clutch shoe make sure that the OUTSIDE mark A in the one way clutch faces to the clutch housing Install the clutch housing CLUTCH HOUSING CASE Apply SUZUKI SUPER GREASE A to the O ring Install the oil jet 1 as shown 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the dowel pins 2 and clutch housing case gasket 3 The removed ...

Page 153: ...4 GEAR POSITION SWITCH Install the springs 1 and switch contacts 2 Apply SUZUKI SUPER GREASE A to the O ring 3 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the gear position switch and tighten the gear position switch bolts CLUTCH INNER COVER Install the cushions 1 Removed O ring must be replaced with a new one to prevent oil leakage Removed O ring must be replaced with a new one...

Page 154: ...ce assembly 1 The r emoved cl utch in ner cov er ga sket must b e replaced with a new one Tighten the clutch inner cover bolts A first and then other ones diagonally Degrease th e fi xed d rive f ace Use no nflammable cleaning solvent to wipe off oily or greasy matter and make its surfaces completely dry The drive belt should be installed so that the arrows on the drive belt periphery point in the...

Page 155: ...ction of the collar 4 Tighten the movable drive face bolt to the specified torque with the special tool Movable drive face bolt 110 N m 11 0 kgf m 79 5 lb ft 09930 40113 Rotor holder NOTE Turn the fixed drive face until the belt is seated in and both the drive and driven faces will move together smoothly without slip Install the dowel pins 6 Degrease the movable drive face assembly Use non flammab...

Page 156: ... 8 kgf m 5 7 lb ft OIL PUMP Apply a small quantity of THREAD LOCK SUPER 1303 to the oil pump mounting screws 99000 32030 THREAD LOCK SUPER 1303 Install the oil pump 1 and tighten the oil pump mounting screws Install the washer 2 and pin 3 NOTE Be careful not to drop the washer 2 and pin 3 into the crank case The removed c lutch c over g asket must b e replaced with a new one Tighten the clutch cov...

Page 157: ...ank balancer drive gear 2 and washer 3 Hold the crank balancer drive gear with the special tool 09920 53740 Clutch sleeve hub holder 09924 52460 Socket wrench 52 mm Tighten the crank balancer drive gear nut to the specified torque Crank balancer drive gear nut 150 N m 15 0 kgf m 108 5 lb ft Lock the crank balancer drive gear nut with a center punch The re moved crank ba lancer d rive g ear nu t mu...

Page 158: ...ENGINE Install the key 4 Install the oil pump drive gear 5 NOTE Be careful direction of the oil pump drive gear Install the crank balancer driven gear 6 NOTE Align the matching marks A as shown OUTSIDE INSIDE ...

Page 159: ...e hub holder Crank balancer driven gear bolt 50 N m 5 0 kgf m 36 0 lb ft CAM CHAIN Install the cam chain 1 onto the crankshaft sprocket 2 STARTER CLUTCH AND GENERATOR ROTOR Apply engine oil to the starter driven gear bearing 1 and crankshaft 2 Install the starter driven gear 3 Degrease the tapered portion of the generator rotor assembly and also the crankshaft Use nonflammable cleaning solvent to ...

Page 160: ...sher 2 gearshift cam stopper 3 gearshift cam stopper bolt 4 NOTE Hook the return spring end A to the gearshift cam stopper Tighten the gearshift stopper bolt securely Install the gearshift cam stopper plate 5 NOTE Align the pin groove A of the gearshift cam stopper plate with the pin of the gearshift cam Tighten the gearshift cam stopper bolt securely Make su re t hat t he st arter cl utch o n t h...

Page 161: ...e gearshift cam stopper plate STARTER IDLE GEAR NO 1 AND NO 2 Install the starter idle gear shaft 1 and starter idle gear No 2 2 Install the starter idle gear shaft 3 and starter idle gear No 1 4 GENERATOR COVER Install the dowel pins 1 and generator cover gasket 2 The r emoved ge nerator co ver gasket mu st be replaced with a new one to prevent oil leakage ...

Page 162: ...1 to the specified torque with a suitable bar 2 Starter cup nut 37 5 N m 3 75 kgf m 27 0 lb ft WATER PUMP Install the water pump 7 14 PISTON RING Install the piston rings in the order of oil ring 2nd ring and 1st ring The first member to go into the oil ring groove is a spacer 1 After placing the spacer fit the two side rails 2 NOTE Side designations top and bottom are not applied to the spacer an...

Page 163: ...sition the gaps of the three ring as shown Before inserting each piston into the cylinder check that the gaps are so located A Exhaust side B Intake side 5 2nd ring and lower side rail 6 Upper side rail 7 1st ring and spacer PISTON AND CYLINDER Apply molybdenum oil solution onto the piston pin and small end of the conrod NOTE Install the piston with the punch mark A on the piston head fac ing towa...

Page 164: ...e of the piston and piston rings Install the dowel pins 1 and cylinder gasket 2 onto the crankcase MOLYBDENUM OIL SOLUTION Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder Make sure that the piston rings are caught by the cylinder skirt NOTE When mounting the cylinder after attaching the camshaft drive chain keep the camshaft drive chain taut Th...

Page 165: ...ial 25 N m 2 5 kgf m 18 0 lb ft Final 37 N m 3 7 kgf m 27 0 lb ft NOTE Apply engine oil to the threaded parts of the cylinder head bolts M10 and both sides of the its washers Be sure to install the washer with rounded side facing up After tightening the cylinder head bolts M10 to specification tighten the cylinder head bolts M8 1 and cylinder base nuts 2 to the specified torque Cylinder head bolt ...

Page 166: ...s and cam faces Install the camshaft 2 onto the cylinder head Install the C ring 3 onto the ring groove of the cylinder head Align the engraved lines C on the camshaft is parallel with the mating surface of the cylinder head cover Set the locating pin D of camshaft to the camshaft sprocket NOTE Do not rotate the crankshaft while installing the camshaft or cam chain If th e crankshaft is tu rned wi...

Page 167: ...ise with a screwdriver until the push rod locked Install the gasket 5 and cam chain tension adjuster to the cyl inder Tighten the cam chain tension adjuster mounting bolts to the specified torque Cam chain tension adjuster mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Turn the adjusting screw counterclockwise with a screw driver until the push rod unlocked Install the gasket 6 and cam chain tension adj...

Page 168: ...n installing the cylinder head cover the piston must be at the top dead center on the compression stroke Apply engine oil to both sides of the washer Tighten the cylinder head cover bolts to the specified torque diagonally Cylinder head cover bolt 10 N m 1 0 kgf m 7 0 lb ft Be sure to check the valve clearance 2 6 The r emoved cy linder head cover p lug mu st b e replaced with a new one to prevent...

Page 169: ...uivalent grease Install the spark plug 2 7 VALVE TIMING INSPECTION PLUG Install the valve timing inspection plug 1 and tighten the valve timing inspection plug to the specified torque Valve timing inspection plug 22 5 N m 2 25 kgf m 16 5 lb ft OIL FILTER Install the oil flitter RECOIL STARTER Apply a small quantity of THREAD LOCK SUPER 1303 to the recoil stater bolts Install the recoil starter 1 9...

Page 170: ...UPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the starter motor and tighten the starter motor mounting bolts to the specified torque Starter motor mounting bolt 10 N m 1 0 kgf m 7 0 lb ft The removed O ring must be replaced with a new one ...

Page 171: ...TMENT 4 18 REASSEMBLY INFORMATION 4 21 FRONT PROPELLER SHAFT 4 22 REMOVAL 4 22 INSPECTION 4 22 REASSEMBLY 4 23 REAR DRIVE TRAIN 4 25 CONSTRUCTION 4 25 REMOVAL 4 26 DISASSEMBLY 4 27 INSPECTION 4 31 REASSEMBLY 4 32 REMOUNTING 4 35 SHIM ADJUSTMENT 4 36 REASSEMBLY INFORMATION 4 39 REAR PROPELLER SHAFT 4 40 REMOVAL AND DISASSEMBLY 4 40 INSPECTION 4 42 REASSEMBLY AND INSTALLATION 4 43 ...

Page 172: ...seal 7 Shim left side M Boot 8 2WD 4WD shifting cam N Front propeller shaft spring 9 2WD 4WD shifting fork O Front propeller shaft 0 2WD 4WD shifting fork shaft P Circlip A Oil seal Q Universal joint B O ring R Boot C 4WD diff lock actuator S Breather rubber case D Bearing A Front drive train differential gear case mounting nut ITEM N m kgf m lb ft E Drive bevel gear B Front drive train differenti...

Page 173: ...nboard joint 1 of the front drive shaft and tug the drive shaft horizontally NOTE If it is difficult to remove the front drive shaft from the front differ ential gear case using the suitable tool Remove the foot brake switch lead wire clamp Remove the 4WD diff lock actuator lead wire and foot brake switch lead wire band Disconnect the 4WD diff lock actuator lead wire coupler ...

Page 174: ...frame DISASSEMBLY 4WD DIFF LOCK ACTUATOR Remove the 4WD diff lock actuator assembly BREATHER CASE Remove the breather case FRONT DRIVE TRAIN DIFFERENTIAL GEAR Remove the front drive train differential gear case bolts diag onally and evenly Remove the front drive train differential gear case cover 1 with the special tool 09912 34510 Cylinder disassembling tool ...

Page 175: ...fting cam 4 Remove the front drive train differential gear assembly 5 diff lock shifting fork 6 and shifting fork shaft 7 Remove the right side shim 8 and left side shim 9 Remove the oil seals 0 and A 09913 50121 Oil seal remover 2WD 4WD SHIFTING CAM Remove the snap ring 1 ...

Page 176: ...4WD shifting cam bearing with the special tool 09921 20240 Bearing remover set 17 NOTE If there is no abnormal noise the bearing removal is not neces sary 2WD 4WD SHIFTING DEVICE Remove 2WD 4WD gear shifting fork shaft 1 and 2WD 4WD shifting fork 2 Remove the oil seal cap 3 and oil seal 4 ...

Page 177: ...ove the input shaft 6 Remove the 2WD 4WD shifting sleeve 7 Remove the snap ring 8 Remove the input shaft bearing with the special tool 09913 60910 Bearing and gear puller NOTE If there is no abnormal noise the bearing removal is not neces sary ...

Page 178: ...emove the drive bevel gear pilot bearing with the special tools 09921 20240 Bearing remover set 15 09917 50410 Bearing remover 09924 84521 Bearing installer set NOTE If there is no abnormal noise the bearing removal is not neces sary FRONT DRIVE TRAIN DIFFERENTIAL GEAR Remove the front drive train differential gear bearing with the special tool 09913 60910 Bearing and gear puller NOTE If there is ...

Page 179: ...ff lock shifting fork 1 and 2WD 4WD shifting fork 2 for wear or damage If any defects are found replace the shifting forks with new ones 2WD 4WD SHIFTING CAM Inspect the 2WD 4WD shifting cam for wear or damage If any defects are found replace the 2WD 4WD shifting cam with a new one 2WD 4WD SHIFTING SLEEVE Inspect the 2WD 4WD shifting sleeve for wear or damage If any defects are found replace the 2...

Page 180: ...place the drive bevel gear with a new one INPUT SHAFT Inspect the input shaft for wear or damage If any defects are found replace the input shaft with a new one FRONT DRIVE TRAIN DIFFERENTIAL GEAR Inspect the front drive train differential gear for stick or dam age If any defects are found replace the front drive train differential gear with a new one BREATHER CASE Inspect the breather case for we...

Page 181: ... gear assembly with the special tool 09913 70210 Bearing installer set 35 FRONT DRIVE TRAIN DIFFERENTIAL GEAR CASE COVER Install the oil seal into the front drive train differential gear case with the special tool 09913 70210 Bearing installer set 47 NOTE Insert the oil seal until the specified value as shown Apply SUZUKI SUPER GREASE A to the lip of oil seal 99000 25010 SUZUKI SUPER GREASE A or e...

Page 182: ...VEL GEAR Install the bearing onto the drive bevel gear shaft with the special tool 09913 70210 Bearing installer set 25 Install the bearing into the front drive train differential gear case with the special tool 09913 70210 Bearing installer set 25 Install the drive bevel gear into the front drive train differen tial gear case and fix the snap ring 1 The removed oil seal must be replaced with a ne...

Page 183: ...l 09913 70210 Bearing installer set 40 Install the snap ring 1 Install the snap ring 2 to the input shaft 3 Install the 2WD 4WD shifting sleeve 4 to the input shaft 3 Install the input shaft into the front drive train differential gear case The remove bearing must be replaced with a new one ...

Page 184: ... seal cap 6 with the special tool 09924 52460 Long socket 52 mm 2WD 4WD SHIFTING DEVICE Install the 2WD 4WD shifting fork 7 onto the groove of the 2WD 4WD shifting sleeve 8 Apply front differential gear oil to the 2WD 4WD sifting fork shaft 9 Install the 2WD 4WD sifting fork shaft 9 Install the shim s to the case and cover The removed oil seal must be replaced with a new one ...

Page 185: ... shaft Align the shifting fork pin A with the groove of the shifting cam B After the backlash and tooth contact have been checked or adjusted apply SUZUKI BOND 1215 to the mating surface of the case 99000 31110 SUZUKI BOND 1215 or equivalent bond Turn the shifting cam C clockwise and install the 2WD 4WD shifting fork pin to the bottom Align the 2WD 4WD shifting fork pin D with the groove of the 2W...

Page 186: ... the case cover bolts 4WD DIFF LOCK ACTUATOR Apply SUZUKI SUPER GREASE A to the O rings 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply a small quantity of THREAD LOCK SUPER 1303 to the 4WD diff lock actuator mounting bolts 99000 32030 THREAD LOCK SUPER 1303 Install the 4WD diff lock actuator assembly and tighten its mounting bolts to the specified torque 4WD diff lock actuator mounti...

Page 187: ... to the specified torque Front drive train diffrential gear case mounting bolt nut 50 N m 5 0 kgf m 36 0 lb ft Install the stopper ring 3 into the groove of front drive shaft spline Apply SUZUKI SUPER GREASE A to the spline 99000 25010 SUZUKI SUPER GREASE A or equivalent grease NOTE After installing both drive shafts make sure the stopper rings are seated properly by pulling both inboard joints li...

Page 188: ...nd the backlash should be re checked until the back lash is within specification Refer to the chart at the right for the appropriate shim thickness Backlash Standard 0 05 0 10 mm 0 0020 0 0040 in NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the removed shims as a guide If the backlash is too small replace the right side shim s with a thicker one If the...

Page 189: ... bolts Front drive train diffrential gear case bolt 22 N m 2 2 kgf m 16 0 lb ft Remove the gear case cover 4 4 Measure the thickness of compressed solders 1 with the micrometer 09900 20205 Micrometer Select the proper size of shim s from the right chart accord ing as the compressed solder thickness After selecting the proper size of shim s check or adjust the backlash and tooth contact Part No Shi...

Page 190: ...otate the front drive train differential gear several turns in each direction This will provide a contact pattern on the coated teeth of ring gear Remove the front drive train differential gear and compare the coated teeth to the examples shown in 1 2 and 3 If tooth contact is found to be correct example 2 go to page 4 12 to complete installation If tooth contact is found to be incorrect example 1...

Page 191: ...DRIVE TRAIN 4 21 REASSEMBLY INFORMATION 3 5 gram shim shim Mating surfaces 3 5 gram 22 N m 2 2 kgf m 16 0 lb ft 1 3 N m 0 13 kgf m 0 94 lb ft 3 5 gram ...

Page 192: ...he removing direction of the universal joint boot before removing Using a screwdriver or the like into a notch of the universal joint and remove the front propeller shaft Remove the universal joint from the joint portion at the engine side with special tools 09923 74511 Bearing remover 20 38 09930 30104 Sliding shaft INSPECTION FRONT PROPELLER SHAFT Inspect the front propeller shaft for wear or da...

Page 193: ...ll the front proper shaft boot 1 and universal joint boot 2 to the front propeller shaft Apply WATER RESISTANCE GREASE to the hole inside of the boots 1 99000 25160 WATER RESISTANCE GREASE Apply a small quantity of WATER RESISTANCE GREASE to the spline of universal joint 1 99000 25160 WATER RESISTANCE GREASE Connect the propeller shaft to the universal joint Apply a small quantity of WATER RESISTA...

Page 194: ...n the boot clamp screw Install the front propeller shaft spring Apply small quantity of WATER RESISTANCE GREASE to the spline of the front propeller shaft and front propeller shaft spring 1 99000 25160 WATER RESISTANCE GREASE Install the front drive train differential gear case assembly 4 17 ...

Page 195: ...int 6 Bearing J Spring plate 7 Oil seal K Rear propeller shaft joint boot 8 Oil seal L Spring 9 Washer M Rear propeller shaft ITEM N m kgf m lb ft 0 Bearing A Rear pinion gear lock nut A 100 10 0 72 5 A Shim B Rear drive bearing lock nut B 100 10 0 72 5 B Rear pinion gear C Final gear case bolt M8 C 26 2 6 19 0 C Bearing D Final gear case bolt M10 D 55 5 5 40 0 D Input shaft E Final gear case moun...

Page 196: ...emove the rear suspension 8 84 Hold the inboard joint 1 of the rear drive shaft and tug the rear drive shaft horizontally NOTE If it is difficult to remove the rear drive shaft from the rear differ ential gear case using the suitable tool Remove the outlet pipe 2 Remove the breather hose 3 Remove the trailer towing 4 ...

Page 197: ...ASSEMBLY FINAL GEAR AND FINAL GEAR CASE Remove the rear brake 8 73 Remove the final gear case bolts diagonally and evenly Pry the final gear case cover 1 with 5 mm screw as shown Remove the final gear case cover 1 Remove the ring gear 2 and O ring 3 from the final gear case cover 4 Remove the shim s 5 from the ring gear ...

Page 198: ...70210 Bearing installer set 09944 66010 Bearing installer NOTE If there is no abnormal condition the bearing removal is not nec essary Remove the shim s 7 Remove the oil seal 8 with the special tool 09913 50121 Oil seal remover Remove the gear final case bearing with a suitable tool NOTE If there is no abnormal condition the bearing removal is not nec essary ...

Page 199: ...k the rear drive bearing lock nut 1 with a chisel Remove the rear drive bearing lock nut with the special tool 09924 41830 Bearing lock nut wrench Remove the rear pinion gear 2 and shim 3 Unlock the rear pinion gear lock nut 4 with a chisel ...

Page 200: ... and suitable tool A 09917 50410 Bearing remover NOTE If there is no abnormal condition the bearing removal is not nec essary Remove the rear pinion gear bearing inner race 7 with the special tool and suitable tool A 09913 60910 Bearing and gear puller puller Remove the rear pinion gear pilot bearing 8 with the special tool 09921 20240 Bearing remover set 20 NOTE If there is no abnormal condition ...

Page 201: ...h a new one REAR PINION GEAR Inspect the rear pinion gear for wear or damage If any defects are found replace the pinion gear with a new one BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation If there is anything unusual replace the bearing with a new one Play Play ...

Page 202: ... oil seal to the final gear case with the special tool 09951 15810 Bearing installer Apply SUZUKI SUPER GREASE A to the lip of the oil seal 99000 25010 SUZUKI SUPER GREASE A or equivalent grease REAR PINION GEAR Install the pinion bearing to the rear pinion gear with the spe cial tool 09913 70210 Bearing installer set 47 Install the washer 1 and rear pinion gear lock nut 2 to the rear pinion gear ...

Page 203: ... shim s 3 and rear pinion gear 4 to the final gear case Tighten the bearing lock nut with the special tool to the speci fied torque 09924 41830 Bearing lock nut wrench Rear drive bearing lock nut 100 N m 10 0 kgf m 72 5 lb ft NOTE After the backlash and tooth contact have been checked or adjusted stake the collar of the bearing lock nut into the notch in the shaft The rem oved rea r pin ion ge ar ...

Page 204: ...FINAL GEAR CASE Install the ring gear 1 and shim s 2 into the final gear case 3 Install the O ring 4 to the final gear case cover 5 Apply SUZUKI SUPER GREASE A to the O ring 4 99000 25010 SUZUKI SUPER GREASE A or equivalent grease NOTE After the backlash and tooth contact have been checked or adjusted install the O ring 4 and apply grease Install the shim s 6 and final gear case cover 5 The remove...

Page 205: ...olt M8 26 N m 2 6 kgf m 19 0 lb ft Final gear case bolt M10 55 N m 5 5 kgf m 40 0 lb ft NOTE After the backlash and tooth contact have been checked or adjusted apply THREAD LOCK SUPER 1303 to the case cover bolts Install the rear brake 8 81 REMOUNTING Remount the final gear case assembly in the reverse order of removal Pay attention to the following points Install the final gear case assembly 8 81...

Page 206: ... be re checked until the back lash is within specification Refer to the chart for the appropriate shim thickness Backlash Standard 0 02 0 06 mm 0 0008 0 0024 in Without gear case cover specification 0 08 0 15 mm 0 0031 0 0059 in Gear case cover assembled specification NOTE Adjust the backlash by referring to the chart at the right and using the thickness of the removed shims as a guide Backlash Sh...

Page 207: ...b ft Final gear case bolt M10 55 N m 5 5 kgf m 40 0 lb ft Remove the final gear case cover 4 27 Measure the thickness of compressed solder with the micrometer 09900 20205 Micrometer 0 25 mm Decide the proper shim thickness by the following formula D 0 10 mm Shim thickness 0 10 mm Proper clearance D Compressed solder thickness B Proper shim thickness Select the proper size of shim s from the right ...

Page 208: ...n 1 2 and 3 If tooth contact is found to be correct example 2 go to page 4 30 to complete installation If tooth contact is found to be incorrect examples 1 and 3 the shim between the pinion gear bearing and final gear case must be changed and the tooth contact should be re checked until the tooth contact is found to be correct example 2 Tooth contact Shim adjustment Contact at tooth top 1 Decrease...

Page 209: ...N 26 N m 2 6 kgf m 19 0 lb ft shim left side shim right side Pinion gear shim S 100 N m 10 kgf m 72 5 lb ft 100 N m 10 kgf m 22 5 lb ft 100 N m 10 kgf m 22 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft 2 0 N m 0 2 kgf m 1 5 lb ft 3 5 gram 3 5 gram ...

Page 210: ...VAL AND DISASSEMBLY Remove the rear final gear case assembly 4 26 Remove the rear propeller shaft joint 1 Remove the O ring 2 Remove the rear propeller shaft spring 3 Loosen the boot clamp screw Draw out the rear propeller shaft 4 horizontally ...

Page 211: ... shaft joint boot 5 and universal joint boot 6 Remove the O ring 7 Remove the circlips from the universal joint Remove the bearings 8 by tapping with the special tool 09913 70210 Bearing installer set 20 Remove the universal joint 9 and yoke 0 ...

Page 212: ...oint 1 and outer surface of the bearing 2 for scuffing wear and damage If any defects are found replace the bearings and universal joint as a set Insert the universal joint to the bearing and check the play by turning the universal joint as shown If excessive play is found replace the bearings and universal joint as a set SHAFT BOOT Inspect the rear propeller shaft joint boot 1 and universal joint...

Page 213: ...00 N m 10 0 kgf m 72 5 lb ft Stake the collar of the rear output shaft nut into the notch in the shaft Install the universal joint 3 and yoke 4 Install the bearing 5 by tapping with the special tool 09913 70210 Bearing installer set 20 Install the circlips to the universal joint Install the O ring to the rear propeller shaft The removed rear output shaft nut must be replaced with a new one The rem...

Page 214: ... 8 and tighten the boot clamp screw Install the rear propeller shaft spring 9 Apply WATER RESISTANCE GREASE to the rear propeller shaft spring 1 99000 25160 WATER RESISTANCE GREASE Install the O ring 0 to the rear propeller shaft joint Apply WATER RESISTANCE GREASE to the spline of rear propeller shaft joint 1 99000 25160 WATER REISISTANCE GREASE Install the rear propeller shaft joint A Install th...

Page 215: ......

Page 216: ...5 19 VISUAL INSPECTION 5 20 SELF DIAGNOSTIC PROCEDURES 5 21 SELF DIAGNOSIS RESET PROCEDURE 5 21 USE OF SDS DIAGNOSTIC PROCEDURES 5 22 USE OF SDS DIAGNOSIS RESET PROCEDURE 5 23 SHOW DATA WHEN TROUBLE DISPLAYING DATA AT THE TIME OF DTC 5 24 MALFUNCTION CODE AND DEFECTIVE CONDITION 5 25 C12 P0335 CKP SENSOR CIRCUIT MALFUNCTION 5 27 C13 P0105 H L IAP SENSOR CIRCUIT MALFUNCTION 5 30 C14 P0120 H L TP SE...

Page 217: ...N 5 59 CKP SENSOR REMOVAL AND INSTALLATION 5 59 IAP SENSOR INSPECTION 5 59 TP SENSOR INSPECTION 5 59 IAT SENSOR INSPECTION 5 59 ECT SENSOR INSPECTION 5 59 ECT SENSOR REMOVAL AND INSTALLATION 5 59 TO SENSOR INSPECTION 5 60 TO SENSOR REMOVAL AND INSTALLATION 5 60 ...

Page 218: ...e coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnormal...

Page 219: ...connector for excessive opening Also check the coupler for locking loose ness corrosion dust etc 1 Coupler 2 Probe 3 Where male terminal fits FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse ECM VARIOUS SENSORS Since each component is a high precision part great...

Page 220: ...uch removal is made damaging counter elec tromotive force will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check with a low voltage battery will lead to erroneous diagno sis Never connect any tester voltmeter ohmmeter or whatever to the ECM when its coupler is disconnec...

Page 221: ...so check for condition of the coupler lock if equipped 1 Sensor 2 ECM 1 Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is fully inserted in the coupl...

Page 222: ... circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals A and B Voltage Between C and body ground App...

Page 223: ...ose parts Otherwise diagnosis will be misled 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 1 Other parts 1 To other parts Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal A and body ground If continuity is ind...

Page 224: ...hen measuring the resistance with the multi circuit tester 1 will be shown as 10 00 MΩ and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After using the tester turn the power off 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side o...

Page 225: ...and various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air pressure signal Engine speed signal Throttle opening signal Crankshaft Position Sensor CKP Sensor Throttle Position Sensor TP Sensor Various Sensors Various signals Injection signal Injector ECM Bas...

Page 226: ...ime volume A longer injection time is needed to adjust injection volume in the case of low voltage ENGINE RPM SIGNAL At high speed the injection time volume is increased STARTING SIGNAL When starting engine additional fuel is injected during cranking engine ACCELERATION SIGNAL DECELERATION SIGNAL During acceleration the fuel injection time volume is increased in accordance with the throttle openin...

Page 227: ...r E Crankshaft position sensor CKPS B Throttle position sensor TPS F Combination meter C Intake air pressure sensor IAPS G Diff lock relay D Intake air temperature sensor IATS H Engine coolant temperature sensor ECTS NOTE B C and D devices are combined into one ECM ...

Page 228: ...5 12 FI SYSTEM DIAGNOSIS I Tip over sensor TOS L Fuel pump relay FP RELAY J Fuel injector M Fuel pump FP K Ignition coil ECM ...

Page 229: ... pump Engine stop switch START button Starter motor Parking brake relay Gear position switch N L H 30 A 15 A 10 A Combination meter Override switch 4WD diff lock relay 4WD diff lock switch Diff lock relay LOCK 4WD 2WD 4WD diff lock actuator Diff lock position switch Intake air pressure sensor IAP sensor Throttle position sensor TP sensor Intake air temperature sensor IAT sensor Bl G R B Gr W Y R Y...

Page 230: ...Relay 5 Brake switch BRK H Serial data for self diagnosis SDL 6 Power source for sensors VCC I Serial data for combination meter TECH 7 ECM ground E1 J Sensor ground E2 8 Forward sensor signal FOW K Override switch OVR 9 CKP sensor signal CKP L Neutral switch NT 0 TO sensor signal TO M Test switch TS A ECT sensor signal ECT N IAT sensor signal IAT B IAP sensor signal IAP O Diff lock switch DL C TP...

Page 231: ...ch signal is not sent to ECM In this case FI is indicated in the LCD panel Vehicle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 3 seconds For Example The ignition switch is turned ON and the engine stop switch is turned OFF In this case the com bination meter does not receive any signal from ECM and the panel indicates CHEC If CHEC is ind...

Page 232: ...devices These affected devices are indicated in the code form 09930 82720 Mode select switch Before checking the malfunction code do not disconnect the ECM lead wire couplers If the couplers from the ECM are disconnected the malfunction code memory is erased and the malfunction code can not be checked MALFUNCTION LCD DISPLAY INDICATION FI LIGHT INDICATION INDICATION MODE NO C00 YES C code is indic...

Page 233: ...r CKPS Intake air pressure sensor IAPS Throttle position sensor TPS Engine coolant temperature sensor ECTS Diff lock relay Intake air temperature sensor IATS Tip over sensor TOS Ignition signal IG coil Fuel injector signal FI Fuel pump control system FP control system No defective part Pick up coil signal signal generator Fuel pump Fuel pump relay The TP sensor is preset at the factory therefore n...

Page 234: ...nly emergency help by fail safe circuit In this case it is nec essary to bring the vehicle to the workshop for complete repair ITEM FAIL SAFE MODE STARTING ABILITY RUNNING ABILITY IAP sensor Intake air pressure is fixed to 760 mmHg YES YES TP sensor The throttle opening is fixed to full open position Ignition timing is also fixed YES YES ECT sensor Engine coolant temperature value is fixed to 80 C...

Page 235: ...ondition LED Always ON Sometimes ON Always OFF Good condition Malfunction display code LCD User mode No display Malfunction display Dealer mode No code Malfunction code PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at cold warm always Surging Abnormal knocking Other E...

Page 236: ...ay 2 13 Burnt LCD FI panel and LED FI light operation 5 15 and 9 30 Each warning light operation 9 30 Exhaust gas leakage and noise 2 5 Each coupler disconnection Clogged radiator core 7 5 VEHICLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Temperature Frequency Fair Cloudy Rain Snow Always Other Hot Warm Cool Cold F C Always Always Sometimes times day month Only on...

Page 237: ...al tool to the dealer mode coupler at the wir ing harness and start the engine or crank the engine for more than 4 seconds Turn the special tool s switch to ON and check the malfunc tion code to determine the malfunction part 09930 82720 Mode select switch SELF DIAGNOSIS RESET PROCEDURE After repairing the trouble turn the ignition switch to OFF and turn to ON again If the malfunction code indicat...

Page 238: ...CAUTIONS IN SERVICING 5 2 before inspection and observe what is written there Remove the seat 8 6 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code and Show data when trouble displayed data at the time of DTC according to instructions displayed on SDS Not only is SDS used for detecting Diagnostic Trouble Codes but also for reproducing an...

Page 239: ...ed in the ECM Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS Click Clear 2 to delete history code Past DTC Follow the displayed instructions C...

Page 240: ... or stopped when a malfunction was detected by checking the Show data when trouble This Show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a function to store each Show data when trouble for two different malfunctions in the order as the malfunction is detected Utilizing this function it is possible to know the order of malfunctions that ...

Page 241: ... V sensor voltage 4 8 V In other than the above value C14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value TP sensor circuit open or shorted to ground or VCC circuit open C15 ECT sensor The sensor voltage should be the fol lowing 0 15...

Page 242: ...nition sig nal CKP sensor signal is produced but signal from ignition coil is interrupted 8 times or more continuously In this case the code C24 P0351 is indi cated Ignition coil lead wire coupler connection power supply from the battery P0351 C32 Fuel injector CKP sensor signal is produced but fuel injector signal is interrupted 4 times or more continuously In this case the code C32 P0201 is indi...

Page 243: ...ce 3 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 200 250 Ω Blue White DETECTED CONDITION POSSIBLE CAUSE The signal does not reach ECM for 3 sec or more after receiving the starter signal Metal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction ECM CKP sensor CKP CK...

Page 244: ...CKP sensor continuity Ω Infinity Blue Ground White Ground 09900 25008 Multi circuit tester set 2 Tester knob indication Resistance Ω Are the resistance and continuity OK 5 After repairing the trouble clear the DTC using SDS tool 5 23 YES Go to step 2 NO Replace the CKP sensor with a new one 1 ...

Page 245: ...to ground Loose or poor contacts on the CKP sensor cou pler or ECM coupler terminal 9 or D If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Inspect that metal particles or foreign material stuck on the CKP sensor and rotor tip If there are no me...

Page 246: ...or voltage 4 85 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECM malfunction P0105 H Sensor vo...

Page 247: ...tage 4 Is the voltage OK Step 1 When indicating P0105 H 1 Remove the left side cover 8 9 2 Turn the ignition switch to OFF 3 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between Red wire A and G B wire B If the sound is not heard from the tester the circuit condition is OK YES...

Page 248: ...ft side cover 8 9 2 Turn the ignition switch to OFF 3 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between G B wire B and ground 6 Also check the continuity between G B wire B and B O wire C If the sound is not heard from the tester the circuit condi tion is OK When us ing the...

Page 249: ...set 6 Tester knob indication Continuity test 5 Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool 5 23 When us ing the m ulti circuit te ster do no t s trongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 1 4 31 and go to Step 2 NO Red wire open or G B wire shorted to ground 1 EC...

Page 250: ...set 3 Tester knob indication Voltage 4 Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool 5 23 YES R G B or B O wire open or shorted to ground or poor 6 B or J connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again Re...

Page 251: ...TECTED CONDITION POSSIBLE CAUSE C14 Output voltage is not within the following value Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 2 V Sensor voltage 4 8 V TP sensor circuit open or short TP sensor malfunction ECM malfunction P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open TP ...

Page 252: ...ltage 4 Is the voltage OK Step 1 When indicating P0120 H 1 Remove the left side cover 8 9 2 Turn the ignition switch to OFF 3 Check the TP sensor coupler for loose or poor contacts If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between Red wire A and Yellow wire B If sound is not heard from the tester the circuit condition is OK YES Go...

Page 253: ...ted probe set 6 Tester knob indication Continuity test 5 Is the continuity OK 8 After repairing the trouble clear the DTC using SDS tool 5 23 When us ing the m ulti circuit te ster do no t s trongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 2 NO Yellow wire shorted to VCC or B O wire open 1 ECM coupler Ha...

Page 254: ...ECM coupler 8 Check the continuity between Red wire A and terminal 6 9 Also check the continuity between Yellow wire B and termi nal C TPS lead wire continuity Continuity 5 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 6 Tester knob indication Continuity test 5 Is the continuity OK T 10 After repairing the trouble clear the DTC using SDS tool 5 23 1 1 When us ing the mu...

Page 255: ...indication Voltage 4 Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 5 23 When us ing the m ulti circuit te ster do no t s trongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Red Yellow or B O wire open or shorted to ground or poor 6 C or J connection If wire and connection are OK intermit...

Page 256: ... wire terminal B ECT sensor voltage 4 5 5 5 V B Bl Ground B Bl B O 09900 25008 Multi circuit tester set 3 Tester knob indication Voltage 4 Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C15 Output voltage is not within the following value 0 15 Sensor voltage 4 85 V ECT sensor circuit open or short ECT sensor malfunction ECM malfunction P0115 H Sensor voltage is higher than specified value ECT...

Page 257: ...o then check the continuity between B O wire B and ter minal J ECTS lead wire continuity Continuity 5 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 6 Tester knob indication Continuity test 5 Is the continuity OK 7 After repairing the trouble clear the DTC using SDS tool 5 23 1 When us ing the m ulti circuit te ster do no t s trongly touch the terminal of the ECM coupler...

Page 258: ...r the circuit condition is OK 6 Tester knob indication Continuity test 5 6 Connect the ECT sensor coupler 7 Insert the needle pointed probes to the lead wire coupler 8 Turn the ignition switch to ON 9 Measure the voltage between B Bl wire A and ground ECT sensor output voltage 0 1 4 6 V B Bl Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 3 Tester knob indication V...

Page 259: ...ire open or shorted to ground or poor A or J connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Replace the ECT sensor with a new one When us ing the m ulti circuit te ster do no t s trongly touch the terminal of the ECM coupler with a ...

Page 260: ...ff lock relay circuit open or short Diff lock relay malfunction ECM malfunction YES Inspect the 4WD diff lock switch 9 37 Y B wire open or shorted to ground or poor G connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Replace the diff l...

Page 261: ...he 4WD diff lock switch 4WD switch 1 and diff lock switch 2 is turned OFF 2 Set up the SDS tool Refer to the SDS operation manual for further details 3 Open the Data monitor 4 Check that both Differential lock position switch signal 3 and Differential lock switch signal 4 are Open ...

Page 262: ... 4WD switch and diff lock switch to ON position 6 Check that both Differential lock position switch signal 5 and Differential lock switch signal 6 are GND If the 4WD diff lock switch dose not function properly inspect the 4WD diff lock switch for details 9 37 ...

Page 263: ...en wire terminal A and B O wire terminal B IAT sensor voltage 4 5 5 5 V Green Ground Green B O 09900 25008 Multi circuit tester set 3 Tester knob indication Voltage 4 Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE C21 Output voltage is not within the following value 0 15 Sensor voltage 4 85 V IAT sensor circuit open or short IAT sensor malfunction ECM malfunction P0110 H Sensor voltage is hig...

Page 264: ... check the continuity between B O wire B and terminal J IATS lead wire continuity Continuity 5 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 6 Tester knob indication Continuity test 5 Is the continuity OK 7 After repairing the trouble clear the DTC using SDS tool 5 23 1 When us ing the multi circuit te ster do no t strongly touch the terminal of the ECM coupler with a n...

Page 265: ...e circuit condition is OK 6 Tester knob indication Continuity test 5 6 Connect the IAT sensor coupler 7 Insert the needle pointed probes to the lead wire coupler 8 Turn the ignition switch to ON 9 Measure the voltage between Green wire A and ground Output voltage 1 88 3 06 V at 20 C 68 F Green Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 3 Tester knob indication...

Page 266: ...trouble clear the DTC using SDS tool 5 23 2 YES Green or B O wire open or shorted to ground or poor J or N connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Replace the IAT sensor throttle body assembly with a new one When us ing the m...

Page 267: ...l B 09900 25008 Multi circuit tester set 2 Tester knob indication Resistance Ω Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE C23 The sensor voltage should be the fol lowing for 2 sec and more after ignition switch is turned ON 0 2 Sensor voltage 4 8 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor circu...

Page 268: ...isconnect the ECM coupler 7 Check the continuity between B O wire C and terminal J TOS lead wire continuity Coninuty 5 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 6 Tester knob indication Continuity test 5 Is the continuity OK 8 After repairing the trouble clear the DTC using SDS tool 5 23 1 1 When us ing the multi circuit te ster do no t strongly touch the terminal o...

Page 269: ...onnect the ECM coupler 8 Check the continuity between Red wire A and terminal 6 9 Also check the continuity between Br W wire B and terminal 0 TOS lead wire continuity Coninuity 5 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 6 Tester knob indication Continuity test 5 Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool 5 23 1 1 V When us ing...

Page 270: ...ter knob indication Voltage 4 Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 5 23 C24 P0351 IGNITION COIL CIRCUIT MALFUNCTION Refer to the IGNITION SYSTEM for details 8 18 YES Red B Br or B O wire open or shorted to ground or poor 6 0 or J connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circu...

Page 271: ...uity between each terminal and ground Injector continuity Ω Infinity Terminal Ground 09900 25008 Multi circuit tester set 2 Tester knob indication Resistance Ω Are the resistance and continuity OK 6 After repairing the trouble clear the DTC using SDS tool 5 23 DETECTED CONDITION POSSIBLE CAUSE CKP signal is produced but fuel injector signal is interrupted 4 times or more continuously Injector circ...

Page 272: ...iring the trouble clear the DTC using SDS tool 5 23 When us ing the multi circuit te ster do no t strongly touch the terminal of the ECM coupler with a ne edle pointed te ster p robe t o pre vent th e te rminal da mage or terminal bend YES Gr W wire open or shorted to ground or poor 2 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harnes...

Page 273: ...uel pump although fuel pump relay is turned OFF Fuel pump relay switch circuit shorted to power source Faulty fuel pump relay switch side Fuel pump relay coil circuit open or short Faulty fuel pump relay coil side L Less than 0 3V is applied to fuel pump although fuel pump relay is turned ON YES Y Bl or O W wire open or shorted to ground or poor E connection Y R or R B wire open or shorted to grou...

Page 274: ...YES Y R wire shorted to power source Y Bl wire shorted to ground If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Replace the FP relay with a new one ECM coupler wiring harness side 1 YES Y Bl wire open or poor E connection O W wire open or shor...

Page 275: ...throttle body 6 11 TP SENSOR INSPECTION The throttle position sensor is installed at the left side of the throttle body 6 11 IAT SENSOR INSPECTION The intake air temperature sensor is installed at the left side of the throttle body 6 11 ECT SENSOR INSPECTION The engine coolant temperature sensor is installed on the cylin der head 7 11 ECT SENSOR REMOVAL AND INSTALLATION Remove the right side cover...

Page 276: ...ed in front of the throttle body 5 51 TO SENSOR REMOVAL AND INSTALLATION Remove the air cleaner box 6 10 Remove the TO sensor from its bracket 5 51 Install the TO sensor in the reverse order of removal NOTE When installing the TO sensor the arrow mark A must be pointed upward ...

Page 277: ...L MESH FILTER 6 7 FUEL TANK PRESSURE CONTROL FTPC VALVE INSPECTION 6 8 THROTTLE BODY 6 9 CONSTRUCTION 6 9 AIR CLEANER BOX REMOVAL 6 10 AIR CLEANER BOX INSTALLATION 6 10 THROTTLE BODY REMOVAL 6 11 THROTTLE BODY DISASSEMBLY 6 12 THROTTLE BODY INSPECTION 6 14 THROTTLE BODY REASSEMBLY 6 14 THROTTLE BODY INSTALLATION 6 14 FUEL INJECTOR REMOVAL 6 15 FUEL INJECTOR INSPECTION 6 15 FUEL INJECTOR INSTALLATI...

Page 278: ...gulated by the fuel pressure regulator As the fuel pressure applied to the fuel injector the fuel pressure in the fuel delivery pipe is always kept at absolute fuel pressure of 2 94 kgf cm 294 kPa 41 81 psi the fuel is injected into the throttle body in conic dispersion when the injector opens according to the injection signal from the ECM The fuel relieved by the fuel pressure regulator flows bac...

Page 279: ...eed hose 1 from the fuel pump 2 Disconnect the fuel pump coupler 3 from the fuel pump Disconnect the fuel tank breather hose 4 from the fuel tank Remove the fuel tank mounting bolts Remove the fuel tank 5 Remove the fuel tank lower cover 6 FUEL TANK INSTALLATION Install the fuel tank in the reverse order of removal Gasoline is highly flammable and explosive Keep heat spark and flame away ...

Page 280: ...gauge hose Turn the ignition switch ON and check the fuel pressure Fuel pressure Approx 294 kPa 2 94 kgf cm 41 81 psi If the fuel pressure is lower than the specification inspect the following items Fuel feed hose leakage Clogged fuel filter Pressure regulator Fuel pump If the fuel pressure is higher than the specification inspect the following items Fuel pump Pressure regulator A To fuel pump B T...

Page 281: ...ver sensor and fuel pump circuit con nections are OK the fuel pump may be faulty replace the fuel pump with a new one FUEL DISCHARGE AMOUNT INSPECTION Remove the rear fender 8 15 Place a rag under the fuel feed hose 1 and disconnect the fuel feed hose 1 from the fuel pump Connect a proper fuel hose 2 to the fuel pump Place the measuring cylinder and insert the fuel hose end into the measuring cyli...

Page 282: ...specified it means that the fuel pump is defective or that the fuel filter is clogged Fuel discharge amount Approx 55 5 ml 1 8 1 9 US Imp oz and more 10 sec NOTE The battery must be in fully charged condition FUEL PUMP RELAY INSPECTION Fuel pump relay is located in light side of the ECM Remove the seat 8 6 Remove the fuel pump relay 1 First check the insulation between A and B terminals with pocke...

Page 283: ...sket 3 Remove the fuel cup holder 4 with a screwdriver 5 FUEL MESH FILTER INSPECTION AND CLEANING If the fuel mesh filter 1 is clogged with sediment or rust fuel will not flow smoothly and loss in engine power may result Blow the fuel mesh filter with compressed air NOTE If the fuel mesh filter is clogged with many sediment or rust replace the fuel mesh pump assembly with a new one Gasoline is hig...

Page 284: ...ghten the fuel pump retainer 3 to the specified torque with the special tool 09941 51012 Riug lock nut wreuch Fuel pump retainer 35 N m 3 5 kgf m 25 5 lb ft FUEL TANK PRESSURE CONTROL FTPC VALVE INSPECTION Remove the FTPC valve Check the FTPC valve if air can pass through smoothly when blown from the orange color side and not from the other side If abnormal condition is found replace the FTPC valv...

Page 285: ...E BODY 6 9 THROTTLE BODY CONSTRUCTION 1 Throttle body 5 Injector seal 2 Fuel delivery pipe 6 Starter valve 3 O ring 7 Throttle cable cover ITEM N m kgf m lb ft 4 Fuel injector A Fuel delivery pipe mounting screw A 5 0 0 5 3 7 ...

Page 286: ...the air cleaner box AIR CLEANER BOX INSTALLATION Install the air cleaner box in the reverse order of removal Pay attention to the following points Install the air cleaner box and tighten the throttle body clamp screw as shown in the illustration Tighten the air cleaner box mounting bolts to the specified torque Air cleaner box mounting bolt 4 5 N m 0 45 kgf m 3 3 lb ft 1 10 10 VIEW OF TOP LEFT SID...

Page 287: ... Remove the throttle cable cover 4 Disconnect the throttle cable from drum Disconnect the starter cable 5 from the throttle body assem bly Gasoline is highly flammable and explosive Keep heat spark and flame away Be careful n ot t o t ouch th e electrical t erminal o f th e TP IAP IAT sensor After di sconnecting the th rottle ca bles do not sn ap the thro ttle v alve fro m full op en to f ull cl o...

Page 288: ...ing 8 from the starter cable Loosen the throttle body clamp screw and remove the throttle body assembly THROTTLE BODY DISASSEMBLY Remove the fuel delivery pipe 1 Remove the fuel injector 2 from the fuel delivery pipe Remove the O ring 3 and injector seal 4 from the fuel injec tor ...

Page 289: ...e idle air screw 5 Never remove the TP IAP IAT sensor 6 Never remove the throttle valve 7 Never us e car buretor cl eaning chemicals t o t he throttle body assembly Never use compressed air to passageways Avoid removing the throttle lever stopper screw 8 ...

Page 290: ...pipe 4 to the injector Tighten the fuel delivery pipe mounting screws to the speci fied torque Fuel delivery pipe mounting screw 5 0 N m 0 5 kgf m 3 7 lb ft THROTTLE BODY INSTALLATION Install the throttle body assembly in the reverse order of removal Pay attention to the following points Align the groove of starter valve with the starter cable end Apply thin coat of the engine oil to the O ring Th...

Page 291: ...dence of dirt and contamination If present clean and check for presence of dirt in the fuel lines and fuel tank The fuel injector can be checked without removing it from the throttle body Refer to page 5 55 for details FUEL INJECTOR INSTALLATION Apply thin coat of the engine oil to injector seal and O ring Install the injector by pushing it straight to the throttle body Never turn the injector whi...

Page 292: ...IR TANK 7 7 COOLING FAN 7 8 REMOVAL 7 8 INSTALLATION 7 9 INSPECTION 7 9 COOLING FAN THERMO SWITCH 7 10 REMOVAL 7 10 INSPECTION 7 10 INSTALLATION 7 10 ECT SENSOR 7 11 REMOVAL 7 11 INSPECTION 7 11 INSTALLATION 7 12 THERMOSTAT 7 12 REMOVAL 7 12 INSPECTION 7 13 INSTALLATION 7 14 WATER PUMP 7 15 REMOVAL AND DISASSEMBLY 7 15 INSPECTION 7 17 REASSEMBLY AND INSTALLATION 7 18 LUBRICATION SYSTEM 7 22 OIL FI...

Page 293: ... more anti freeze or 50 and less Refer to below figure Do not use a radiator anti leak additive Anti freeze 1 225 ml 1 3 1 1 US lim pt Water 1 225 ml 1 3 1 1 US lim pt 20 40 60 80 100 Density 0 10 20 30 40 50 60 70 32 14 4 22 40 58 76 94 Freezing point Fig 1 C F 0 10 20 30 40 50 60 Density 150 140 130 120 110 100 Boiling point C F 302 284 266 248 230 212 Engine coolant density boiling point curve ...

Page 294: ... the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the leaking com ponent or part Do n ot r emove t he r adiator ca p when t he e ngine is hot WATER PUMP RADIATOR COOLING FAN THERMO SWITCH ENGINE COOLANT TEMPERATURE SENSOR THERMOSTAT CYLINDER HEAD CYLINDER RESERVOIR TANK BYPASS When remo...

Page 295: ... front fender 8 15 Drain engine coolant 2 14 Disconnect the cooling fan thermo switch coupler 1 and cool ing fan motor lead wire coupler 2 Disconnect the inlet hose 3 Disconnect the outlet hose 4 Remove the radiator mounting bolts Remove the radiator Be careful not bent the radiator fin ...

Page 296: ...Fit the cap 1 to the radiator cap tester 2 Build up pressure slowly by operating the tester Make sure that the pressure build up stops at 108 137 kPa 1 08 1 37 kgf cm 15 4 19 5 psi and that with the tester held stand still the cap is capable of holding that pressure for at least 10 seconds Replace the cap if it is found not to satisfy either of these two requirements Radiator cap valve opening pre...

Page 297: ...own or dented can be repaired by straightening them with the blade of a small screwdriver RADIATOR INSTALLATION Install the radiator in the revers order of removal Pay attention to the following points Install the cooling fan thermo switch 7 10 Align the grooves on the radiator covers with the boss on the radiator Install the siphon hose and radiator hoses 10 22 Pour engine coolant 2 14 ...

Page 298: ... leakage from the connecting section should be corrected by proper tightening RADIATOR RESERVOIR TANK REMOVAL AND REMOUNTING Remove the right inner fender 8 10 Remove the reservoir tank mounting bolts and disconnect the siphon hose from the reservoir tank and drain engine coolant Install the reservoir tank in the reverse order of removal Pour engine coolant 2 14 ...

Page 299: ...OOLING AND LUBRICATION SYSTEM COOLING FAN REMOVAL Remove the front fender 8 15 Disconnect the cooling fan motor lead wire coupler 1 Remove the cooling fan unit 2 Remove the cushion 3 Remove the cooling fan 4 ...

Page 300: ...the front fender 8 15 Disconnect the cooling fan lead wire coupler 1 Test the cooling fan motor for load current with an ammeter connected as shown in the illustration The voltmeter is for making sure that the battery 2 applies 12 volts to the cooling fan motor 3 With the cooling fan motor with electric motor fan running at full speed the ammeter 4 should be indicating not 5 amperes and more If th...

Page 301: ...it tester set 6 Tester knob indication Continuity test 5 Cooling fan thermo switch operating temperature Standard OFF ON Approx 93 C 199 F ON OFF Approx 87 C 189 F INSTALLATION Install the cooling fan thermo switch in the reverse order of removal Pay attention to the following points Apply engine coolant to the O ring 1 Tighten the cooling fan thermo switch to the specified torque Cooling fan ther...

Page 302: ...owly and read the col umn thermometer 3 and the ohmmeter If the ECT sensor ohmic value does not change in the propor tion indicated replace the ECT sensor with a new one Temperature sensor specification If the resistance is noted to show infinity or too much different resistance value replace the ECT sensor with a new one Temperature Standard resistance 20 C 68 F Approx 2 45 kΩ 40 C 104 F Approx 1...

Page 303: ...upler Check the engine coolant level 2 14 THERMOSTAT REMOVAL Remove the left side cover 8 9 Remove the gear shift arm 8 97 Drain the engine coolant 2 14 Place a rag under the thermostat case Disconnect the inlet hose 1 Remove the engine mounting damper plate 2 and thermostat case 3 Remove the thermostat 4 The removed gasket must be replaced with a new one to prevent engine coolant leakage Take sp ...

Page 304: ...perature on a thermome ter 5 Read the thermometer just when opening the thermostat This reading which is the temperature level at which the thermo stat valve begins to open should satisfy the standard value Thermostat valve opening temperature Standard 80 5 83 5 C 177 182 F Keep on heating the water to raise its temperature Just when the water temperature reaches specified value the thermostat val...

Page 305: ...he lug on the thermostat A with the groove on the cylin der head B NOTE The jiggle valve C of the thermostat faces upside Install the thermostat case 1 and engine mounting damper plate 2 Tighten the thermostat case bolts to the specified torque Thermostat case bolt 23 N m 2 3 kgf m 16 5 lb ft After installing the thermostat thermostat case and engine mounting damper plate be sure to add engine coo...

Page 306: ...p and crankcase If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the mechanical seal and seal ring 7 17 Remove the left upper mad guard 8 9 Remove the left mad guard 8 9 Drain engine coolant 2 14 Drain engine oil 2 9 Disconnect the outlet hose 1 and water bypass hose 2 Remove the water pump 3 Remove the O rings 4 and 5 ...

Page 307: ...ring 7 Remove the E ring 8 pin holder 9 pin 0 and washer A Remove the impeller B from the water pump body C Remove the mechanical seal D with the special tool 09921 20240 Bearing remover set 12 mm NOTE If there is no abnormal condition the mechanical seal removal is not necessary ...

Page 308: ...ller INSPECTION MECHANICAL SEAL Visually inspect the mechanical seal for damage with particu lar attention given to the sealing face Replace the mechanical seal that shows indications of leak age OIL SEAL Visually inspect the oil seal for damage with particular atten tion given to the lip Replace the oil seal that shows indications of leakage IMPELLER SHAFT JOURNAL Visually inspect the journal for...

Page 309: ...E The stamped mark on the oil seal faces outside Apply a small quantity of the SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the mechanical seal with a suitable size socket wrench NOTE On the mechanical seal the sealer A has been applied The removed oil seal must be replaced with a new one The removed mechanical seal must be replaced with ...

Page 310: ...he paint marked side B of the mechanical seal ring faces the impeller Apply SUZUKI SUPER GREASE A to the impeller shaft 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the impeller shaft 3 to the water pump body Apply SUZUKI SUPER GREASE A to the washer and pin holder 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the washer 4 pin 5 pin holder 6 and E ring 7 ...

Page 311: ...to the O ring 0 Install the O ring 0 to the water pump cover A Install the water pump cover to the water pump body B Tighten the water pump cover screws to the specified torque Water pump cover screw 5 5 N m 0 55 kgf m 4 0 lb ft Install the water pump to the generator cover NOTE Set the water pump shaft end C to the oil pump shaft D as shown The removed O rings must be replaced with new ones The r...

Page 312: ...ION SYSTEM 7 21 Tighten the water pump mounting bolts to the specified torque Water pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Connect the outlet hose and water bypass hose Pour engine coolant 2 14 Pour engine oil 2 10 ...

Page 313: ...7 22 COOLING AND LUBRICATION SYSTEM LUBRICATION SYSTEM OIL FILTER 2 10 OIL PRESSURE 2 33 OIL PUMP 3 58 OIL SUMP FILTER 3 58 ...

Page 314: ...IEF VALVE OIL FILTER CRANK MAIN GALLERY CASE R CYLINDER CYLINDER HEAD CRANKSHAFT BEARING R CRANKSHAFT R CAMSHAFT JOURNAL CAMSHAFT ONE WAY CLUCH CONROD BIG END BEARING CYLINDER WALL PISTON CLUCH SHOE CRANK CASE L CYLINDER HEAD COVER ROCKER ARM CAM CHAIN CAM FACE OIL PAN OIL JET COUNTER SHAFT GEARS ...

Page 315: ...7 24 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM To cylinder head OIL PUMP ...

Page 316: ...COOLING AND LUBRICATION SYSTEM 7 25 EXHAUST SIDE INTAKE SIDE ...

Page 317: ......

Page 318: ...RAKE FLUID REPLACEMENT 8 29 BRAKE CALIPER REMOVAL AND DISASSEMBLY 8 29 BRAKE CALIPER INSPECTION 8 31 BRAKE CALIPER REASSEMBLY AND INSTALLATION 8 32 BRAKE DISC REMOVAL AND DISASSEMBLY 8 34 BRAKE DISC INSPECTION 8 35 BRAKE DISC REASSEMBLY AND INSTALLATION 8 35 MASTER CYLINDER REMOVAL AND DISASSEMBLY 8 36 BRAKE MASTER CYLINDER INSPECTION 8 38 BRAKE MASTER CYLINDER REASSEMBLY AND INSTALLATION 8 38 FRO...

Page 319: ...EMOVAL 8 67 INSPECTION AND REASSEMBLY 8 69 INSTALLATION 8 71 REAR BRAKE 8 72 CONSTRUCTION 8 72 REMOVAL AND DISASSEMBLY 8 73 INSPECTION 8 77 REASSEMBLY 8 79 REMOUNTING 8 81 REAR SUSPENSION 8 83 CONSTRUCTION 8 83 REMOVAL 8 84 INSPECTION AND DISASSEMBLY 8 86 REASSEMBLY AND INSTALLATION 8 90 REAR WHEEL REAR SUSPENSION AND REAR DRIVE SHAFT REASSEMBLING INFORMATION 8 95 TRANSFER GEAR SHIFT LEVER 8 96 CO...

Page 320: ...8 2 CHASSIS EXTERIOR PARTS CONSTRUCTION 1 Front fender 5 Right inner fender 2 Radiator cap lid 6 Left inner fender 3 Right side cover 7 Front box 4 Left side cover 8 Front grill upper cover ...

Page 321: ...CHASSIS 8 3 1 Rear fender 4 Left upper mud guard 2 Right mud guard 5 Rear box 3 Left lower mud guard ...

Page 322: ...fastener a Installation Let the center piece stick out toward the head so that the pawls 2 close Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face ...

Page 323: ...astener center piece 1 with a screw driver Pull out the fastener a Installation Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece ...

Page 324: ...NT CARRIER Remove the front grill lower cover 1 by removing the right and left clips 2 and bolts 3 Remove the front grill upper cover clips 4 left and right Remove the front grill upper cover 5 Disconnect the horn coupler 6 Remove the left front carrier mounting bolt with horn 7 for E 17 E 24 ...

Page 325: ...ove the right front carrier mounting bolt Remove the front carrier mounting bolts left and right Remove the front carrier B FRONT FENDER MUD GUARD For E 17 E 24 Remove the front fender mud guard clips 1 left and right ...

Page 326: ...and right HEADLIGHT Remove the front grill 8 6 Remove the headlight housing screws left and right Disconnect the headlight couplers left and right Remove the headlight 1 left and right FRONT GRIP BAR Remove the front carrier 8 6 Remove the headlight above ...

Page 327: ...front grip bar 1 FRONT FENDER Remove the seat 8 6 Remove the front carrier 8 6 Remove the air cleaner box cover 1 Remove the left upper mud guard Remove the left side cover Remove the left mud guard clip 2 screws 3 and bolt 4 ...

Page 328: ...10 CHASSIS Remove the left inner fender 5 Remove the right side cover 6 Remove the right mud guard clips 7 screws 8 and bolt 9 Remove the right inner fender 0 Disconnect the power source socket coupler A ...

Page 329: ...the front box cap wire Remove the front box mounting screw Turn the front box counterclockwise and remove it Remove the cushion 2 from the front box as shown in the illustration NOTE Installing the cushion to the front box align the cutout 3 SIDE COVER Remove the left upper mud guard 1 ...

Page 330: ...8 12 CHASSIS Remove the left side cover 2 Remove the right side cover 3 MUD GUARD Remove the left side cover above Remove the left mud guard 1 ...

Page 331: ... 12 Remove the right mud guard 2 FOOTREST Remove the side cover 8 12 Remove the mud guard above Remove the rear brake cable clamp 1 Remove the right footrest 2 REAR FENDER MUD GUARD For E 17 E 24 Remove the rear fender mud guard left and right ...

Page 332: ...8 14 CHASSIS REAR CARRIER Remove the rear carrier REAR BOX Remove the rear box 1 ...

Page 333: ...e mud guard left and right Remove the side cover left and right Disconnect the battery cable first and then battery cable Remove the battery stay 1 and the battery Remove the fuse box 2 Disconnect the couplers Remove the fuel tank cap 3 Remove the rear fender 4 FUEL TANK COVER Remove the fuel tank cover ...

Page 334: ...mounting bolts 99000 32050 THREAD LOCK 1342 Apply a small quantity of THREAD LOCK 1342 to the front carrier mounting bolts 99000 32050 THREAD LOCK 1342 Apply a small quantity THREAD LOCK SUPER 1303 to the footrest mounting bolts and tighten them to the specified torque 99000 32030 THREAD LOCK SUPER 1303 Footrest mounting bolt M8 26 N m 2 6 kgf m 19 0 lb ft M10 55 N m 5 0 kgf m 40 0 lb ft ...

Page 335: ...CHASSIS 8 17 Apply a small quantity of THREAD LOCK 1342 to the rear carrier mounting bolts 99000 32050 THREAD LOCK 1342 ...

Page 336: ... reverse order of removal Pay atten tion to the following points Installing each wheel make sure the arrow A on the tire points in the direction of rotation Tighten the wheel set nuts to the specified torque Front and rear wheel set nut 60 N m 6 0 kgf m 43 5 lb ft 1 Front tire 5 Rear wheel 2 Front wheel 6 Rear wheel air valve ITEM N m kgf m lb ft 3 Front wheel air valve A Front wheel set nut A 60 ...

Page 337: ...rim with a new one Clear up the sealing portion of the rim Apply tire lubricant to the tire bead and the flange of the rim Mount the tire on the rim by hand as shown When using the tire levers do not scratch or hit the sealing portion hump of the wheel or it may cause air leakage Never ap ply gr ease oi l or ga soline to the ti re be ad because they will deteriorate the tire The standard ti re f i...

Page 338: ...y and unseat the tire bead on both sides Then coat the bead with clean water and re seat the tire Adjust the tire pressure to the specified pressure Cold inflation tire pressure Front 35 kPa 0 35 kgf cm2 5 1 psi Rear 30 kPa 0 30 kgf cm2 4 4 psi Vehicle load capacity 172 kg 380 lbs 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 Place t...

Page 339: ...e shaft horizontally NOTE If it is difficult to remove the front drive shaft from the front differ ential gear case using the suitable tool 09924 21940 Wheel hub remover 09924 21920 Drive shaft remover 09930 30104 Sliding hammer 09924 21950 Front drive shaft remover 1 Circlip 6 Inner boot band small 2 Snap ring 7 Drive shaft 3 Stopper ring 8 Outer boot band small 4 Inner boot band large 9 Outer bo...

Page 340: ... front drive shaft and remove the stopper ring from the outer race Separate the outer race from the front drive shaft Wipe off any grease and remove the snap ring Remove the cage and boot from the front drive shaft Do not disassemble the wheel side joint If any dam ages are found replace it with a new one ...

Page 341: ...n the drive shaft end fitting the small diameter side of the boot to the shaft groove fix its end with the boot band Install the cage 1 on the shaft A Large diameter B Small diameter Clean al l p arts be fore i nstallation cl ean th e ins ide 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 cause...

Page 342: ...ase is included in the wheel side boot set or differential side joint set of spare parts Insert the cage into the outer race and install the new stopper ring to the groove of the outer race Position Grease Wheel side Differential side Quantity 40 g 70 g Locate the opening of the stopper ring 1 so that the opening is not lined up with a ball ...

Page 343: ...ints Install the stopper ring 3 into the groove of front drive shaft spline Apply SUZUKI SUPER GREASE A to the spline 99000 25010 SUZUKI SUPER GREASE A or equivalent grease NOTE After installing both drive shafts make sure the stopper rings are seated properly by pulling both inboard joints lightly Pour the specified hypoid gear oil SAE 90 through the filler hole 2 11 Gear oil capacity 500 ml 16 9...

Page 344: ... Brake master cylinder clamp bolt A 11 1 1 8 0 7 Spring B Front brake hose union bolt B 25 2 5 18 0 8 Brake master cylinder C Brake pipe nut C 16 1 6 11 5 9 Front brake hose No 1 D Front brake air bleeder valve D 6 0 0 6 4 3 0 Front brake hose No 2 E Front brake caliper mounting bolt E 26 2 6 19 0 A Front brake pipe F Front brake pad mounting pin F 17 1 7 12 5 B Piston G Caliper holder pin G 17 1 ...

Page 345: ... periods 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 the brake disc with high quality brake cleaner...

Page 346: ...ting bolts 1 99000 32130 THREAD LOCK SUPER 1360 Tighten the front brake caliper mounting bolts 1 to the speci fied torque Front brake caliper mounting bolt 26 N m 2 6 kgf m 19 0 lb ft Apply THREAD LOCK 1342 to the brake pad mounting pins 2 99000 32050 THREAD LOCK 1342 Tighten the front brake pad mounting pins 2 to the specified torque Front brake pad mounting pin 17 N m 1 7 kgf m 12 5 lb ft NOTE A...

Page 347: ...he reservoir with new brake fluid to the upper end of the inspection window Front brake air bleeder valve 6 0 N m 0 6 kgf m 4 3 lb ft BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the front wheel 8 18 Disconnect the brake hose from the front brake caliper by removing the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle Remove the brake caliper by removing the br...

Page 348: ...the brake caliper piston to prevent it from popping out and then force out the piston using compressed air Remove the dust seal 3 and piston seal 4 Do not use high pressure air to prevent brake caliper piston damage Do not reuse the dust seal and piston seal to prevent fluid leakage ...

Page 349: ... with a new one BRAKE CALIPER PISTON Inspect the brake caliper piston for any scratches or damage If any defects are found replace the piston with a new one RUBBER PARTS Replace the removed rubber parts with new ones CALIPER HOLDER Inspect the caliper holder 1 and caliper holder pin 2 and cali per holder slide pin 3 for damage If any defects are found replace them with new ones ...

Page 350: ... Install the piston seal as shown 1 Dust seal 2 Piston seal 3 Caliper body BRAKE CALIPER PISTON Install the brake caliper piston Clean the brake caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to clean them Do no t wip e t he bra ke fl uid off a fter c leaning the components When cleaning the co mponents us e th e sp ecified brake fl uid Never use...

Page 351: ...NE GREASE Install the brake caliper holder 3 to the brake caliper 4 Install the brake pad spring 5 Install the brake pads to the brake caliper 4 Apply a small quantity of THREAD LOCK SUPER 1360 to the front brake caliper mounting bolts 6 99000 32130 THREAD LOCK SUPER 1360 Apply a small quantity of THREAD LOCK SUPER 1303 to the brake pad mounting pins 7 99000 32050 THREAD LOCK 1342 Tighten the brak...

Page 352: ...ront brake hose union bolt 25 N m 2 5 kgf m 18 0 lb ft BRAKE DISC REMOVAL AND DISASSEMBLY Remove the front wheel 8 18 Remove the front wheel hub 8 41 Remove the brake disc 1 The r emoved f ront br ake ho se w ashers mu st b e replaced with new ones to prevent brake fluid leak age Bleed air f rom t he s ystem af ter reassembling t he front brake caliper 2 24 ...

Page 353: ... 3 mm 0 012 in If either measurement exceeds the service limit replace the brake disc with a new one Install the brake caliper 8 33 Install the front wheel 8 18 BRAKE DISC REASSEMBLY AND INSTALLATION Reassemble and install the brake disc in the reverse order of removal and disassembly Pay attention to the following points Install the brake disc to the wheel hub with the punching letter showed Appl...

Page 354: ...disconnect the front brake hose Disconnect the front brake switch coupler 1 Remove the brake master cylinder assembly 2 Remove the front brake lever 3 and front brake switch 4 Remove the reservoir cap 5 and diaphragm 6 Immediately and completely wipe off any brake fluid contacting any p art o f the veh icle T he brake fluid reacts chemically with paint plastics rubber materi als etc and will damag...

Page 355: ...CHASSIS 8 37 Remove the dust boot 7 and circlip 8 Remove the piston secondary cup primary cup and spring 9 Secondary cup 0 Piston A Primary cup B Spring ...

Page 356: ...BLY AND INSTALLATION Reassemble and install the brake master cylinder in the reverse order of removal and disassembly Pay attention to the following points Specification and classification DOT 4 Clean t he br ake ma ster cy linder c omponents wit h fresh brake fluid before reassembly Do no t wip e t he bra ke fl uid off a fter c leaning the components When cleaning the co mponents us e th e sp eci...

Page 357: ... Handlebars Install the front brake hose union bolt 1 with the front brake hose washers 2 Tighten the front brake hose union bolt to the specified torque Front brake hose union bolt 25 N m 2 5 kgf m 18 0 lb ft NOTE After contacting the front brake hose union to the stopper tighten the union bolt The r emoved f ront brake ho se w asher mu st be replaced with new ones in order to prevent leakage of ...

Page 358: ...uckle B Front shock absorber mounting lower nut ITEM N m kgf m lb ft 5 Tie rod C Front wishbone arm pivot nut upper A 55 5 5 40 0 6 Tie rod end D Front wishbone arm pivot nut lower B 60 6 0 43 5 7 Front hub bearing E Steering knuckle end nut upper and lower C 60 6 0 43 5 D 65 6 5 47 0 8 Front knuckle end F Tie rod end nut E 29 2 9 21 0 9 Dust seal G Tie rod lock nut F 29 2 9 21 0 0 Bush G 45 4 5 3...

Page 359: ...8 Remove the cotter pin Loosen the hub nut 1 Remove the front brake caliper 8 29 Remove the front hub nut 1 Remove the front wheel hub 2 Remove the front brake hose clamp 3 Remove the front drive shaft cover 4 Remove the front brake disc cover 5 Remove the cotter pin and tie rod end nut ...

Page 360: ...ar ing joint remover 7 Remove the cotter pins and steering knuckle end nuts Remove the steering knuckle 8 with a commercially available bearing joint remover 9 Remove the front shock absorber 0 Remove the front upper wishbone arms A Remove the front lower wishbone arms B ...

Page 361: ...ONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or damage If any defects are found replace the shock absorber with a new one FRONT UPPER WISHBONE ARM Inspect the front upper wishbone arm for wear or damage If any defects are found replace the front upper wishbone arm with a new one FRONT UPPER WISHBONE ARM BUSH Remove the front upper wishbone arm bush with the special tools 09923 732...

Page 362: ...shbone arm dust seal with a new one SPACER Inspect the spacer for wear or damage If any defects are found replace the spacer with a new one FRONT UPPER WISHBONE ARM KNUCKLE END Inspect the front upper wishbone arm knuckle end for wear or damage If any defects are found replace the front upper wish bone arm knuckle end with a new one Inspect the front upper wishbone arm knuckle end for smooth movem...

Page 363: ...one FRONT LOWER WISHBONE ARM BUSH Inspect the front lower wishbone arm bush wear or damage If any defects are found replace the front lower wishbone arm bush with new ones STEERING KNUCKLE Inspect the front lower knuckle end for wear or damage If any defects are found replace the front lower knuckle end with a new one Inspect front lower knuckle end for smooth movement If there are any abnormaliti...

Page 364: ... SEAL Remove the steering knuckle dust seals with the special tool 09913 50121 Oil seal remover FRONT HUB BEARING Inspect the inner race play of the front hub bearing 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 Remove the snap ring 1 ...

Page 365: ...al and disassembly Pay attention to the following points STEERING KNUCKLE Install the front hub bearing 1 with the special tool 09913 70210 Bearing installer set 47 Install the snap ring 2 Install the steering knuckle dust seal 3 with the special tool 09913 70210 Bearing installer set The rem oved be aring must be replaced w ith a new one The removed dust seal must be replaced with a ne w one ...

Page 366: ...eals 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the steering knuckle end 5 with the special tool 09913 70210 Bearing installer set 35 Install the snap ring 6 FRONT UPPER WISHBONE ARM Install the front upper wishbone arm knuckle end with the spe cial tool 09913 70210 Bearing installer set 35 The removed dust seal must be replaced with a n ew one ...

Page 367: ...R 1303 to the front lower wish bone arm pivot nuts Tighten the front wishbone arm pivot nuts upper and lower to the specified torque 99000 32030 THREAD LOCK SUPER 1303 Front wishbone arm pivot nut upper 60 N m 6 0 kgf m 43 5 lb ft Front wishbone arm pivot nut lower 65 N m 6 5 kgf m 47 0 lb ft Tighten the front shock absorber mounting upper bolt to the specified torque Front shock absorber mounting...

Page 368: ...ghten them securely 9 99000 32130 THREAD LOCK SUPER 1360 Front brake disk cover mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Apply SUZUKI SUPER GREASE A to the wheel hub spline 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the wheel hub 1 washer 2 and front hub nut 3 Tighten the front hub nut to the specified torque Front hub nut 110 N m 11 0 kgf m 79 5 lb ft The removed cotter pins m...

Page 369: ...ut 60 N m 6 0 kgf m 43 5 lb ft SPRING PRE LOAD ADJUSTMENT After installing the front shock absorbers adjust the spring pre load Position 1 provides the minimum spring pre load Position 5 provides the maximum spring pre load STD POSITION 2 5 POSITION 1 POSITION 5 Front wheel side Front wheel hub side Be su re t o ad just t he s pring p re load o n t he b oth shock absorbers equally ...

Page 370: ... shaft A Handlebar upper clamp bolt 4 Throttle cable B Rear brake lever holder clamp bolt ITEM N m kgf m lb ft 5 Rear brake cable C Throttle lever case bolt A 26 2 6 19 0 6 Starter cable D Handleber holder nut B 10 1 0 7 5 7 Throttle lever a Apply handle grip bond C 5 0 5 3 5 8 Front brake lever D 60 6 0 43 5 ...

Page 371: ... master cylinder 3 from the handlebars 8 36 Disconnect the brake hose clamp Remove the left grip 4 Remove the left handlebar switch box 5 Remove the rear brake lever assembly 6 Disconnect the brake lever switch coupler 7 Remove the handle cover and combination meter 9 28 Remove the cover brace 8 ...

Page 372: ... adhesive agent to the handlebar right and left end and right and left grip inner wall HANDLE GRIP BOND commercial available Align the punched mark A on the handlebars with the mating surface B of handlebar holder First tighten the handlebar upper clamp bolts 1 to the speci fied torque and then tighten the handlebar upper clamp bolts 2 to the specified torque Handlebar upper clamp bolt 26 N m 2 6 ...

Page 373: ...he punch mark D on the handlebars with the mating surface E of rear brake lever assembly Tighten the rear brake lever holder clamp bolts to the speci fied torque Rear brake lever holder clamp bolt 10 N m 1 0 kgf m 7 5 lb ft Apply the grease to the end of starter cable 99000 25010 SUZUKI SUPER GREASE A or equivalent grease When installing the left handle switch engage the stopper F with the handleb...

Page 374: ...crew Install the brake master cylinder 8 38 Align the punch mark H on the handlebars with the mating surface I of throttle lever case Tighten the throttle lever case bolts to the specified torque Throttle lever case bolt 5 N m 0 5 kgf m 3 5 lb ft ...

Page 375: ...ft 3 Steering shaft A Handleber upper clamp bolt A 26 2 6 19 0 4 Steering shaft holder B Handleber holder nut B 60 6 0 43 5 5 Dust seal C Steering shaft holder bolt C 23 2 3 16 5 6 Bush D Steering shaft lower nut D 170 17 0 123 0 7 Dust seal E Tie rod lock nut E 45 4 5 32 5 8 O ring F Tie rod end nut F 29 2 9 21 0 ...

Page 376: ...e handlebar holder nuts washers and handlebar holder 1 Remove the cotter pins tie rod end nuts and spring washers Remove the tie rod end 2 with a commercially available ball bearing joint remover 3 Remove the cotter pin and steering shaft lower nut 4 washer 5 steering arm plate 6 Remove the dust seal 7 and O ring 8 ...

Page 377: ...plate 6 with a commercially avail able ball bearing joint remover 3 Disconnect the brake hose clamp Remove the cable clamp Remove the steering shaft plate 9 Remove the steering shaft holder 0 and collars A Remove the steering shaft holder bush B from the steering shaft Remove the steering shaft C ...

Page 378: ... a new one 1 Tie rod end 2 Lock nut 3 Lock nut 4 Tie rod TIE ROD END Inspect the tie rod ends for smooth movement If there are any abnormalities replace the tie rod ends with new ones Inspect the tie rod end boots for wear or damage If any defects are found replace the tie rod ends with new ones STEERING SHAFT Inspect the steering shaft for distortion or bend If any defects are found replace the s...

Page 379: ...steering shaft bush 1 and dust seal 2 for wear and damage If any defects are found replace them with new ones Remove the steering shaft bush and dust seal with the special tools and a suitable size socket wrench 3 09924 84510 Bearing installer set 09930 30721 Rotor remover Install the steering shaft bush and dust seal with the special tool and a suitable size socket wrench 4 09924 84521 Bearing in...

Page 380: ...SE A to the bush and dust seal 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply SUZUKI SUPER GREASE A to the steering shaft holders before installing the steering shaft holders 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Tighten the steering shaft holder bolts to the specified torque Steering shaft holder bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE Make sure that the wiring harnes...

Page 381: ...of steering shaft with slit C of steering arm plate Apply a small quantity THREAD LOCK SUPER 1303 to the thread part of steering shaft 99000 32030 THREAD LOCK SUPER 1303 or equivalent thread lock Tighten the steering shaft lower nut 1 to the specified torque Steering lower shaft nut 170 N m 17 0 kgf m 123 0 lb ft Install the cotter pin The removed O ring must be replaced with a new one The removed...

Page 382: ...tie rod make sure the narrow end 1 of the tie rod comes out HANDLEBAR HOLDER Tighten the handlebar holder nut to the specified torque Handlebar holder nut 60 N m 6 0 kgf m 43 5 lb ft Install the handlebars 8 54 Install the front fender Install the front wheels 8 18 The removed cotter pins must be r eplaced with new ones The lock nuts 2 have left hand threads Forward ...

Page 383: ...ght or left until the toe out is within the specified range B A Toe out Toe out Standard 10 4 mm 0 39 0 16 in Temporarily tighten the four lock nuts Check that the distances C and D are equal as shown If the distances are not equal adjust the tie rod to the right or left until the toe out is within specification Check the toe out again by measuring distances A and B If the toe out is not within sp...

Page 384: ...EASSEMBLING INFORMATION ITEM N m kgf m lb ft ITEM N m kgf m lb ft ITEM N m kgf m lb ft 1 26 2 6 19 0 6 45 4 5 32 5 A 29 2 9 21 0 2 60 6 0 43 5 7 55 5 5 40 0 B 60 6 0 43 5 3 23 2 3 16 5 8 60 6 0 43 5 C 110 11 0 49 5 4 29 2 9 21 0 9 65 6 5 47 0 D 29 2 9 21 0 5 170 17 0 123 0 0 60 6 0 43 5 ...

Page 385: ...onally NOTE If it is difficult to remove the rear drive shaft from the front differ ential gear case using the suitable tool 09924 21940 Wheel hub remover 09924 21920 Drive shaft remover 09930 30104 Sliding hammer 09924 21950 Front drive shaft remover 1 Circlip 6 Inner boot band small 2 Snap ring 7 Drive shaft 3 Stopper ring 8 Outer boot band small 4 Inner boot band large 9 Outer boot 5 Inner boot...

Page 386: ...e rear drive shaft and remove the stopper ring from the outer race Separate the outer race from the rear drive shaft Wipe off any grease and remove the snap ring Remove the cage and boot from the rear drive shaft Do not disassemble the wheel side joint If any dam ages are found replace it with a new one ...

Page 387: ...on the drive shaft end fitting the small diameter side of the boot to the shaft groove fix its end with the boot band Install the cage 1 on the shaft A Large diameter B Small diameter Clean al l p arts be fore i nstallation cl ean th e ins ide and outside of the boot with a cloth Do not wash the boots in any commercially available degreaser such as gasoline or kerosene Washing in a degreaser cause...

Page 388: ...int grease is included in the wheel side boot set or final gear side joint set of spare parts Insert the cage into the outer race and fit a stopper ring in the groove of the outer race Position Grease Wheel side Final gear side Quantity 40 g 65 g Locate the opening of the stopper ring 1 so that the opening is not lined up with a ball ...

Page 389: ...ing points Install the stopper ring 3 into the groove of drive shaft spline Apply SUZUKI SUPER GREASE A to the spline 99000 25010 SUZUKI SUPER GREASE A or equivalent grease NOTE After installing both drive shafts make sure the stopper rings are seated properly by pulling both inboard joints lightly Pour the specified mobil fluid 424 gear oil or equivalent through the filler hole 2 12 Gear oil capa...

Page 390: ...m lever 2 Friction plates 9 Rear brake case 3 Rear brake return spring 0 Bearing 4 Rear brake pressure plate A Snap ring 5 Ball B Oil seal ITEM N m kgf m lb ft 6 Gasket A Rear brake case bolts A 26 2 6 19 0 7 Rear brake cam shaft B Rear brake cam lever nut B 11 1 1 8 0 ...

Page 391: ...final gear oil 2 12 Remove the rear suspension 8 84 Remove the rear drive shaft 8 67 Remove the rear brake adjust nuts 1 and 2 Remove the rear brake cables Remove the breather hose 3 Loosen the outlet pipe connecting screws Remove the outlet pipe 4 ...

Page 392: ...emove the rear final gear case assembly mounting bolts Remove the final gear case assembly for a while back Remove the rear brake cam lever 6 limit indicator 7 and return spring 8 Remove the rear brake case 9 Remove the gasket 0 and dowel pins ...

Page 393: ...e the rear brake pressure plate B and balls Remove the rear brake cam shaft C Unlock the rear drive gear shaft lock nut with a chisel Remove the rear drive gear shaft lock nut rear propeller shaft coupling D and washer E with the special tool 09924 52450 Output shaft holder ...

Page 394: ...Remove the snap ring BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearing is in the rear brake case Replace the bearing in the following procedure if there is any thing unusual Remove the bearing with the special tool 09921 20240 Bearing remover set 20 Play Play ...

Page 395: ...E REAR BRAKE FRICTION PLATE AND STEEL PLATE Inspect the rear brake side plates 1 rear brake friction plates 2 and steel plates 3 for wear or damage If any defects are found replace them as a set Inspect the rear brake friction plates 2 and steel plates 3 for wear or distortion If any wear or distortion is found replace them as a set Measure the outer distance A between the side plates as shown If ...

Page 396: ... PLATE Inspect the rear blake pressure plate for wear or damage If any defects are found replace brake pressure plate with a new one Inspect the balls for wear or damage If any defects are found replace them with new ones REAR DRIVE GEAR SHAFT Inspect the rear drive gear shaft for wear or damage If any defects are found replace rear final drive gear shaft with a new one Replace the removed plate s...

Page 397: ...ar oil Install the snap ring Install the rear drive gear shaft 1 NOTE If the rear final drive gear shaft install easily lightly top it using a plastic mallet Install the oil seals 3 and 4 with the special tool 09913 70210 Bearing installer set Oil seal 3 55 Attachment Oil seal 4 35 Attachment Apply WATER RESISTANCE GREASE to the oil seals 1 99000 25160 WATER RESISTANCE GREASE Install the rear brak...

Page 398: ... m 10 0 kgf m 72 5 lb ft Stake the collar of the lock nut into the notch in the shaft of the rear propeller shaft coupling Install the balls and rear brake pressure plate 7 NOTE When installing the rear brake pressure plate 7 align its groove to the rear brake cam shaft 2 Install the rear brake plates 8 aligning the grooves of the case Install the dowel pins and gasket 9 The r emoved lo ck nut mu ...

Page 399: ... When installing the limit indicator A align the wide spline Install the rear brake cam lever B to the rear brake cam shaft NOTE When installing the brake cam lever align the punched mark Tighten the cam lever nut C to the specified torque Rear brake cam lever nut 11 N m 1 1 kgf m 8 0 lb ft REMOUNTING Remount the final gear case assembly in the reverse order of removal Pay attention to the followi...

Page 400: ...he specified torque Trailer towing bolt 60 N m 6 0 kgf m 43 5 lb ft Install the outlet pipe 2 Tighten the outlet pipe connecting screws 3 Install the rear brake cables Adjust the rear brake lever play and brake pedal free travel 2 21 Install the rear drive shaft 8 71 Install the rear suspension 8 90 Pour the specified mobil fluid 424 gear oil or equivalent through the filler hole 2 12 Gear oil cap...

Page 401: ... bearing 3 Rear stabilizer bush A Snap ring 4 Rear stabilizer bracket B Dust seal 5 Rear stabilizer link A Rear shock absorber mounting nut ITEM N m kgf m lb ft 6 Upper wishbone arm B Rear wishbone arm pivot nut A 60 6 0 43 5 7 Bushing C Rear knuckle end nut B 60 6 0 43 5 8 Lower wishbone arm C 60 6 0 43 5 ...

Page 402: ...l 8 18 Remove the rear drive shaft cover 1 Remove the cotter pin and rear hub nut Remove the rear wheel hub 2 Remove the rear stabilizer link nuts Remove the rear stabilizer bushes 3 and rear stabilizer brackets 4 Remove the rear stabilizer 5 ...

Page 403: ...CHASSIS 8 85 Remove the rear shock absorber 6 Remove the rear knuckle 7 Remove the rear upper wishbone arm 8 Remove the rear lower wishbone arm 9 ...

Page 404: ... replace the rear stabilizer bar with a new one STABILIZER BRACKET BUSH Inspect the stabilizer bracket 1 for damage If any defects are found replace the stabilizer bracket with a new one Inspect the stabilizer bush for wear or damage If any defects are found replace the stabilizer bush with a new one STABILIZER LINK Inspect the stabilizer link for wear or damage If any defects are found replace th...

Page 405: ...place the rear upper wishbone arm bush with new ones Remove the rear upper wishbone arm bush with the special tools 09923 73210 Bearing remover 09930 30104 Sliding hammer REAR LOWER WISHBONE ARM Inspect the rear lower wishbone arm for wear or damage If any defects are found replace the rear lower wishbone arm with a new one REAR LOWER WISHBONE ARM BUSH Inspect the rear lower wishbone arm bush for ...

Page 406: ...KLE BUSH Inspect the rear knuckle bushes for wear or damage If any defects are found replace rear knuckle bushes with new ones STEERING KNUCKLE DUST SEAL Remove the rear knuckle dust seals with the special tool 09913 50121 Oil seal remover REAR HUB BEARING Inspect the inner race play of the rear hub bearing by hand while it is in the rear knuckle Rotate the inner race by hand to inspect for abnorm...

Page 407: ... Remove the rear hub bearing 2 with the special tool 09921 20240 Bearing remover set REAR KNUCKLE DUST SEAL Inspect the rear knuckle dust seal for wear or damage If any defects are found replace the rear knuckle dust seal with a new one ...

Page 408: ...de of rear upper wishbone arm bush lip of the dust seals and spacer 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the dust seals and spacer to the rear upper wishbone arm REAR LOWER WISHBONE ARM Apply SUZUKI SUPER GREASE A to the inside of rear lower wishbone arm bush lip of the dust seals and spacer 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the dust seals and...

Page 409: ...installer 09944 66030 Oil seal installer Apply SUZUKI SUPER GREASE A to the lip of oil seals 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Apply SUZUKI SUPER GREASE A to the inside of rear knuckle bush lip of the dust seals and spacer 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the dust seals and spacer to the rear knuckle ...

Page 410: ...m 43 5 lb ft Apply a small quantity THREAD LOCK SUPER 1303 to the rear shock absorber mounting bolts Install the rear shock absorber and tighten the shock absorber mounting nuts to the specified torque 99000 32030 THREAD LOCK SUPER 1303 Rear shock absorber mounting nut upper and lower 60 N m 6 0 kgf m 43 5 lb ft Tighten the rear knuckle end nut to the specified torque Rear knuckle end nut 60 N m 6...

Page 411: ...hten the rear stabilizer link nuts to the specified torque Rear stabilizer link nut 34 N m 3 4 kgf m 24 5 lb ft Apply SUZUKI SUPER GREASE A to the wheel hub spline 99000 25010 SUZUKI SUPER GREASE A or equivalent grease Install the wheel hub 4 washer 5 and rear hub nut 6 Tighten the rear hub nut to the specified torque Rear hub nut 130 N m 13 0 kgf m 94 0 lb ft NOTE Install the washer 5 as shown in...

Page 412: ...3 5 lb ft SPRING PRE LOAD ADJUSTMENT After installing the rear shock absorber adjust the spring pre load Position 1 provides the minimum spring pre load Position 5 provides the maximum spring pre load STD POSITION 2 5 POSITION 1 POSITION 5 Be sure to adjust the spring pre load on the both sus pensions equally ...

Page 413: ...R SUSPENSION AND REAR DRIVE SHAFT REASSEMBLING INFORMATION ITEM N m kgf m lb ft ITEM N m kgf m lb ft 1 60 6 0 43 5 6 60 6 0 43 5 2 60 6 0 43 5 7 60 6 0 43 5 3 130 13 0 94 0 8 60 6 0 43 5 4 60 6 0 43 5 9 60 6 0 43 5 5 34 3 4 24 5 ...

Page 414: ...8 96 CHASSIS TRANSFER GEAR SHIFT LEVER CONSTRUCTION 1 Transfer gear shift lever assembly 3 Knob 2 Rod 4 Mounting bolt ITEM N m kgf m lb ft A 10 1 0 7 0 ...

Page 415: ...t lever mounting bolts Keep the gear shift arm 1 in the N position Loosen the bolt 2 and remove the gear shift arm 1 Remove the shift lever assembly INSPECTION Inspect the shift lever assembly for wear or damage If any defects are found replace it with a new one 30 33 33 R N L H ...

Page 416: ...shift lever assembly mounting bolts 99000 32110 THREAD LOCK SUPER 1322 or equivalent thread lock Transfer gear shift lever assembly mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Install the gear shift arm 1 on its shaft NOTE When installing the gear shift arm 1 align the grooves of arm with the spline of the shaft Tighten the bolt 2 securely SHIFT ROD ADJUSTMENT Hold the rod 2 loosen the lock nuts 1 Tu...

Page 417: ......

Page 418: ...TARTER SYSTEM 9 11 TROUBLESHOOTING 9 11 STARTER MOTOR REMOVAL 9 12 STARTER MOTOR DISASSEMBLY 9 13 STARTER MOTOR INSPECTION 9 14 STARTER MOTOR REASSEMBLY 9 15 STARTER MOTOR INSTALLATION 9 15 STARTER RELAY INSPECTION 9 16 NEUTRAL RELAY INSPECTION 9 16 PARKING BRAKE RELAY INSPECTION 9 17 PARKING BRAKE SWITCH 9 17 IGNITION SYSTEM 9 18 TROUBLESHOOTING 9 18 INSPECTION 9 20 4WD DIFF LOCK SYSTEM 9 24 INSP...

Page 419: ...9 33 HEADLIGHT INSTALLATION 9 34 BRAKE LIGHT TAILLIGHT 9 35 REVERSING LIGHT FOR E 17 9 35 DIODE 9 36 REVERSING LIGHT RELAY FOR E 17 9 36 SWITCHES 9 37 BATTERY 9 38 SPECIFICATIONS 9 38 INITIAL CHARGING 9 38 SERVICING 9 40 RECHARGING OPERATION 9 40 ...

Page 420: ...ad wires Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRING HARNESS ROUTING 10 16 Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for the ...

Page 421: ...battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disassem bly or servicing be sure to disconnect the battery lead wire first When connecting the ...

Page 422: ...ed If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position 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 prevent the rubber of the water proof coupler from ...

Page 423: ...NTS 1 Battery 2 Main fuse 3 Starter relay 4 Fuse box 5 Neutral relay 6 Fuel pump relay 7 ECM 8 4WD diff lock relay 9 Starter motor 0 4WD diff lock switch A Brake lever switch R B Ignition switch C Ignition coil D Rear brake switch E Gear position switch ...

Page 424: ...ter button 5 Dimmer switch 6 Engine stop switch 7 Over ride switch 8 Brake lever switch L 9 Parking brake switch 0 Horn button For E 17 E 24 A Regulator rectifier B Parking brake relay C Diff lock relay D Cooling fan E 4WD diff lock actuator F Speed sensor G Generator H High position diode I Low position diode ...

Page 425: ...ted voltage between the battery terminals 9 9 Is the regulated voltage OK Step 4 1 Measure the resistance of the generator coil 9 9 Is the resistance of generator coil OK YES Remove accessories NO Go to Step 2 YES Go to Step 3 NO Short circuit of wire harness Faulty electrical equipment YES Faulty battery Abnormal driving condition NO Go to Step 4 YES Go to Step 5 NO Faulty generator coil Disconne...

Page 426: ...etween battery terminal and the bat tery lead wire with the multi circuit tester If the reading exceeds the specified value leakage is evident 09900 25008 Multi circuit tester set Tester knob indication Current 4 20 mA Battery current leak Under 2 6 mA NOTE When checking for find the excessive current leakage remove the couplers and connectors one by one checking each part YES Go to Step 6 NO Faul...

Page 427: ... condition 09900 25008 Multi circuit tester set 3 Tester knob indication Voltage 4 Regulated voltage Charging output 13 5 15 5 V at 5 000 r min GENERATOR COIL RESISTANCE Remove the rear fender 8 15 Disconnect the generator coupler 1 Measure the resistance between the three lead wires with the multi circuit tester If the resistance is out of specified value replace the stator with a new one Also ch...

Page 428: ...0 r min When engine is cold REGULATOR RECTIFIER Remove the rear fender 8 15 Disconnect the regulator rectifier coupler Measure the voltage between the lead wires with the multi cir cuit tester as indicated in the table below If the voltage is not within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V M...

Page 429: ...motor runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter motor run YES Go to Step 2 NO Go to Step 3 YES Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal NO Faulty starter motor Starter motor Main fuse Starter relay B W Y B R Neutr...

Page 430: ... the parking brake switch OK Step 2 1 Check the parking brake relay Is the parking brake relay OK Engine does not turn though the starter motor runs Faulty stater clutch 3 47 STARTER MOTOR REMOVAL Disconnect the battery lead wire Remove the right side cover 8 10 Disconnect the starter motor lead wire 1 Remove the starter motor 2 YES Go to Step 4 NO Faulty engine stop switch Faulty neutral relay Fa...

Page 431: ...SASSEMBLY Disassemble the starter motor as shown in the illustration 1 O ring 5 Housing end outside 2 Housing end inside A Lead wire connecting nut ITEM N m kgf m lb ft 3 Starter motor case B Mounting bolt A 6 0 6 4 5 4 Armature B 10 1 0 7 0 ...

Page 432: ...ear or undercut A If abnormal wear is found replace the armature with a new one If the commutator surface is discolored polish it with 400 sand paper and wipe it with a clean dry cloth If there is no undercut scrape out the insulator with a saw blade 1 Insulator 2 Segment ARMATURE COIL Check for continuity between each segments and the armature shaft with the multi circuit tester If there is no co...

Page 433: ...OLY PASTE to the arma ture shaft 99000 25140 SUZUKI MOLY PASTE Align the marks on the housing ends with the marks on the starter motor case Apply SUZUKI SUPER GREASE A to the O ring 99000 25010 SUZUKI SUPER GREASE A or equivalent grease STARTER MOTOR INSTALLATION Tighten the starter motor mounting bolts 1 and starter motor lead wire connecting nut 2 to the specified torque Starter motor mounting b...

Page 434: ...ure the relay coil resistance between the terminals with the multi circuit tester If the resistance is not within the specified value replace the starter relay with a new one 09900 25008 Multi circuit tester set 2 Tester knob indication Resistance Ω Starter relay resistance 3 5 Ω NEUTRAL RELAY INSPECTION Remove the seat 8 6 Disconnect the neutral relay Apply 12 V to terminals A and B to A and to B...

Page 435: ... A and B terminals with the multi circuit tester Then apply 12 V to terminals C and D to C and to D and check the continuity between A and B If there is no continuity replace the parking brake relay with a new one 09900 25008 Multi circuit tester set 6 Tester knob indication Continuity set 5 PARKING BRAKE SWITCH 9 37 ...

Page 436: ...uit cuts off fuel at the fuel injector TROUBLESHOOTING No spark or poor spark NOTE Check that the transfer is in neutral and the engine stop switch is in the RUN position Check that the fuse is not blown and the battery is fully charged before diagnosing Step 1 1 Check the ignition system couplers for poor connections Is there connection in the ignition system couplers YES Go to Step 2 NO Poor con...

Page 437: ...easure the CKP sensor peak voltage and its resistance 9 22 and 9 23 NOTE The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resistance OK YES Go to Step 3 NO Faulty ignition switch Faulty engine stop switch Broken wire harness or poor connection of related circuit couplers YES Go to Step 4 NO Go to Step 5 YES Go to ...

Page 438: ... set Shift the transfer to the neutral position and turn the ignition switch to the ON position Push the starter button and allow the engine to crank for a few seconds and then measure the ignition coil primary peak volt age Repeat the above procedure a few times and measure the high est ignition coil primary peak voltage If the voltage is lower than the standard values inspect the ignition coil 9...

Page 439: ... both the primary and sec ondary windings with the multi circuit tester If the resistance in both the primary and secondary windings is close to the speci fied values the windings are in sound condition 09900 25008 Multi circuit tester set 2 Tester knob indication Resistance Ω Ignition coil resistance Primary 0 1 0 6 Ω Terminal Ground Secondary 12 19 kΩ spark plug cap terminal ...

Page 440: ...ure a few times and measure the highest CKP sensor peak voltage 3 Tester knob indication Voltage 4 CKP sensor peak voltage 5 0 V and more NOTE After checking the CKP sensor peak voltage clear the DTC using SDS tool If the peak voltage is lower than the specified valve check the continuity between the CKP sensor coupler and ECM coupler When us ing the multi circuit t ester an d peak v olt adaptor r...

Page 441: ... the resistance between the lead wires and ground If the resistance is not as specified the CKP sensor must be replaced 09900 25008 Multi circuit tester set 2 Tester knob indication Resistance Ω CKP sensor resistance 200 250 Ω White Blue Ω White Ground CKP sensor Bl W CKP sensor coupler ...

Page 442: ... lock actuator below Faulty 4WD diff lock diode 9 36 4WD DIFF LOCK ACTUATOR Remove the front fender 8 9 Remove the front drive train differential gear case assembly 4 4 Remove the 4WD diff lock actuator assembly Connect the 12 V battery to the actuator lead wires Blue wire and Yellow wire If the motor does not run replace the diff lock transfer actuator assembly with a new one Install the diff loc...

Page 443: ...tion between D and F Apply 12 V to the terminals B and E to E and to B check the insulation between A and D If any abnormality is found replace the 4WD diff lock relay with a new one 09900 25008 multi circuit tester set DIFF LOCK RELAY First check the insulation between A and B terminals with the multi circuit tester Then apply 12 V to terminals C and D to C and to D and check the continuity betwe...

Page 444: ...vel LED Light Emitting Diode LED is used for the illumination light and each indicator light LED is maintenance free LED is less electric power consuming and stronger to vibration resistance com pared to the bulb 1 ODO TRIP A TRIP B button 0 Clock hour button 2 LED diff lock A Diff lock indicator 3 LED reverse B 4WD indicator 4 LED neutral C Gear position indicator 5 Speedometer D ODO TRIP A TRIP ...

Page 445: ...anges between odometer tripmeter A and tripmeter B as shown Hold down the ODO TRIP button over two seconds while press ing the CLOCK HOUR button the display changes between mph and km h when displaying odometer as shown With each press of the CLOCK HOUR button the dis play changes between clock and hour as shown ODOMETER Displays the total distance travelled TRIPMETER Displays the distance travell...

Page 446: ...correct minutes by pressing the button Decide the minutes by pressing the ODO TRIP button and then flashing the hour display Select the correct hour by press ing the button Decide the hours by pressing the ODO TRIP button REMOVAL AND DISASSEMBLY Remove the ignition switch holder 1 Remove the combination meter cover 2 Remove the holder cover 3 Loosen the combination meter bolt min hour ...

Page 447: ...ble the combination meter as follows When disconnecting and reconnecting the combina tion meter coupler make sure to turn OFF the igni tion switch or electronic parts may get damaged Make sure that the combination meter coupler boots is positioned properly Do not attempt to disassemble the combination meter unit ...

Page 448: ...ch ON Check the LCD and LED operations when the resistance is adjusted to the specified values If either one or all indications are abnormal replace the combi nation meter with a new one NOTE If the engine stop switch is turned OFF while the ignition switch is ON the LCD displays CHEC But it is not a malfunction This condition implies that combination meter receives no signal from the ECM In that ...

Page 449: ... with a new one FUEL LEVEL GAUGE Remove the fuel pump assembly 6 7 Measure the resistance at each fuel level gauge float position If the resistance is incorrect replace the fuel pump assembly with a new one 09900 25008 Multi circuit tester set 2 Tester knob indication Resistance Ω Resistance Less than 16 Ω 16 5 21 5 Ω 23 5 30 5 Ω 33 41 Ω 53 65 Ω 82 100 Ω 164 208 Ω Fuel level meter Float position R...

Page 450: ...peed sensor 2 by removing its mounting bolt Connect 12 V battery 10 kΩ resistor and the multi circuit tester as shown 09900 25008 Multi circuit tester set 3 Tester knob indication Voltage 4 Above condition if a suitable screwdriver touching the pick up surface of the speed sensor is moved the tester reading volt age changes 0 V 12 V or 12 V 0 V If the tester reading voltage does not change replace...

Page 451: ...HEADLIGHT BULB 12 V 35 35 W 2 1 HEADLIGHT BEAM ADJUSTMENT Vertical Adjust the headlight vertical beam If you have touched and the bulb with your bare hands clean it w ith a cloth moistened with alcohol or soapy water to maintain lens clarity ...

Page 452: ...9 34 ELECTRICAL SYSTEM HEADLIGHT INSTALLATION Head light coupler Head light R Adjusting point ...

Page 453: ... REVERSING LIGHT BULB 12V 21 W 1 If you have touched and the bulb with your bare hands clean it w ith a cloth moistened with alcohol or soapy water to maintain lens clarity If you have touched and the bulb with your bare hands clean it w ith a cloth moistened with alcohol or soapy water to maintain lens clarity ...

Page 454: ...ter knob indication Diode test Unit V More than 1 4 V tester s battery voltage NOTE If the tester reads under 1 4 V when the tester probes are not connected replace the battery of multi circuit tester REVERSING LIGHT RELAY FOR E 17 First check the insulation between A and B terminals with the multi circuit tester Then apply 12 V to terminals C and D to C and to D and check the continuity between A...

Page 455: ...on O O W Color Position O W Y G Color Position B B ON OFF Color Position B B ON OFF 2WD 4WD Diff lock Color Position Bl R O B W Br B R B Y B W Color Position B W Bl B ON OFF Color Position W Bl ON OFF Color Position O W B Color Position G B W SET SECEDE EMERGENCY SWITCH For E 17 Color Position O O G WIRE COLOR B Black Bl Blue Br Brown G Green Gr Gray O Orange R Red W White Y Yellow B W Black with ...

Page 456: ...round Remove the caps 2 NOTE After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte container Insert the nozzles of the electrolyte container 4 into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid t...

Page 457: ...ps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified battery Once the caps have been installed to the battery do not remove the caps Do no t ta p the ca ps w ith a to ol s uch a s ha mmer when installing them CORRECT INCORRECT For charging the battery make sure to use the...

Page 458: ...e If the voltage reading is 12 0 V DC and less recharge the battery with a battery charger A Charging period B Stop charging Recharging time 6 A for 1 hour or 1 2 A for 5 to 10 hours After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester If the battery voltage is 12 5 V and less recharge the battery again If battery voltage is still 12 5 V and less ...

Page 459: ... 21 COOLING SYSTEM HOSE ROUTING 10 22 REAR DRIVE BREATHER HOSE ROUTING 10 23 FRONT BRAKE HOSE AND PIPE ROUTING 10 24 FENDER INSTALLATION 10 25 REAR FENDER HEAT SHIELD INSTALLATION 10 27 BELT COOLING DUCT INSTALLATION 10 28 REAR BRAKE PEDAL 10 29 REAR SIDE REFLEX REFLECTOR INSTALLATION FOR E 28 10 30 TRAILER TOW PLATE INSTALLATION 10 31 ENGINE MOUNTING 10 32 RADIATOR GUARD INSTALLATION For E 24 10 ...

Page 460: ...ng voltage 0 2 V sensor voltage 4 8 V In other than the above value C14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value TP sensor circuit open or shorted to ground or VCC circuit open C15 ECT sensor The sensor voltage should be the f...

Page 461: ...l CKP sensor pick up coil signal is pro duced but signal from ignition coil is interrupted 8 times or more continu ously In this case the code C24 P0351 is indicated Ignition coil lead wire coupler connection power supply from the battery P0351 C32 Fuel injector CKP sensor pick up coil signal is pro duced but fuel injector signal is inter rupted 4 times or more continuously In this case the code C...

Page 462: ...ns No fuel reaching the intake manifold 1 Clogged fuel mesh filter or fuel feed hose 2 Defective fuel pump 3 Defective fuel pressure regulator 4 Defective fuel injector 5 Defective fuel pump relay 6 Defective ECM 7 Open circuited wiring connections Incorrect fuel air mixture 1 Defective fuel pump 2 Defective fuel pressure regulator 3 Defective TP sensor 4 Defective CKP sensor 5 Defective IAP senso...

Page 463: ... sensor 6 Defective thermostat 7 Defective IAT sensor Fuel injector improperly operating 1 Defective fuel injector 2 No injection signal from ECM 3 Open or short circuited wiring connection 4 Defective battery or low battery voltage Control circuit or sensor improperly operating 1 Defective ECM 2 Defective fuel pressure regulator 3 Defective TP sensor 4 Defective IAT sensor 5 Defective CKP sensor ...

Page 464: ...maged mechanical seal 4 Contact between pump case and impeller Noise seem to came from the movable drive and driven face 1 Worn or slipping drive belt 2 Worn rollers in movable drive face Noise seem to came from the transfer 1 Worn or rubbing gear 2 Worn transfer input output shaft 3 Worn bearing 4 Worn splines Noise seems to came from front rear output shaft bevel gear front drive differential be...

Page 465: ...ed air cleaner element 10 Clogged fuel feed hose resulting in inadequate fuel supply to injector 11 Defective fuel pump 12 Defective TP sensor Defective air flow system 1 Clogged air cleaner element 2 Sucking air from throttle body joint 3 Defective ECM Defective control circuit or sensor 1 Low fuel pressure 2 Defective TP sensor 3 Defective IAT sensor 4 Defective CKP sensor 5 Defective IAP sensor...

Page 466: ...r out of adjustment 10 Clogged air cleaner element 11 Sucking air from throttle valve 12 Too much engine oil 13 Defective fuel pump or ECM 14 Defective CKP sensor and ignition coil Defective control circuit or sensor 1 Low fuel pressure 2 Defective TP sensor 3 Defective IAT sensor 4 Defective CKP sensor 5 Defective IAP sensor 6 Defective ECM Adjust Replace Adjust Replace Repair Clean or replace Ad...

Page 467: ...re 3 Defective fuel injector 4 Defective ECT sensor Other factors 1 Ignition timing is too advanced due to defective timing advance system ECT sensor CKP sensor and ECM Clean Add oil Replace or clean Retighten or replace Change See radiator section Repair or replace Repair or replace Replace Replace Replace Dirty or heavy exhaust smoke 1 Too much engine oil in the engine 2 Worn piston rings or cyl...

Page 468: ...ion 4 Improperly operated front differential shifting motor 5 Worn or damaged shifting sleeve shaft and fork of the 2WD 4WD and diff lock shifting 6 Worn or damaged universal joint 7 Worn or damaged front drive shaft or universal joint serration Transfer will not shift back 1 Broken return spring on shift shaft 2 Rubbing or sticky shift shaft 3 Distorted or worn gearshift forks Transfer jumps out ...

Page 469: ... lubricated 3 Low air pressure in front tires 4 Tie rod ends tending to seize 5 Linkage connections tending to seize 6 Distorted steering shaft Adjust Lubricate Adjust Replace Repair or replace Replace Steering wobbles 1 Unequally inflated tires 2 Loose front wheel hub nuts 3 Damaged or worn front wheel hub bearings 4 Worn or loose tie rod ends 5 Defective or incorrect front tires 6 Damaged or wor...

Page 470: ...oose front wheel hub nuts 5 Damaged or worn wishbone arms and related bushes 6 Front shock absorber leaks oil 7 Loose chassis nuts and bolts Replace Replace Replace Tighten Replace Replace Tighten Suspension too noisy 1 Loose suspension system bolts 2 Worn wishbone arms and related bushes Tighten Replace Rear suspension too soft 1 Weakened spring of shock absorber 2 Leakage oil of shock absorber 3...

Page 471: ...6 Clogged return port of master cylinder Repair surface with sand paper Correct pad fitting or replace Replace Replace Replace brake fluid Disassemble and clean master cylinder Excessive brake lever stroke 1 Air in hydraulic system 2 Insufficient brake fluid 3 Improper quality of brake fluid Bleed air Replenish fluid to specified level bleed air Replace with correct fluid Leakage of brake fluid 1 ...

Page 472: ...ctions 2 Short circuited grounded or open generator coil 3 Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Generator does charge but charg ing rate is below the specification 1 Lead wires tend to get shorted or open circuited or loosely connected at terminals 2 Grounded or open circuited generator coil 3 Defective regulator rectifier 4 Defective cell...

Page 473: ...time Replace the battery Replace the battery Battery runs down quickly 1 Trouble in the charging system 2 Cell plates have lost much of their active material as a result of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments to obtain specified charging oper...

Page 474: ...ing harness Generator Gear position switch Clamp Clamp Clamp Clamp Actuator Clamp Clamp Clamp Clamp Actuator Foot brake switch Actuator Foot brake switch To rear fender top Speed sensor Clamp Wiring harness Injector coupler ECT sensor coupler Ignition coil To power source Clamp Clamp Wiring harness Wiring harness TP IAP IAT sensor Wiring harness Wiring harness Actuator Gear position switch Generat...

Page 475: ...nder hole Starter motor terminal Battery ECM Fuse box Master cylinder reservoir tank To combination meter Set sag under combination meter Pass combination meter wire back side upper bracket Horn E 24 Horn switch E 17 E 24 Brake lever switch L Handle switch L Parking brake switch Emergency switch E 17 4WD diff lock switch Combination meter Horn switch E 17 E 24 Brake lever switch L Brake lever swit...

Page 476: ... brake cable Location of cable and harness as shown Parking brake cable Throttle cable Parking brake cable Stater cable Parking brake cable Sterter cable Fix foot brake cable to the footrest bar Parking brake cable guide Handlebar Pin Locate throttle cable as shown Must not locate out of pin ...

Page 477: ...l Washer Fix foot brake cable to the footrest Foot brake cable Rear brake assy Parking brake cable Adjust nut Parking brake cable Frame Rear fender Protector Parking brake cable Parking brake cable Rear fender Screw Wiring harness Tie protector with clamp as shown Frame ...

Page 478: ... FUEL HOSE ROUTING Air cleaner box Fuel feed hose Pass through the fuel feed hose between air cleaner guide ribs Fuel feed hose PCV hose Fuel feed hose Rear Intake pipe Front Right Left Rear Front Right Left PCV hose Outlet tube ...

Page 479: ...21 FUEL TANK BREATHER HOSE ROUTING Frame Fuel tank breather hose Check valve hose Valve Black Check valve hose Valve Orange Fuel tank breather hose Fuel tank Fuel tank pressure control valve Valve Orange Fuel tank breather hose ...

Page 480: ...10 22 SERVICING INFORMATION COOLING SYSTEM HOSE ROUTING Radiator Reservoir tank Thermostat Bypass hose Bypass hose Water pump Radiator lower hose Radiator upper hose ...

Page 481: ...SERVICING INFORMATION 10 23 REAR DRIVE BREATHER HOSE ROUTING Breather hose Breather hose Fuel tank Rear drive assy Rear drive assy Belt cooling outlet duct Fuel tank lower cover 20 30 ...

Page 482: ...er Forward Through front brake hose inside of the suspension arm View E Tighten bolt with end fitting contacted with stopper Stopper Stopper Frame Assemble front brake hose firmly into the clamp Steering shaft Front brake hose E Front brake caliper Master cylinder reservoir tank Master cylinder reservoir tank Union bolt Tighten bolt with the end fitting contacted with the tank Front brake hose Ass...

Page 483: ...SERVICING INFORMATION 10 25 FENDER INSTALLATION Front fender Right inner fender Left mud guard Left inner fender ...

Page 484: ...10 26 SERVICING INFORMATION Rear box Rear fender Right mud guard Left mud guard ...

Page 485: ... INFORMATION 10 27 REAR FENDER HEAT SHIELD INSTALLATION Rear fender 1 3 mm 0 04 0 12 in 30 mm 1 181 in 8 mm 0 32 in 67 mm 2 64 in Heat shield 1 3 mm 0 04 0 12 in 5 mm 0 20 in Heat shield Heat shield Heat shield ...

Page 486: ...10 28 SERVICING INFORMATION BELT COOLING DUCT INSTALLATION 1 5 N m 0 15 kgf m 1 0 lb ft Belt cooling outlet duct 1 5 N m 0 15 kgf m 1 0 lb ft Belt cooling intake duct ...

Page 487: ...m 19 0 lb ft 55 N m 5 5 kgf m 40 0 lb ft 55 N m 5 5 kgf m 40 0 lb ft 26 N m 2 6 kgf m 19 0 lb ft 11 N m 1 1 kgf m 8 0 lb ft Foot brake switch Spring Foot brake pedal Foot brake cable Foot brake pedal adjusting bolt Spring Foot brake cable 12 5 22 5 mm 0 5 0 9 in ...

Page 488: ...10 30 SERVICING INFORMATION REAR SIDE REFLEX REFLECTOR INSTALLATION FOR E 28 Reflex reflector Reflex reflector bracket Rear fender ...

Page 489: ...SERVICING INFORMATION 10 31 TRAILER TOW PLATE INSTALLATION Trailer tow warning label E 17 CH 28 Trailer tow warning label Trailer tow plate mounting bolt 60 N m 6 0 kgf m 43 5 lb ft Trailer tow plate ...

Page 490: ...unting Thermostat case bolt Recoil starter Engine mounting bolt Engine mounting nut Thermostat case 60 N m 6 0 kgf m 43 5 lb ft 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 1 5 N m 0 15 kgf m 1 0 lb ft 5 5 N m 0 55 kgf m 4 0 lb ft Engine mounting bolt Water hose clamp screw ...

Page 491: ...SERVICING INFORMATION 10 33 RADIATOR GUARD INSTALLATION For E 24 Radiator net 0 3 mm 0 0 12 in Clamp Radiator guard Radiator Frame ...

Page 492: ...s 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 09900 20806 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block set 100 mm 09900 22301 09900 22302 Plastigauge 09900 22401 10 18mm 09900 22403 18 35mm Small bore gauge 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 09900 26006 Tachometer 09904 41010 SDS set tool ...

Page 493: ...ge attachment 09915 72410 Oil pressure gauge attachment 09915 74511 Oil pressure gauge set 09915 74521 Oil pressure gauge hose 09915 77331 Meter for high pressure 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 34570 Valve guide reamer 5 0 mm 09916 34542 Reamer handle 09916 34580 Valve guide reamer 10 8 mm 09916 44310 Valve guide remover installer 09...

Page 494: ...e remover 09920 53740 Clutch sleeve hub holder 09921 20240 Bearing remover set 09921 21910 Bearing holder 09922 31430 Movable drive face spring compressor 09923 73210 Bearing remover 09924 21920 Drive shaft remover 09924 21940 Wheel hub remover 09924 21950 Front drive shaft remover 09924 41830 Bearing lock nut wrench 09923 74511 Bearing remover 20 38 09924 52450 Output shaft holder 09924 52460 Soc...

Page 495: ...il seal installer 09930 10121 Spark plug wrench set 09930 30104 Sliding shaft 09930 30721 Rotor remover 09930 40113 Rotor holder 09930 40120 Rotor holder attachment A 09930 82720 Mode select switch 09940 40211 Fuel pressure gauge adaptor 09940 40221 Fuel pressure gauge hose attachment 09940 52861 Front fork oil seal installer 09940 92430 Rear axle wrench A 09941 51012 Ring locknut wrench 09944 660...

Page 496: ...nut 150 15 0 108 5 Movable drive face bolt 110 11 0 79 5 Movable driven face bolt 110 11 0 79 5 Movable driven face ring nut 110 11 0 79 5 Clutch cover bolt 8 0 8 5 7 Clutch inner cover bolt 9 0 9 6 5 Generator rotor nut 140 14 0 101 5 Generator starter bolt 11 1 1 8 0 Speed sensor bolt 10 1 0 7 0 Starter clutch bolt 25 5 2 55 18 5 Exhaust pipe nut 23 2 3 16 5 Muffler connect bolt 23 2 3 16 5 Muff...

Page 497: ... nut 100 10 0 72 5 Final gear case bolt M8 26 2 6 19 0 Final gear case bolt M10 55 5 5 40 0 Final gear case mounting nut 65 6 5 47 0 Rear propeller shaft boot clamp screw 2 0 2 1 5 Final gear oil drain plug 23 2 3 16 5 Output drive gear shaft lock nut 100 10 0 72 5 Output shaft nut 100 10 0 72 5 ITEM N m kgf m lb ft CKP sensor mounting bolt 6 0 6 4 3 CKP sensor bracket bolt 6 0 6 4 3 Fuel delivery...

Page 498: ... 60 6 0 43 5 Front brake hose union bolt 25 2 5 18 0 Front brake air bleeder valve 6 0 0 6 4 3 Front brake pad mounting bolt 17 1 7 12 5 Front brake caliper mounting bolt 26 2 6 19 0 Caliper holder pin 17 1 7 12 5 Caliper holder slide pin 22 2 2 16 0 Front brake pad mounting pin 17 1 7 12 5 Brake pipe nut 16 1 6 11 5 Front brake disc plate mounting bolt 23 2 3 16 5 Brake master cylinder clamp bolt...

Page 499: ...l or 4 marked bolt 7 marked bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 Conventional bolt 4 marked bolt 7 marked bolt ...

Page 500: ...0 030 0 057 0 0012 0 0022 Valve guide I D IN EX 5 000 5 012 0 1968 0 1973 Valve stem O D IN 4 975 4 990 0 1958 0 1964 EX 4 955 4 970 0 1950 0 1956 Valve stem 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 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 38 8 1 52 Valve spring tens...

Page 501: ...645 0 8653 Camshaft runout 0 10 0 004 Rocker arm I D IN EX 12 000 12 018 0 4724 0 4731 Rocker arm shaft O D IN EX 11 973 11 984 0 4713 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure Automatic decomp actuated Approx 1 000 kPa 10 0 kgf cm 142 psi Piston to cylinder clearance 0 030 0 040 0 0012 0 0016 0 120 0 0047 Cylinder...

Page 502: ...ring thickness 1st 1 17 1 19 0 0460 0 0468 2nd 0 97 0 99 0 0382 0 0390 Piston pin bore I D 20 002 20 008 0 7874 0 7877 20 030 0 7885 Piston pin O D 19 992 20 000 0 7870 0 7874 19 980 0 7866 ITEM STANDARD LIMIT Conrod small end I D 20 006 20 014 0 7876 0 7879 20 040 0 7889 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 65 0 004 0 025 1 0 0 039 Conrod big end width 24 95 25 00 0 982...

Page 503: ...th 31 1 1 22 30 1 1 18 Movable driven face spring free length 215 0 8 46 204 3 8 04 Shift fork to groove clearance 0 10 0 30 0 004 0 012 0 50 0 020 Shift fork groove width Reverse 5 50 5 60 0 217 0 220 High 5 50 5 60 0 217 0 220 Shift fork thickness Reverse 5 30 5 40 0 209 0 213 High 5 30 5 40 0 209 0 213 Front rear output shaft bevel gear backlash 0 03 0 15 0 001 0 006 Front drive differential ge...

Page 504: ...an thermo switch operating temperature OFF ON Approx 93 C 199 F ON OFF Approx 87 C 189 F Engine coolant type Use an antifreeze coolant compatible with alu minum radiator mixed with distilled water only at the ratio of 50 50 Engine coolant capacity Reservoir 250 ml 0 26 0 22 US lmp qt Engine 2 200 ml 2 32 1 94 US lmp qt ITEM SPECIFICATION NOTE Injector resistance 11 5 12 5 Ω at 20 C 68 F Fuel pump ...

Page 505: ...e Closed 0 93 1 31 V Opened 3 64 4 82 V ECT sensor input voltage 4 5 5 5 V ECT sensor resistance 20 C 68 F Approx 2 45 kΩ 40 C 104 F Approx 1 15 kΩ 80 C 176 F Approx 0 31 kΩ 100 C 182 F Approx 0 18 kΩ IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage Approx 1 88 3 06 V at 20 C 68 F IAT sensor resistance 20 C 68 F 2 22 3 11 kΩ 40 C 104 F 1 00 1 56 kΩ TO sensor resistance 19 20 kΩ TO sens...

Page 506: ...3 at 1 atm Ignition coil resistance Primary 0 1 0 6 Ω Terminal Ground Secondary 12 19 kΩ Plug cap Terminal Generator coil resistance 0 1 1 0 Ω Generator Max output Approx 375 W at 5 000 r min Generator no load voltage when engine is cold 65 V AC and more at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter relay resistance 3 5 Ω Battery Type designation YTX14 BS Capacity 12 V 43 2 k...

Page 507: ... LED Differential lock indicator light LED ITEM STANDARD SPECIFICATION LIMIT Rear brake pedal height 12 5 22 5 0 5 0 9 Rear brake pedal free travel 20 30 0 8 1 2 Front brake disc thickness 3 3 3 7 0 13 0 15 3 0 0 20 Front brake disc runout 0 30 0 012 Front master cylinder bore 14 000 14 043 0 5512 0 5529 Front master cylinder piston diam 13 957 13 984 0 5495 0 5506 Front brake caliper cylinder bor...

Page 508: ...n Camber 0 64 Caster 1 6 ITEM STANDARD LIMIT Cold inflation tire pressure Solo riding Front 35 kPa 0 35 kgf cm 5 1 psi Rear 30 kPa 0 30 kgf cm 4 4 psi Tire size Front AT 25 8 12 tubeless Rear AT 25 10 12 tubeless Tire tread depth Front 4 0 0 16 Rear 4 0 0 16 ITEM STANDARD LIMIT Front shock absorber spring adjustor 2 5 position Rear shock absorber spring adjuster 2 5 position ...

Page 509: ...an 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible E 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended The others Fuel tank capacity 17 5 L 4 6 3 8 US lmp gal Engine oil type SAE 10 W 40 API SF SG or SH SJ with JASO MA Engine oil capacity change 2 500 ml 2 6 2 2 US lmp qt Filter change 2 700 ml 2 8 2 4...

Page 510: ......

Page 511: ...EMISSION CONTROL INFORMATION 11 1 11 EMISSION CONTROL INFORMATION CONTENTS EMISSION CONTROL SYSTEMS 11 2 FUEL INJECTION SYSTEM 11 2 CRANKCASE EMISSION CONTROL SYSTEM 11 3 ...

Page 512: ... with the programmed injection maps in the ECM by varying engine conditions Adjusting interfer ing with improper replacement or resetting of any of the fuel injection components may adversely affect injection performance and cause the vehicle to exceed the exhaust emission level limits if unable to effect repairs contact the distributor s representative for further technical information and assist...

Page 513: ... is equipped with a PCV system Blow by gas in the engine is constantly drawn into the crank case which is returned to the combustion chamber through the PCV breather hose air cleaner and throttle body 1 PCV breather hose C FUEL AIR MIXTURE A BLOW BY GAS D EXHAUST GAS B FRESH AIR ...

Page 514: ......

Page 515: ...ONT SUSPENSION REASSEMBLING INFORMATION 12 4 REAR SUSPENSION 12 5 REAR SUSPENSION REASSEMBLING INFORMATION 12 6 FUEL LEVEL GAUGE INSPECTION 12 7 NOTE The specifications and service data are the same as the K 7MODEL 2 1 LT A450XK8 08 MODEL 1 LT A450XK8 08 MODEL 12 ...

Page 516: ... A 8 General warning label F A 9 Warning no passenger label E A A A A 0 AGE 16 label F A A Manual notice label E A B Max AMP caution label E A A C Max AMP caution label E F A A D Fuel caution label E A E Front carrier warning label E A A F Front carrier warning label E F A A G Rear carrier warning label E A A H Rear carrier warning label E F A A I ICES Canada label E F A J Compliance label E A K I...

Page 517: ...absorber mounting upper bolt 3 Front lower wishbone arm B Front shock absorber mounting lower nut ITEM N m kgf m lb ft A 55 5 5 40 0 4 Bush C Front wishbone arm pivot nut upper B 60 6 0 43 5 5 Dust seal D Front wishbone arm pivot nut lower C 60 6 0 43 5 6 Spacer D 65 6 5 47 0 LT A450XK8 08 MODEL 1 3 2 ...

Page 518: ...ENSION REASSEMBLING INFORMATION A 7 mm 0 28 in A 7 mm 0 28 in ITEM N m kgf m lb ft 1 60 6 0 43 5 X Apply grease to the inside bush dust seal and seal A Press fitting position of the bush 12 4 LT A450XK8 08 MODEL ...

Page 519: ... B Dust seal 4 Rear stabilizer bracket C Seal 5 Rear stabilizer link D Spacer 6 Upper wishbone arm A Rear shock absorber mounting nut ITEM N m kgf m lb ft 7 Bushing B Rear wishbone arm pivot nut A 60 6 0 43 5 8 Lower wishbone arm C Rear knuckle end nut B 60 6 0 43 5 9 Rear knuckle C 60 6 0 43 5 LT A450XK8 08 MODEL 1 12 5 ...

Page 520: ... 7 mm A 7 mm A ITEM N m kgf m lb ft ITEM N m kgf m lb ft 1 60 6 0 43 5 4 60 6 0 43 5 2 60 6 0 43 5 5 60 6 0 43 5 3 60 6 0 43 5 6 34 3 4 24 5 X Apply grease to the inside bush dust seal and seal A Press fitting position of the bush 12 6 LT A450XK8 08 MODEL ...

Page 521: ...ge float position If the resistance is incorrect replace the fuel pump assembly with a new one 09900 25008 Multi circuit tester set V Tester knob indication Resistance Ω Float position Resistance 27 7 mm 1 09 in 6 4 8 4 Ω 166 mm 6 54 in 216 222 Ω 27 7 mm 1 09 in 166 mm 6 54 in LT A450XK8 08 MODEL 1 12 7 ...

Page 522: ... A450XK8 08 MODEL NOTE Any differences between the LT A450XK8 08 MODEL and LT A450XK9 09 MODEL in specifications are clearly indicated with an asterisk mark Please refer to the chapters 1 through 12 for details which are not given in this chapter LT A450XK9 09 MODEL 13 1 13 SPECIFICATIONS LT A450XK9 13 2 REAR SUSPENSION 13 3 REAR STABILIZER BUSH 13 3 ...

Page 523: ...562 41 16 High 1 240 31 25 Reverse 2 000 32 16 Drive system Shaft drive CHASSIS Front suspension Independent double wishbone coil spring oil damped Rear suspension Independent double wishbone coil spring oil damped Front wheel travel 180 mm 7 1 in Rear wheel travel 200 mm 7 9 in Caster 1 6 Trail 3 4 mm 0 13 in Toe out 12 mm 0 47 in Camber 0 64 Steering angle 46 right left Turning radius 3 1 m 10 2...

Page 524: ...ER BUSH Effective frame No From 5SAAL42A897104381 Do not apply grease to the inside of the stabilizer bushing FWD CHANGE CHANGE ADDITION 1 Rear suspention arm lower 4 Washer 2 Rear stabilizer joint A Rear stabilizer joint nut ITEM N m kgf m lb ft 3 Rear stabilizer A 60 6 0 43 5 Do not apply grease ...

Page 525: ...te tracer G B Green with Black tracer Gr R Gray with Red tracer Gr W Gray with White tracer O B Orange with Black tracer O Bl Orange with Blue tracer O G Orange with Green tracer O R Orange with Red tracer O W Orange with White tracer O Y Orange with Yellow tracer R B Red with Black tracer R G Red with Green tracer W B White with Black tracer W Bl White with Blue tracer W G White with Green tracer...

Page 526: ... Br Br R G B W Bl B Bl R W R W G B W W Bl W Gr W Y R B Bl B Br Dg G B B Br Y R W Y W Y Gr Gr B R B W B Bl B W Bl G B Y B B W R R B W B W B W Bl W Y Y Y Y Y Y Y Y Y B Bl Bl B Bl R W G B W R W Y Y Bl W Bl R B O O R O B Y G B Bl Y B O W Br Gr G B Bl Y Bl Y Bl Y B Y Y B W Y B W Y B W W Y B W W Y B W W Y B W W Y B W W Y B W W B W B W R B R R R B Bl R Bl R R R O O O O O O O O O O O O O O O O O O O O O O...

Page 527: ...r R G B W Bl B Bl R W R W G B W W Bl W Gr W Y R B Bl B Br Dg G B B Br Y R W Y W Y Gr Gr B R B W B Bl B W Bl G B Y B B W R R B W B W B W Bl W Y Y Y Y Y Y Y Y Y B Bl Bl B Bl R W G B W R W Y Y Bl W Bl R B O O R O B Y G B Bl Y B O W Br Gr G B Bl Y Bl Y Bl Y B Y Y B W Y B W Y B W W Y B W W Y B W W Y B W W Y B W W Y B W W O O G O O G G G O O O O O O O O O O O O B R O O O O O O O O O O O O B B B B W Bl W...

Page 528: ...W B R B Bl W Bl W Bl R R O O O O O Bl Gr O B R Bl R O B W Bl Br B G B Y B W G B O W Br Br R G B W Bl B Bl R W G B W W Bl W Gr W Y R B Bl B Br Dg G B B Br Y R W Y W Y Gr Gr B R B W B Bl B W Bl G B Y B B W R R B W B W B W Bl W Y Y Y Y Y Y Y Y Y B Bl Bl B Bl R W G B W R W Y Y Bl W Bl R B O O O R O B Y G B Bl O Y Y B O W Br Gr G B Bl Y Bl Y Bl Y Y Y Y B W W Y B W W Y B W W Y B W W Y B W W Y B W W B Y ...

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