Suzuki LT-F400 Owner'S Manual Download

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5-18

Washing the Element
Wash the element as follows:

1. Fill a wash pan larger than the

element with a non-flammable
cleaning solvent

. Dip the

element in the solvent and
wash it.

2. Squeeze the element by

pressing it between the palms
of both hands to remove
excess solvent. Do not twist or
wring the element, or it will
develop cracks.

3. Dry the element.
4. Put the element in a plastic

bag. Pour in some air filter oil

and work the oil into the ele-

ment.

5. Squeeze the element to

remove excess oil.

6. Clean any dirt or debris from

inside the air cleaner case. Be
sure no dirt enters the carbure-
tor.

7. Reinstall the cleaned element

in reverse order of removal. Be
sure that the element is
securely in position and is
properly sealed.

DRY

CAUTION

A torn air filter can damage
your ATV.

Dirt and dust may get inside
the engine if the element is
torn.

Carefully examine the element
for tears before and after clean-
ing it. Replace the element with
a new one if it is torn.

CORRECT

INCORRECT

www.quad-forum.sk

Summary of Contents for LT-F400

Page 1: ...ET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to ...

Page 2: ... resold or other wise transferred to a new owner or operator The manual con tains important safety information and instructions which should be read carefully before operating the vehicle This hang tag is not to be removed before sale This ATV is for RECREATIONAL or UTILITY USE NO OPERATOR UNDER AGE 16 OPERATOR ONLY NO PASSENGERS This category G GENERAL USE ATV is for off road use only for recreat...

Page 3: ...special informa tion to make maintenance easier or instructions clearer WARNINGs and CAUTIONs are arranged like this WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage WARNING or CAUTION This first part will identify a POTENTIAL HAZARD This second part will describe WHAT CAN HAPPEN if you ignore the WAR...

Page 4: ...ain with the vehicle when you sell it The next owner will need this manual also Store the owner s manual in the box under the seat Review the Tips and Practice Guide handbook supplied with this owner s manual owner s in U S A This spe cial handbook contains a vari ety of safety tips helpful hints and practice exercises that can increase your riding enjoyment and safety All information illustration...

Page 5: ...T SUZUKI MOTOR CORPORATION 2008 NOTICE TO OWNER S AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles dif ferently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precau tions SEVERE INJURY OR DEATH can result if you do not foll...

Page 6: ...ars and both feet on the footrests of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain condi tions when operating the ATV Never operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such ter rain Always be especially cau tious on th...

Page 7: ...a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper proce dures when operating over obstacles as described in this manual Always be careful when skid ding or sliding Learn to s...

Page 8: ... manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY owners in the USA can call the Consumer Product Safety Commission at 1 800 638 2772 or the ATV Distrib utors Safety Hotline at 1 800 852 5344 WARNING Indicates a potential hazard that could result in death or injury www quad forum sk ...

Page 9: ...ONTROLS EQUIPMENT AND ADJUSTMENTS RIDING YOUR ATV ACCESSORY USE AND VEHICLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING PREPARATION FOR WINTER RIDING TRANSPORTING CLEANING PROCEDURE AND STORAGE PROCEDURE CONSUMER INFORMATION SPECIFICATIONS INDEX www quad forum sk ...

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Page 11: ...1 1 1 FUEL AND OIL RECOMMENDATIONS FUEL 1 2 ENGINE OIL 1 3 FRONT DIFFERENTIAL GEAR OIL LT F400F AND FINAL GEAR OIL 1 4 www quad forum sk ...

Page 12: ...nol content is not greater than 10 Gasoline Methanol Fuels containing 5 or less meth anol wood alcohol may be suit able for use in your ATV if they contain co solvents and corro sion inhibitors DO NOT USE fuels containing more than 5 methanol under any circumstances Fuel system damage or ATV performance problems resulting from the use of such fuels are not the responsibil ity of Suzuki and may not...

Page 13: ...select good quality engine oil Suzuki recommends the use of SUZUKI PERFOR MANCE 4 MOTOR OIL or equiva lent engine oil Use oil with an API American Petroleum Institute classification of SF SG or SH SJ or with a JASO classification of MA API American Petroleum Institute JASO Japanese Automobile Standards Organization SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W 40 engine oil If SAE ...

Page 14: ...erving Suzuki does not recommend the use of ENERGY CONSERVING oils Some engine oils which have an API classification of SH or higher have an ENERGY CON SERVING indication in the API classification doughnut mark These oils can affect engine life and clutch performance Not recommended Recommended FRONT DIFFERENTIAL GEAR OIL LT F400F AND FINAL GEAR OIL Use a SAE 90 hypoid gear oil which is rated GL 5...

Page 15: ...OMETER AND INDICATOR LIGHTS 2 7 RANGE LEVER 2 8 SELECTION LEVER LT F400F 2 9 GEARSHIFT LEVER 2 10 LEFT HANDLEBAR 2 10 RIGHT HANDLEBAR 2 13 THROTTLE LIMITER 2 14 REAR BRAKE PEDAL 2 14 FUEL VALVE 2 15 RECOIL STARTER 2 16 FUEL TANK CAP 2 16 SEAT LOCK 2 18 FLAG BRACKET 2 18 BOX 2 19 www quad forum sk ...

Page 16: ...S 1Rear brake lever 2Left handlebar switches 3Choke lever 4Speedometer and indicator lights 5Selection lever LT F400F 6Front brake fluid reservoir 7Front brake lever 8Range lever 9Fuel tank cap 0Fuel gauge AIgnition switch BThrottle lever www quad forum sk ...

Page 17: ...2 3 CFuel valve DBox ESeat lock FRecoil starter GGearshift lever HFootrests www quad forum sk ...

Page 18: ...2 4 IRear brake pedal www quad forum sk ...

Page 19: ...ce An identifying number is stamped on the keys Use this number when making a replace ment key Please write down your key num ber in the box provided for your future reference WARNING Indicates a potential hazard that could result in injury or death Key No www quad forum sk ...

Page 20: ...be removed in this posi tion LIGHTS position The ignition circuit is on and the headlight and taillight turn on The key cannot be removed in this position CAUTION Leaving the ignition switch in the position for a long time can damage the ATV s bat tery The battery will run down if the lights are no for a long time when the engine is not run ning Always leave the ignition switch in the OFF position...

Page 21: ...l come on if the engine oil gets too hot The light will come on during starting to check bulb operation The light should be off during normal oper ation NOTE High engine speed low vehi cle speeds or heavy load can increase engine oil tempera ture Decrease engine speed reduce load and select an appropriate transmission gear to lower the temperature Debris or mud in front of the engine or packed bet...

Page 22: ... NOTE The gearshift lever can be operated in L and H range Select proper gear position with range lever and gearshift lever WARNING Operating the range lever when the ATV is moving can be haz ardous If you shift into reverse gear when the LT F400 F is moving it could stop suddenly throw ing you from the ATV If you shift from high range to low range when the LT F400 F is moving it could reduce spee...

Page 23: ... right front wheel and left front wheel can turn at different speeds This position provides more traction than 2WD and should be used for riding on slip pery surfaces To shift the selection lever 1 Stop the vehicle completely 2 Move the selection lever to the desired position 2WD 4WD WARNING Shifting the selection lever when the ATV is moving can be hazardous Removing a hand while riding can lose ...

Page 24: ... impossible to upshift or downshift more than one gear at a time LEFT HANDLEBAR Rear Brake Lever 1 Apply the rear brake by squeezing the rear brake lever towards the grip Parking Brake Lock 2 Use this lock to set and lock the parking brake Use the parking brake to help prevent the LT F400 F from moving when it is parked being started or at idle To lock the parking brake squeeze the rear brake leve...

Page 25: ...r dimmer switch opera tion can damage the ATV Holding the dimmer switch between and posi tion will light both and headlight beam This operation can damage the ATV Use the dimmer switch only at or position CAUTION Sticking some tape or placing objects in front of the headlight can damage the headlight Sticking some tape or placing objects in front of the headlight can obstruct headlight heat radiat...

Page 26: ...tral Push the electric starter button to start the engine NOTE The engine can be started in any gear if it is hard to shift into neutral by squeezing the rear brake lever fully you will hear the starter interlock switch click CAUTION Engaging the starter motor for more than five seconds at a time can damage the ATV The starter motor and wiring harness may overheat If the engine does not start afte...

Page 27: ...e is warm you do not need to use the choke system for starting NOTE Refer to the RIDING YOUR ATV section of the manual for the engine starting procedure RIGHT HANDLEBAR Front Brake Lever 1 Apply the front brake by squeez ing the front brake lever towards the grip Throttle Lever 2 Control the engine speed with the position of the throttle lever Oper ate this lever with your thumb Push it forward to...

Page 28: ...To adjust the throttle limiter 1 Loosen the lock nut 1 2 Turn the throttle limiter screw 2 clockwise to restrict maxi mum engine power or counter clockwise to increase the maximum engine power 3 Tighten the lock nut 1 REAR BRAKE PEDAL Pressing the rear brake pedal will apply the rear brake NOTE The rear brake may also be applied by squeezing the rear brake lever www quad forum sk ...

Page 29: ...e fuel valve to the car buretor unless the engine is run ning or being started Reserve fuel supply 2 9 L 0 8 US gal PRI PRIME Position In this position fuel can flow from the fuel valve to the carbureter This position is used for checking the fuel supply system Turn the fuel valve to the PRI position when the engine is hard to start below freezing point ON RES WARNING Leaving the fuel valve in the...

Page 30: ...its nor mal position NOTE The engine can be started in any gear if it is hard to shift into neutral by squeezing the rear brake lever fully you will hear the starter interlock switch click Switch off the headlight when starting the engine with the recoil starter FUEL TANK CAP To open the fuel tank cap remove the end of the vent tube from the vehicle body Turn the fuel tank cap counterclockwise To ...

Page 31: ...t expands Fuel expands due to engine heat or heating by the sun Fuel that overflows can catch fire Stop adding fuel when the fuel level reaches the bottom of the filler neck WARNING Improper fueling of the ATV can be hazardous Failure to follow safety precau tions when refueling could result in a fire or cause you to breathe toxic fumes Refuel in a well ventilated area Make sure the engine is off ...

Page 32: ...eat hook retainer and push down firmly FLAG BRACKET A bracket is provided so you can mount a flag on your LT F400 F WARNING Improperly installing the seat can be hazardous Failure to install the seat prop erly could allow the seat to move and cause loss of rider control Make sure to properly position and securely attach the seat when you install it www quad forum sk ...

Page 33: ... wind breaker can be placed in the box NOTE The box can get very hot since the heated engine is under the box Do not keep any flamma ble items low heat resistant items foods or drink in the box Do not keep valuable items in the box when leaving the vehi cle unattended www quad forum sk ...

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Page 35: ... 3 4 WHAT TO WEAR 3 6 BREAK IN 3 7 STARTING THE ENGINE 3 8 STARTING OFF AND SHIFTING 3 10 BRAKING 3 15 TURNING 3 16 SKIDDING OR SLIDING 3 17 OPERATION ON HILLS 3 18 RIDING OVER OBSTACLES 3 23 RIDING THROUGH WATER 3 24 RIDING IN COLD WEATHER 3 25 RIDING IN REVERSE 3 29 www quad forum sk ...

Page 36: ... haz ardous Your risk of having an accident greatly increases if you do not know how to operate the ATV properly in different situations and on different types of ter rain Beginning and inexperienced operators should complete the certified training course offered by Suzuki You should regularly practice the skills learned in the course and the operating techniques described in this owner s man ual ...

Page 37: ...od place to practice review the controls on your ATV before riding Learn to find these controls without looking for them You will not have time to look for them when you are riding WARNING Operation of this ATV by chil dren under age 16 can be haz ardous Use by children under age 16 can lead to their severe injury or death Children under age 16 may not have the size strength skills or judgment nee...

Page 38: ... sure can be hazardous If you use improper tires or improper or uneven tire pres sure you may lose control of the ATV This will increase your risk of an accident Always use tire of the size and type specified in this owner s manual Always maintain proper tire pressure as described in the INSPECTION AND MAINTENANCE section WARNING Operating this ATV with improper modifications can be hazardous Impr...

Page 39: ...nance checks except when checking the light engine stop switch and throttle WHAT TO CHECK CHECK FOR Steering 1 Smoothness 2 No restriction of movement 3 No play or looseness Brakes 1 Fluid level in the reservoir to be above LOWER line 2 No fluid leakage or damage 3 Proper pedal and lever play 4 No sponginess 5 Parking brake effectiveness Tire 1 Proper pressure 2 Enough tread depth 3 No cracks rips...

Page 40: ...pair of gloves strong boots that fit over the ankle long pants and a long sleeve shirt WARNING Operating this ATV without wearing an approved motorcy cle helmet eye protection and protective clothing can be haz ardous Operating without an approved motorcycle helmet or eye pro tection increases your chances of a severe head injury or death in the event of an accident Operating without protective cl...

Page 41: ...aze and not seat prop erly Allow the engine to acceler ate freely through the gears without exceeding the maximum recommended throttle opening Allow the Engine Oil to Circulate Before Riding Allow enough idling time after warm or cold engine starting before revving the engine or plac ing the transmission in gear This allows time for the lubricating oil to reach all critical engine compo nents Obse...

Page 42: ... is Cold If the ambient temperature is below 5 C 40 F 1 Move the choke lever to the ENGAGE position 2 Push the electric starter button or use the recoil starter as described above to start the engine 3 Immediately after the engine starts return the choke lever halfway 4 When the engine is sufficiently warmed up move the choke lever to the OFF position NOTE If the ATV is used under extremely cold c...

Page 43: ...f the choke is not necessary to start the engine Operation of the choke can make the engine hard to start due to too rich fuel air mixture WARNING Leaving the fuel valve in the PRI position when the engine is off can be hazardous The carburetor may overflow and fuel may run into the engine This can cause a fire or cause severe damage to the ATV when you start the engine Always leave the fuel valve...

Page 44: ... so you can change position to maneuver the ATV It is not for carrying passengers WARNING Operating this ATV on paved surfaces including sidewalks paths parking lots driveways and streets can be hazardous ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control Avoid operating the ATV on paved surface...

Page 45: ...WARNING Operating this ATV at exces sive speeds can be hazardous Riding at excessive speeds increases your chances of los ing control of the ATV which can result in an accident Always go at a speed that is proper for the terrain visibility and operating conditions your skills and experience WARNING Attempting wheelies jumps and other stunts can be haz ardous Stunt riding increases the chance of an...

Page 46: ...injure you or cause an accident Always keep both hands on the handlebars and both feet on the foot pegs of your ATV dur ing operation WARNING Failure to use extra care when operating on excessively rough slippery or loose terrain can be hazardous Failure to use extra care can cause loss of traction or vehi cle control This could result in an accident including an over turn Do not operate under the...

Page 47: ...fting sequence Reduce vehicle speed before shifting down To shift down release the throttle and shift down to engage a lower gear WARNING Failure to use extra care when operating this ATV on unfamil iar terrain can be hazardous You can come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to over turn or go out of control Go slowly and be extra careful when op...

Page 48: ...ning the throttle suddenly can be hazardous The front wheels can lift off the ground and cause loss of con trol of the ATV Always open the throttle gradu ally when you accelerate WARNING Shifting incorrectly can be haz ardous Downshifting at too high of a speed can cause sudden slow ing and may pitch the rider for ward Also engine and drivetrain damage can occur if you do not shift correctly Slow ...

Page 49: ...f control if you brake too hard Apply the brakes lightly and with care on slippery surfaces WARNING Operating the parking brake lock when the ATV is moving can be hazardous The rear wheels can lock caus ing a skid and an accident Use the parking brake only after you stop the ATV WARNING Braking on hills can be hazard ous As the LT F400F is four wheel drive using either the front brake alone or the...

Page 50: ... the handlebars while looking in the direction of the turn For HIGHER SPEEDS or SHARPER TURNS Use the same technique that you use for turning at low speeds but move your body weight farther toward the inside of the turn to maintain your balance Natural turning forces which can push the vehicle to the outside of the turn increase as speed or turn sharpness increases This means you must lean your bo...

Page 51: ...kid Shift your body weight away from the skid slightly Avoid using the throttle or brakes until you regain directional control of the vehicle WARNING Skidding or sliding improperly can be hazardous You may lose control of your ATV or regain traction unex pectedly which may cause the ATV to overturn Learn to safely control skid ding or sliding by practicing at low speeds and on level smooth terrain...

Page 52: ...rdous Climbing hills improperly can cause loss of control or cause the ATV to overturn Always follow the proper pro cedures for climbing hills as described in this section Always check the terrain carefully before you start up any hill Never climb hills with exces sively slippery or loose sur faces Shift your weight forward Never open the throttle sud denly or make sudden gear changes The ATV coul...

Page 53: ...top of the hill WARNING Braking on hills can be hazard ous As the LT F400F is four wheel drive using either the front brake alone or the rear brake alone will actually brake all four wheels Therefore any applica tion of the brakes will result in braking force being applied to the downhill wheels This could cause the vehicle to overturn Be extra careful when braking on a hill WARNING Stalling rolli...

Page 54: ...e and dis mount to the left side while still leaning uphill 5 Use one of the following proce dures to turn the vehicle around a If you are able to drag the rear end of the LT F400 F around until the vehicle points downhill Stay on the uphill side of the vehicle while dragging it around b Turn the handlebars fully to the left Stand on the uphill side of the vehicle Release the parking brake and pum...

Page 55: ...lls as described in this section OK WARNING Braking on hills can be hazard ous As the LT F400 F is four wheel drive using either the front brake alone or the rear brake alone will actually brake all four wheels Therefore any applica tion of the brakes will result in braking force being applied to the downhill wheels This could cause the vehicle to overturn Be extra careful when braking on a hill w...

Page 56: ...gle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Traversing a Slope When traversing a slope you should 1 Lean your body uphill 2 Steer slightly uphill if neces sary to maintain a straight course WARNING Crossing hills or turning on hills improperly can be hazard ous Crossing hills or turning on hills improperly can cause loss of control or cause...

Page 57: ...le after the front wheels have cleared the obstacle 5 Return to your normal riding position after the rear wheels clear the obstacle Remember that some obstacles are too high for your ATV or for your abilities If you are not sure that you can safely cross over an obstacle back up and ride around the obstacle WARNING Improperly operating this ATV over obstacles can be hazard ous Improperly crossing...

Page 58: ... WARNING Operating this ATV through deep or fast flowing water can be hazardous The ATV tires may float caus ing loss of traction and loss of control This could lead to an accident Never operate this ATV in fast flowing water or in water deeper than described in this section Remember that wet brakes may have reduced stopping ability Test your brakes after leaving the water If neces sary apply them...

Page 59: ... ground and do not exceed walking speed Be sure to check the operation of both front and rear brakes If the brakes do not work adequately stop riding the ATV Bring the ATV to a warmer area to allow the brakes to thaw out After the brakes thaw dry them by applying them sev eral times while riding slowly If the brakes do not regain full stop ping power have your local Suzuki dealer check them before...

Page 60: ...tures can also lead to hypoth ermia Hypothermia occurs when your body s inner temperature drops Symptoms include numb ness in the extremities hands feet arms and legs and shiver ing Damp clothing contributes to hypothermia because cold water on your skin will drain heat from your body s core WARNING Operating the ATV without a properly functioning brake sys tem can be hazardous Wet or frozen brake...

Page 61: ... your ATV can be hazard ous Loose clothing such as a long scarf or shawl can get caught in an ATV s moving parts Never wear loose clothing when riding your ATV WARNING Riding on snow covered terrain without care can be hazardous The snow may be covering rocks holes ice or other haz ards that can cause a loss of control Severe injury or death could occur if you lose control of the ATV Go slowly and...

Page 62: ...ight reach ing your eyes Always use clear eye protection when riding at night On overcast days you may find it helpful to use yellow tinted eye protection WARNING Failure to use extra care when operating on slippery surfaces such as hard packed snow and ice can be hazardous Failure to use extra care can cause loss of traction or loss of vehicle control This could result in an accident including an...

Page 63: ...his ATV in reverse can be hazardous You could hit an obstacle or person behind you resulting in injury When you select reverse gear make sure there are no obsta cles or people behind When it is safe back up slowly WARNING Sudden application of the throttle or making abrupt turns in reverse gear can be hazard ous Throttle surges or abrupt turns could cause you to lose control of the ATV When you ri...

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Page 65: ...4 1 4 ACCESSORY USE AND VEHICLE LOADING ATV WINCH LEAD WIRES 4 4 www quad forum sk ...

Page 66: ...install them correctly The guidelines below should help you decide how to equip your ATV and how to use it correctly when you use accessories or carry cargo WARNING Operating this ATV with improper modifications can be hazardous Improper installation of acces sories or modification of the vehicle may cause changes in handling which could lead to an accident Never modify the ATV with improper insta...

Page 67: ...ls or other equipment 5 Do not carry heavy or bulky cargo Cargo racks are designed to carry light items 6 Distribute cargo weight evenly between the front and rear of the vehicle as well as both sides of the vehicle Locate cargo weight as close to the center of the vehicle as possi ble e g load cargo to the rear of front racks and to the front of rear racks Do not let cargo stick out beyond the ed...

Page 68: ...that can be used to attach a Suzuki genuine acces sory ATV winch rated line pull 1360 kg 3000 lbs The part num ber of the Suzuki ATV winch for this vehicle is 99000 990YW 016 Consult your Suzuki dealer for details about attaching the acces sory ATV winch www quad forum sk ...

Page 69: ...EL HOSE 5 10 ENGINE OIL 5 11 AIR CLEANER 5 16 AIR CLEANER DRAIN TUBE 5 19 GEAR OIL CHANGE 5 20 TIRES 5 21 BRAKES 5 24 FRONT BRAKE 5 25 REAR BRAKE 5 28 REAR BRAKE LINING WEAR LIMIT 5 30 FRONT AND REAR WHEEL REMOVAL 5 31 SPARK ARRESTER 5 32 DRIVE SHAFT BOOTS LT F400F 5 33 LIGHT BULB REPLACEMENT 5 33 FUSE 5 35 OUTPUT TERMINAL 5 36 GENERAL LUBRICATION 5 37 TRAILER TOWING 5 38 www quad forum sk ...

Page 70: ...ths Initial 1 Every 3 Every 6 Air cleaner element C C Exhaust pipe nuts and muffler mounting bolts T T T Valve clearance I I Spark plug I Replace every 6000 km 4000 miles Spark arrester C Fuel hose I I Replace every 4 years Engine oil and oil filter R R Front differential gear oil LT F400F Final gear oil I Replace every 2 years Throttle cable play I I I Idle speed I I I Clutch I Drive shaft boots ...

Page 71: ...H HAS BEEN CERTI FIED UNDER THE PROVI SIONS IN THE CLEAN AIR ACT Sec 207 a 2 WARNING Improper maintenance or fail ure to perform recommended maintenance can be hazard ous If you perform improper main tenance or do not maintain your ATV you may have an accident Keep your ATV in good condi tion Ask your Suzuki dealer or a qualified mechanic to do the maintenance items marked with an asterisk You may...

Page 72: ...areas These conditions can cause the ATV to wear more quickly Perform maintenance more often than shown in the chart If you have any questions regarding maintenance inter vals consult your Suzuki dealer CAUTION Using poor quality replacement parts can damage your ATV Poorly made replacement parts can cause your ATV to wear more quickly and may shorten its useful life When replacing parts on your v...

Page 73: ...dically To remove the battery loosen the bolts 1 and remove the bracket 2 If the battery is discharged recharge the battery The stan dard charging rate is 1 4A 5 to 10hr and the maximum charging rate is 6 0A 1hr WARNING Battery posts terminals and related accessories contain lead and lead compounds which can be hazardous When working near the battery you can come in contact with lead and lead comp...

Page 74: ...ximum charging rate for the ATV bat tery can damage your ATV If you charge the battery at a rate too high it will decrease the life of the battery Never exceed the maximum charging rate CAUTION Reversing the battery lead wires can harm your ATV Reversing the battery lead wires can damage the charging system and the battery The red lead must go to the positive terminal and the black or black with w...

Page 75: ...ight brown color indicates that the plug is correct A white or dark insulator indicates that the engine may need adjustment or another plug type may be needed Consult your Suzuki dealer if your plug insulator is not a light brown color CAUTION Failure to use the proper spark plug can be hazardous An improper spark plug may have an incorrect fit or heat range for your engine This may cause severe e...

Page 76: ... If the standard plug tends to run hot CAUTION Improper installation of the spark plug can damage your ATV An overly tight or cross threaded plug will damage the aluminum threads of the cylin der head Carefully turn the spark plug by hand into the threads If the spark plug is new tighten it with a wrench about 1 2 turn past finger tight If you are reusing the old spark plug tighten it with a wrenc...

Page 77: ... not within the specified limits 6 Replace the boot WARNING Improper adjustment of the idle speed can be hazardous An idle that is too high can cause the ATV to lurch forward when you shift to first gear This may cause an accident Excessive engine wear may also result if idle speed is adjusted improperly or when the engine is not fully warmed up Adjust the idle to the correct speed Make sure the e...

Page 78: ...he proper amount of outer cable free play 0 5 1 0 mm 0 02 0 04 in Measure choke cable free play by pull ing on the outer cable 4 After adjusting the play tighten the lock nut 1 5 Replace the boot FUEL HOSE Replace the fuel hose every 4 years even if it appears to be in good condition Damage from aging may not always be visible www quad forum sk ...

Page 79: ...es out together with the oil filler cap as shown The level found in the dipstick should be between L Low and F Full lines The oil level inspection should be performed under the following conditions Park the vehicle on level ground The oil filler cap threads are not run in but touching the filler hole upper edge F L CAUTION Operating the vehicle with an incorrect amount of oil can damage your ATV T...

Page 80: ...z ardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals Brief con tact with used oil may irritate skin Keep new and used oil and used oil filters away from chil dren and pets To minimize your exposure to used oil wear a long sleeve shirt and mois ture proof gloves such as dishwashing gl...

Page 81: ...ove the left inner cover 3 Available from Suzuki dealer Oil filter wrench Part No 09915 40610 5 Turn the oil filter 4 counter clockwise with a Suzuki cap type oil filter wrench or a strap type filter wrench of the proper size www quad forum sk ...

Page 82: ...rface a small resistance will be felt NOTE To tighten the oil filter properly it is important to accu rately identify the position at which the filter gasket first con tacts the mounting surface CAUTION Failure to use the correct oil fil ter can damage your ATV Engine damage may occur if you use oil filter with the wrong design or thread specifica tions Be sure to use a genuine SUZUKI oil filter o...

Page 83: ...minutes 12 Turn the engine off and wait for three minutes Recheck the oil level with the engine oil dip stick The oil level should be at the F full mark If it is lower than the F mark add oil until it reaches the F mark Inspect the area around the drain plug and oil filter for leaks Mark top dead center Oil filter wrench In the position at which the filter gasket first contacts the mounting surfac...

Page 84: ...without the air cleaner element to stop it Severe engine dam age can also occur if dirt enters the engine due to run ning the engine without the air cleaner element Never run the engine without the air cleaner element in place WARNING Indicates a potential hazard that could result in injury or death CAUTION Failure to inspect the air cleaner element frequently if the vehicle is used in dusty wet o...

Page 85: ...t 1 Remove the seat 2 Remove the fastener Unhook the hooks and take off the air cleaner case cover 1 3 Remove the screw 2 then remove the element assembly 3 4 Pull out the foam element from the element frame www quad forum sk ...

Page 86: ...me air filter oil B and work the oil into the ele ment 5 Squeeze the element to remove excess oil 6 Clean any dirt or debris from inside the air cleaner case Be sure no dirt enters the carbure tor 7 Reinstall the cleaned element in reverse order of removal Be sure that the element is securely in position and is properly sealed DRY CAUTION A torn air filter can damage your ATV Dirt and dust may get...

Page 87: ...ent away from children and pets Dispose of used oil and solvent properly CAUTION Failure to position the air cleaner element properly can damage your ATV Air can bypass the air cleaner element if the element is not positioned properly This will cause the engine parts to wear more rapidly Be sure to position the air cleaner element properly WARNING Failure to properly dispose of the drained oil or ...

Page 88: ...cle on level ground 2 Remove the cover under the gear case 3 Remove the oil filler cap 1 for the front differential gear or the filler cap 3 for the final gear Front differential gear oil LT F400F Final gear oil 4 Remove the drain plug 4 or 5 from the bottom of the gear case and drain the oil into a drain pan 5 Reinstall the drain plug and tighten it securely after all the oil has been drained out...

Page 89: ...ear a long sleeve shirt and moisture proof gloves such as dishwashing gloves when changing oil If oil con tacts your skin wash thor oughly with soap and water Launder any clothing or rags if wet with oil Recycle or prop erly dispose of used oil Front Rear Size AT25 8 12 AT25 10 12 Type MAXXIS M913S MAXXIS M909S WARNING Operating this ATV with improper tires or with improper or uneven tire pres sur...

Page 90: ...ading measurements can result WARNING The use of very worn tires can be hazardous The traction of the vehicle will be decreased with worn tires This increases your risk of hav ing an accident Replace the front and rear tires when the depth on the tread is 4 0 mm 0 16 in or less 4 0 mm 0 16 in LOAD TIRE PRESSURE FRONT REAR Up to 172 kg 380 lbs 32 5 kPa 0 325 kgf cm2 4 7 psi 30 kPa 0 30 kgf cm2 4 4 ...

Page 91: ...el surface or the tire bead Tubeless Tire Repair Should a leak or flat tire occur due to a puncture the tire may be repaired using a plug type patch If the damage is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operating your LT F400 F in areas where trans portation or service facilities are not readily available it is strongly recommended that you...

Page 92: ...hicle according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTE NANCE SCHEDULE WARNING Operating the ATV in harsh conditions can be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your vehicle under these conditions the ...

Page 93: ...us to animals Keep out of the reach of chil dren and animals WARNING Failure to use proper brake fluid can be hazardous The use of any fluid except DOT4 brake fluid from a sealed container can damage the brake system and lead to an accident Use only DOT4 brake fluid from a sealed container Never use or mix with different types of brake fluid WARNING Failure to keep the brake fluid reservoir full c...

Page 94: ...ake fluid can damage your ATV Brake fluid can damage painted surfaces and plastic parts Be careful not to spill any fluid when filling the brake fluid res ervoir Wipe spilled fluid up immediately WARNING Failure to maintain the brake pads and replace them when recommended can be hazard ous Riding with unevenly worn brake pads will increase your chances of having an accident If you need to replace ...

Page 95: ...u can not get enough braking perfor mance and may result in an accident Pump the brake lever several times until brake pads are pressed against the brake disks and proper lever stroke and firm feel are restored WARNING Replacing only one of the two brake pads can be hazardous Replacing only one brake pad can result in uneven braking action Replace both pads together www quad forum sk ...

Page 96: ... of free travel WARNING Misadjusting the rear brake pedal and lever can be hazard ous The rear brake lever and brake pedal operate the rear brake in a complementary manner When one of these is misad justed the brake system as a whole will not operate properly Misadjusting the rear brake lever and brake pedal can cause brake dragging or inade quate braking performance Adjust both the brake pedal an...

Page 97: ... 5 After adjusting the play check that the rear wheels roll freely with the brake disengaged the transmission in neutral and the rear wheels off the ground 6 Set the parking brake and check that the rear wheels are locked by trying to move the vehicle back and forth while it is in neutral 7 Readjust the rear brake lever adjusting nut if the rear wheels could not roll freely in step 5 or if the rea...

Page 98: ...n the range Fig A 3 If the extension line is beyond the range Fig B have the brake shoes replaced by your Suzuki dealer to insure safe operation Range Index mark Fig A Fig B WARNING Failure to check brake lining wear and replace brake shoes as recommended can be haz ardous Riding with worn brake shoes or brake shoes that are unevenly worn will increase your chances of having an accident Inspect br...

Page 99: ...ning torque chart to determine the tightness of the wheel nuts Tighten the nuts in a cross wise pattern Tightening Torque FRONT 60 N m 6 0 kgf m 43 lb ft REAR 60 N m 6 0 kgf m 43 lb ft WARNING Failure to tighten the wheel nuts to the specified torque can be hazardous If the wheel nuts are not prop erly tightened the wheel can come off causing an accident Be sure to tighten the wheel nuts to the sp...

Page 100: ...ll out the spark arrester 2 2 Use a brush to remove carbon deposits from the spark arrester screen Be careful not to damage the spark arrester screen Check that the screen has no holes or tears Replace the screen if necessary 3 Reinstall the spark arrester in reverse order of removal WARNING A hot muffler can harm you You can be burned if you touch the hot muffler Wait until the muffler cools to a...

Page 101: ... is shown in the following chart When replacing a burned out bulb always use the same watt age rating Headlight 12V 35 35W HS1 2 Brake light Taillight 12V 21 5W CAUTION Failure to use a light bulb with the correct wattage rating can damage your ATV The electrical system can over load or the bulb may burn out sooner Use only the light bulbs shown in the chart as replacement bulbs www quad forum sk ...

Page 102: ...lder spring 4 and pull out the bulb 5 5 To replace the headlight bulb reverse the above sequence CAUTION Touching the headlight bulb glass with a bare hand may damage the bulb The bulb s life may be short ened by oil from your fingers if you touch it When replacing the headlight bulb be careful not to touch the glass Grasp the new bulb with a clean cloth www quad forum sk ...

Page 103: ...and turn it to the right while pushing in FUSE The main fuse is located under the seat One 30A spare fuse is located inside the fuse box cover The fuses are located under the seat 10A spare fuses are pro vided inside the fuse box The fuses are designed to open when a circuit overload exists in individual electrical system cir cuits If any electrical system fails to operate then the fuses must be c...

Page 104: ...essory wattage should be less than 120W Check electrical accessory voltage and wattage before attaching accessories to the out put terminal CAUTION Failure to install the correct fuse can damage your ATV Installing a fuse of incorrect rating or using aluminum foil or wire instead of a fuse may seri ously damage the electrical system Always replace a blown fuse with a fuse of the same type and rati...

Page 105: ...TE NANCE CHART He she will lubricate things such as wheel bearings rear axle housings swing arm bearings steering shaft holder odometer cable choke cable etc Motor oil Grease 1 Brake lever holder 2 Throttle lever 3 Steering shaft holder 4 Brake pedal 5 Brake cam 6 Rear axle spline 7 Drive shaft spline LT F400F CAUTION Lubricating switches can dam age your ATV Lubricating switches can dam age the s...

Page 106: ...nd trailer properly you must know how to measure Gross Trailer Weight and Trailer Tongue Weight Gross Trailer Weight is the weight of the trailer plus cargo in it You can measure Gross Trailer Weight by putting each wheel of the fully loaded trailer on a bathroom scale Add the weights shown on the scales Tongue Weight is the downward force exerted on the hitch by the trailer coupler when the trail...

Page 107: ...ur trailer can be hazard ous Improper cargo distribution can affect the handling of the ATV Always make sure that Trailer Tongue Weight is about 10 of Gross Trailer Weight WARNING Allowing cargo to shift in a trailer while moving can be hazardous Cargo weight shifting while moving can affect your ability to handle the ATV safely Make sure that the load in your trailer is properly secured and will ...

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Page 109: ...6 1 6 TROUBLESHOOTING FUEL SYSTEM CHECK 6 2 IGNITION SYSTEM CHECK 6 3 www quad forum sk ...

Page 110: ...in the fuel from the carburetor into a container CAUTION Failure to troubleshoot a prob lem correctly can damage your ATV Improper repairs or adjust ments may damage the vehicle instead of fixing it Such dam age may not be covered under warranty If you are not sure about the proper action consult your Suzuki dealer about the prob lem WARNING Draining fuel from the carbure tor can be hazardous Fuel...

Page 111: ...there is no spark take your machine to your authorized Suzuki dealer COMPLAINT Engine stalls 1 Make sure there is enough fuel in the fuel tank 2 Check to see that the spark plug is not fouled Remove the plug and clean it Replace it if necessary 3 Make sure the fuel valve is not clogged Also check to be sure the air vent hose connected to the fuel tank is not clogged 4 Check the engine idle speed I...

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Page 113: ...7 1 7 PREPARATION FOR WINTER RIDING ENGINE OIL CHANGE 7 2 www quad forum sk ...

Page 114: ...he right oil for cold weather according to the chart in the FUEL AND OIL REC OMMENDATIONS section ENGINE OIL CHANGE Dirt and dust in the oil will affect engine performance especially when the weather is cold Change the engine oil before using your ATV in cold weather below freez ing even if the oil that is in the engine is the right type for colder temperatures www quad forum sk ...

Page 115: ...8 1 8 TRANSPORTING TRANSPORTING 8 2 www quad forum sk ...

Page 116: ...rburetor into an empty container by loosening the carburetor drain screw 3 When the fuel has drained retighten the drain screw CAUTION Failure to properly secure the ATV when transporting it can be hazardous Failure to properly secure the vehicle may result in an acci dent or damage to the vehicle When transporting the LT F400 F lock the parking brake lever and tie down the vehicle securely with s...

Page 117: ...ire if you do not handle it properly When draining the carburetor always shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks Do not spill the fuel or you may create a fire hazard Dispose of drained fuel properly www quad forum sk ...

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Page 119: ...OCEDURE AND STORAGE PROCEDURE PREPARATION FOR CLEANING 9 2 WASHING YOUR ATV 9 3 INSPECTION AFTER CLEANING 9 4 STORAGE PROCEDURE 9 4 MAINTENANCE DURING STORAGE 9 5 PROCEDURE FOR RETURNING TO SERVICE 9 5 www quad forum sk ...

Page 120: ...tem can reduce engine cooling conceal damage or increase wear of cer tain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the ATV before any mud dries on the ATV Block or seal the end or the exhaust pipe muffler using a piece of plastic wrap cloth rag or another method to prevent water from entering the engine CAUTION High pressure washers can damage your A...

Page 121: ...move all dirt and debris without excessive water pressure even at remote areas such as linkages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plas tic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth CAUTION Improper cleaning can damage the oil cooler Oil c...

Page 122: ...ne for storage yourself follow the general guidelines below VEHICLE Place the vehicle on level ground and wash the entire vehicle FUEL Drain the fuel from the fuel tank using a hand pump or siphon Drain the fuel from the carburetor using the carburetor drain screw WARNING Operating the ATV with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could l...

Page 123: ...er protectant Spray unpainted surfaces with rust preventative Coat painted surfaces with car wax MAINTENANCE DURING STORAGE Once a month recharge the bat tery The standard charging rate is 1 4A 5 to 10hr PROCEDURE FOR RETURNING TO SERVICE Clean the entire vehicle Drain all the engine oil Install a new oil filter and fill the engine with fresh oil as out lined in this manual Remove the spark plug T...

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Page 125: ...10 10 1 CONSUMER INFORMATION EMISSION CONTROL WARRANTY 10 2 SERIAL NUMBER LOCATION 10 2 LOCATION OF LABELS 10 3 www quad forum sk ...

Page 126: ...th your ATV New ATV Limited Warranty ATV Federal Emission Control System Limited Warranty SERIAL NUMBER LOCATION You need to know the frame and engine serial numbers to get title documents for your ATV You also need these numbers to help your dealer when you order parts The frame number 1 is stamped on the left side of the frame The engine serial number 2 is stamped on the left side of the crankca...

Page 127: ...o n AT V NEVER tow from cargo rack MAXIMUM CARGO CAPACITY 66lbs 30kg WARNING WARNING Failure to stop vehicle completely before doing the following could result in your being thrown from the ATV To engage reverse To engage Hi Lo range Stop vehicle completely Bring engine to idle Operate range lever while applying brake Stop vehicle completely Shift transmission to neutral Bring engine to idle Apply...

Page 128: ...D R U G S O R A L C O H O L without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may...

Page 129: ... trailer Read owner s manual for details Trailer Tongue Weight should be about 10 of the Gross Trailer Weight and should not exceed 45 kg 99 lbs MAXIMUMTOWING CAPACITY 450 kg 992 lbs The owner smanualcontainsimportantsafety information and instructionswhichshouldbe read carefullybeforeoperatingthevehicle If the vehicle has been resold obtain the owner s manual from the previous owner or contact yo...

Page 130: ...ratio 9 0 1 Carburetor KEIHIN CVK32 single Air cleaner Polyurethane foam element Starter system Electric and recoil starter Lubrication system Wet sump DRIVE TRAIN Clutch Wet multi plate automatic centrifugal type Transmission 5 speed forward constant mesh Transfer 2 speed forward with reverse Gearshift pattern All up foot lever operated Primary reduction ratio 2 392 67 28 Secondary reduction 1 13...

Page 131: ... 12 Tubeless ELECTRICAL Ignition type Electronic ignition CDI Spark plug NGK CR7E or DENSO U22ESR N Battery 12V 43 2 kC 12Ah 10HR Fuse 30 10 10 10 10 10 10A Generator Three phase A C generator Headlight 12V 35 35W HS1 2 Brake Taillight 12V 21 5W Speedometer light 12V 1 7W Oil temperature indicator light 12V 3 4W Neutral indicator light 12V 3 4W Reverse indicator light 12V 3 4W CAPACITIES Fuel tank...

Page 132: ...INE OIL CHANGE 7 2 F FLAG BRACKET 2 18 FRONT AND REAR WHEEL REMOVAL 5 31 FRONT BRAKE 5 25 FRONT DIFFERENTIAL GEAR OIL LT F400F AND FINAL GEAR OIL 1 4 FUEL 1 2 FUEL HOSE 5 10 FUEL SYSTEM CHECK 6 2 FUEL TANK CAP 2 16 FUEL VALVE 2 15 FUSE 5 35 G GEAR OIL CHANGE 5 20 GEARSHIFT LEVER 2 10 GENERAL LUBRICATION 5 37 I IDLE SPEED ADJUSTMENT 5 9 IGNITION SWITCH 2 6 IGNITION SYSTEM CHECK 6 3 INSPECTION AFTER...

Page 133: ...ANGE LEVER 2 8 REAR BRAKE 5 28 REAR BRAKE LINING WEAR LIMIT 5 30 REAR BRAKE PEDAL 2 14 RECOIL STARTER 2 16 RIDING IN COLD WEATHER 3 25 RIDING IN REVERSE 3 29 RIDING OVER OBSTACLES 3 23 RIDING THROUGH WATER 3 24 RIGHT HANDLEBAR 2 13 S SEAT LOCK 2 18 SELECTION LEVER LT F400F 2 9 SERIAL NUMBER LOCATION 10 2 SKIDDING OR SLIDING 3 17 SPARK ARRESTER 5 32 SPARK PLUG 5 7 SPEEDOMETER AND INDICATOR LIGHTS 2...

Page 134: ...ADJUSTMENT 5 9 THROTTLE LIMITER 2 14 TIRES 5 21 TOOL 5 5 TRAILER TOWING 5 38 TRANSPORTING 8 2 TURNING 3 16 W WASHING YOUR ATV 9 3 WHAT TO WEAR 3 6 WHAT YOU SHOULD KNOW BEFORE RIDING 3 2 Total page 136 www quad forum sk ...

Page 135: ...WARNING Indicates a potential hazard that could result in injury or death www quad forum sk ...

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Page 139: ... resold or other wise transferred to a new owner or operator The manual con tains important safety information and instructions which should be read carefully before operating the vehicle This hang tag is not to be removed before sale This ATV is for RECREATIONAL or UTILITY USE NO OPERATOR UNDER AGE 16 OPERATOR ONLY NO PASSENGERS This category G GENERAL USE ATV is for off road use only for recreat...

Page 140: ...ET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to ...

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