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Suzuki LT-Z400, Owner'S Manual

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Suzuki LT-Z400 Owner'S Manual Download Page 85

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GENERAL LUBRICATION

Proper lubrication is important for
safe, smooth operation and long life
of your vehicle. Be sure that all lubri-
cation is performed during periodic
maintenance on the vehicle. Shorten
intervals when you use your ATV in
severe conditions. Your authorized
Suzuki dealer should do general lubri-
cation as shown in the MAINTE-
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.

1

 Brake lever holder

2

 Throttle lever

3

 Steering shaft holder

4

 Brake pedal

5

 Drive shaft joint spline

.... Motor oil

.... Grease

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 seriously
damage the electrical system.

Always replace a blown fuse with
a fuse of the same type and rating.
If the new fuse blows in a short
time, consult your Suzuki dealer
immediately.

CAUTION

Lubricating switches can damage
your ATV.

Lubricating switches can damage
the switches.

Do not apply grease and oil to the
switches.

Summary of Contents for LT-Z400

Page 1: ...o 16649 LT Z400 99011 07G54 28B 01B 2 1 DIC184 TDP006 DIC157 This owner s manual contains important safety information Please read it carefully Never allow anyone under 16 years old to ride this ATV Ce Manuel du propriétaire contient des informations importantes concernant la sécurité Le lire soigneusement Ne jamais autoriser les enfants âgés de moins de 16 ans à piloter ce V T T Denne brugervejle...

Page 2: ...sidered a permanent part of the vehi cle and should remain with the vehicle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle ...

Page 3: ...l contains important safety and maintenance information Read it carefully before you ride your new ATV Failure to follow the warnings con tained in this manual can result in INJURY or DEATH Do not allow anyone under age 16 to ride this ATV It is important that this manual remain with the vehicle when you sell it The next owner will need this manual also Store the owner s manual in the ATV s tail b...

Page 4: ...thout wearing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at excessive speeds Always go at a speed that is proper for the terrain visibility and operating conditions your skills and experience Never ...

Page 5: ...sing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling use the proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and r...

Page 6: ... Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pull ing a trailer Allow greater dis tance for braking Do not tow a trailer This vehicle is a performance ATV and is not designed for such use WARNING Indicates a potential hazard that could result in injury or death ...

Page 7: ......

Page 8: ...NE OIL RECOMMENDATION CONTROLS EQUIPMENT AND ADJUSTMENTS RIDING YOUR ATV ACCESSORY USE AND VEHICLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING PREPARATION FOR WINTER RIDING TRANSPORTING CLEANING PROCEDURE CONSUMER INFORMATION SPECIFICATIONS INDEX ...

Page 9: ......

Page 10: ...1 1 1 FUEL AND ENGINE OIL RECOMMENDATION FUEL 1 2 ENGINE OIL 1 2 ...

Page 11: ...ited warranty may not cover these prob lems Some states require fuel suppli ers to label pumps which dispense gasoline alcohol blends containing certain percentages of alcohol These labels may provided enough informa tion for you to determine if the fuel is appropriate In other states pumps may not be clearly labeled about the content or type of alcohol If you are unsure about the content or type ...

Page 12: ...ses MA and MB The oil container shows the classifica tion as follows 1 Code number of oil sales company 2 Oil classification Energy Conserving 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 CONSERVING indication in the API classification doughnut mark These oils can affect engine life and clutch performan...

Page 13: ......

Page 14: ...TCH 2 5 INDICATOR LIGHTS 2 6 GEARSHIFT LEVER 2 7 REVERSE SELECTION KNOB 2 7 LEFT HANDLEBAR 2 8 CHOKE LEVER 2 9 RIGHT HANDLEBAR 2 9 THROTTLE LIMITER 2 10 REAR BRAKE PEDAL 2 10 FUEL VALVE 2 10 FUEL TANK CAP 2 11 SEAT LOCK 2 13 FLAG BRACKET 2 13 FRONT SUSPENSION 2 14 REAR SUSPENSION 2 15 ...

Page 15: ... LOCATION OF PARTS 1 Clutch lever 2 Left handlebar switches 3 Choke lever 4 Parking brake lock 5 Indicator lights 6 Ignition switch 7 Front brake fluid reservoir 8 Front brake lever 9 Fuel tank cap 0 Reverse selection knob A Throttle lever ...

Page 16: ...2 3 B Seat lock C Fuel valve D Gearshift lever E Footrests ...

Page 17: ...2 4 F Rear brake pedal ...

Page 18: ... The ignition circuit is on and the engine can be started The key can not be removed in this position LIGHTS position The ignition circuit is complete and the headlight and taillight turn on The key cannot be removed in this posi tion WARNING Indicates a potential hazard that could result in injury or death Key No CAUTION Leaving the ignition switch in the position without the engine running for a...

Page 19: ...speeds or heavy load can increase engine coolant tempera ture Decrease engine speed reduce load and select an appro priate transmission gear to lower the temperature Debris or mud in front of the engine or packed between the radiator fins can reduce cooling ability Remove any debris or mud preventing any debris or mud pre venting air flow to the engine CAUTION Operating the ATV while the cool ant ...

Page 20: ...ERSE SELECTION KNOB This vehicle has a reverse gear To shift into reverse gear completely stop the vehicle and shift the trans mission into 1st gear while holding the clutch lever in Turn the reverse selection knob clockwise and push down the gearshift lever Lift up the gearshift lever to shift into 1st gear NOTE Depress the rear brake pedal and engage clutch partially if it is hard to shift into ...

Page 21: ... will come on When you move the dimmer switch to the LO position the low beam will light Engine Stop Switch 4 OFF position The ignition circuit is off and the engine cannot start or run RUN position The ignition circuit is on and the engine can run Electric Starter Button 5 Use this button to turn the starter motor Before starting the engine turn the ignition switch and engine stop switch to the O...

Page 22: ...the engine 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 squeezing the front brake lever towards the grip Throttle Lever 2 Control the engine speed with the position of the throttle lever Operate this lever with your thumb Push it for...

Page 23: ...l will apply the rear brake FUEL VALVE This vehicle is equipped with an auto matic type diaphragm style fuel valve There are three positions ON RES and PRI ON Position The normal position for the fuel valve lever is in the ON position In this position no fuel will flow from the fuel valve to the carburetor unless the engine is running or being started RES RESERVE Position If the fuel level in the ...

Page 24: ...body Turn the fuel tank cap counter clockwise To close the fuel tank cap turn it clockwise and tighten it securely Be sure that the vent tube is securely connected to the cap and is properly routed as shown 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 dam...

Page 25: ...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 and avoid spilling fuel on a hot engine Do not smoke and make sure there are no open flames or sparks in the area Avoid breath ing...

Page 26: ...ok into the seat hook retainer and push down firmly FLAG BRACKET A bracket is provided so you can mount a flag on your ATV WARNING Improperly installing the seat can be hazardous Failure to install the seat properly 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 ...

Page 27: ...can be individually adjusted by turning the respective adjusters The rebound damping force adjuster 1 is located at the bottom of the front suspension The compression damp ing force adjuster 2 is located at the top of the front suspension To adjust the damping force set the adjuster to the standard setting first and then adjust the adjuster to the desired position To set the rebound damping force ...

Page 28: ...iffen the damp ing force Turn the adjuster counter clockwise to soften the damping force The damping force should be adjusted gradually 1 8 turn at a time to fine tune the suspension REAR SUSPENSION Spring Pre load Adjustment The adjustment can be performed by changing the adjuster ring position However Suzuki recommends that this adjustment be done by your authorized Suzuki dealer since a special...

Page 29: ...ust the adjuster to the desired position To set the rebound damping force adjuster to the standard position turn the adjuster clockwise until it stops and then turn it counterclockwise 1 1 2 turns To set the compression damping force adjuster to the standard posi tion turn the adjuster clockwise until it stops and then turn it counterclock wise 2 turns Turn the adjuster clockwise from the standard...

Page 30: ...ING 3 3 WHAT TO WEAR 3 5 BREAK IN 3 6 STARTING THE ENGINE 3 7 STARTING OFF AND SHIFTING 3 8 BRAKING 3 13 PARKING 3 13 TURNING 3 14 SKIDDING OR SLIDING 3 15 OPERATION ON HILLS 3 15 RIDING OVER OBSTACLES 3 19 RIDING THROUGH WATER 3 19 RIDING IN COLD WEATHER 3 20 RIDING IN REVERSE 3 23 ...

Page 31: ...eas can remain open for you to use in the future After you have found a good 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 Indicates a potential hazard that could result in injury or death WARNING Operation of this ATV by children under age 16 can be hazardous...

Page 32: ...re pressure can be hazardous If you use improper tires or improper or uneven tire pressure 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 MAINTE NANCE section WARNING Operating this ATV with improper modifications can be hazardou...

Page 33: ...sure 2 Enough tread depth 3 No cracks rips or other damage Fuel 1 Enough fuel for the intended run 2 Fuel hose connected securely 3 No damage to fuel tank or cap 4 Tank cap closed securely Lighting Proper operation of all lights Headlight Brake Taillight Indicator lights Engine stop switch Proper operation Engine oil Correct level Cooling system 1 Proper coolant level 2 No leaks or damage Throttle...

Page 34: ...r a good pair of gloves strong boots that fit over the ankle long pants and a long sleeve shirt WARNING Operating this ATV without wear ing an approved motorcycle hel met eye protection and protective clothing can be hazardous Operating without an approved motorcycle helmet or eye protec tion increases your chances of a severe head injury or death in the event of an accident Operating without prot...

Page 35: ...arts to glaze and not seat properly Allow the engine to accelerate freely through the gears without exceeding the max imum 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 placing the transmission in gear This allows time for the lubri cating oil to reach all critical engine compone...

Page 36: ...lve to ON or RES after start ing the engine If the ambient temperature is at or above 5 C 40 F 1 Move the choke lever to the ENGAGE position halfway 2 Apply the rear brake pedal and release the parking brake by squeezing the clutch lever 3 Squeeze the clutch lever and push the electric starter button 4 When the engine is sufficiently warmed up move the choke lever to the OFF position NOTE If the a...

Page 37: ...ing har ness may overheat If the engine does not start after several tries check the fuel supply and ignition system WARNING Running your ATV indoors where there is little or no ventilation can be hazardous When breathed in exhaust gases from the ATV can cause death or severe injury Always run your ATV outdoors where there is fresh air WARNING Carrying a passenger on this ATV can be hazardous Carr...

Page 38: ...urns or stops WARNING Operating this ATV on public streets roads or highways can be hazardous You can collide with another vehi cle if you ride on public roads Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways WARNING Operating this ATV at excessive speeds can be hazardous Riding a...

Page 39: ... or feet from the foot rests during operation can be haz ardous If you remove even one hand or foot from the ATV you can reduce your ability to control the ATV This could cause you to lose your balance and fall off the ATV If you remove a foot from a footrest your foot or leg may come in contact with the rear wheels This could injure you or cause an accident Always keep both hands on the handlebar...

Page 40: ... kinds of terrain WARNING Failure to use extra care when operating this ATV on unfamiliar terrain can be hazardous You can come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to overturn or go out of con trol Go slowly and be extra careful when operating on unfamiliar ter rain Always be alert to changing terrain conditions when operating the ATV WARNING The ...

Page 41: ...ar shift lever to engage second gear and release the clutch lever You can select third fourth and top gear in succession by repeating this shifting sequence Reduce vehicle speed before shifting down To shift down release the throt tle and push down on the gearshift lever to engage a lower gear WARNING Opening the throttle suddenly can be hazardous The front wheels can lift off the ground and cause...

Page 42: ...ch to the OFF posi tion Always remove the key from the ATV when leaving the ATV WARNING Braking while turning the ATV can be hazardous Use of the brake when turning could cause the ATV to slide or roll over Use the brakes to slow down before you begin to turn WARNING Braking hard on slippery surfaces can be hazardous The ATV can skid and go out of control if you brake too hard Apply the brakes lig...

Page 43: ...n the direc tion of the turn Shift body weight slightly forward and support your weight on the outer footrest This will reduce the load on the inside rear wheel reducing its traction Lean upper body into the turn At HIGHER SPEEDS Use the same technique that you use for turning at low speeds but lean far ther into the turn Natural turning forces which can push the vehicle to the outside of the turn...

Page 44: ...TION ON HILLS WARNING Skidding or sliding improperly can be hazardous You may lose control of your ATV or regain traction unexpectedly which may cause the ATV to over turn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or slid ing ...

Page 45: ...ontrol or cause the ATV to overturn Always follow the proper proce dures for climbing hills as described in this section Always check the terrain care fully 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 could flip over backwards Never go over the top of any...

Page 46: ...e parking brake 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 ATV 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...

Page 47: ... Traversing a Slope When traversing a slope you should 1 Lean your body uphill 2 Steer slightly uphill if necessary to maintain a straight course WARNING Going down a hill improperly can be hazardous Going down a hill improperly can cause loss of control or cause the ATV to overturn Always follow the proper proce dures for going down hills as described in this section OK WARNING Crossing hills or ...

Page 48: ...re you ride through any water Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard If you are unfa miliar with the area park the ATV and inspect the stream first to find a suit able spot for crossing When cross ing operate the ATV at a slow steady speed Be careful not to damage banks when crossing WARNING Improperly operating this ATV over obstacles ...

Page 49: ...TV in water sand or mud causes rapid brake wear Excessive brake wear can cause the brakes to be less effective After repeated operation of the ATV in these condition bring it to your Suzuki dealer to have the brakes inspected and cleaned CAUTION Using engine power to free up fro zen wheels can damage your ATV Severe damage to the drive train may occur if you use engine power to free frozen wheels ...

Page 50: ... were standing still at a temperature of 23 C 9 F At this temperature exposed flesh will freeze in just a few minutes Continued exposure to cold tempera tures can also lead to hypothermia Hypothermia occurs when your body s inner temperature drops Symptoms include numbness in the extremities hands feet arms and legs and shivering Damp clothing contributes to hypothermia because cold water on your ...

Page 51: ... 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 hazards that can cause a loss of control Severe injury or death could occur if you lose control of the ATV Go slowly and be extra careful when riding on snow covered ter rain Always be alert to changing terrain condition...

Page 52: ...r shift lever twice NOTE Depress the rear brake pedal and engage clutch partially if it is hard to shift into reverse Check that the reverse indicator is lit after shifting into reverse 4 Look to make sure there is noth ing in your way behind you 5 Release the brake pedal Slowly release the clutch lever and apply the throttle WARNING Failure to use extra care when operating on slippery surfaces su...

Page 53: ...aking abrupt turns in reverse gear can be hazardous Throttle surges or abrupt turns could cause you to lose control of the ATV When you ride in reverse go slowly and turn carefully WARNING Indicates a potential hazard that could result in injury or death ...

Page 54: ...4 1 4 ACCESSORY USE AND VEHICLE LOADING ACCESSORY USE AND VEHICLE LOADING 4 2 ...

Page 55: ...e should be as light as possible The extra weight can cause the vehicle to be harder to steer 4 Do not add accessories or cargo which interfere with controls or other equipment 5 Do not carry heavy or bulky cargo 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 vehi cle as possible 7 Se...

Page 56: ...STMENT 5 7 CHOKE CABLE ADJUSTMENT 5 7 FUEL HOSE 5 7 ENGINE OIL 5 8 AIR CLEANER 5 12 AIR CLEANER DRAIN TUBE 5 15 CLUTCH ADJUSTMENT 5 16 DRIVE CHAIN 5 16 ENGINE COOLANT 5 19 TIRES 5 20 BRAKES 5 22 PARKING BRAKE ADJUSTMENT 5 25 FRONT AND REAR WHEEL REMOVAL 5 26 SPARK ARRESTER 5 27 LIGHT BULB REPLACEMENT 5 28 FUSE 5 29 GENERAL LUBRICATION 5 30 ...

Page 57: ...st pipe bolts and muffler bolts T T T Valve clearance I I Spark plug I Replace every 18 months Fuel line I I Replace every 4 years Engine oil and oil filter R R Engine oil hoses I I I Drive chain Inspect every time before riding Idle speed I I I Throttle cable play I I I Clutch I I Spark arrester C Coolant Replace every 2 years Radiator hose I Replace every 4 years Brake I I I Brake hose I Replace...

Page 58: ...you have mechanical experience If you are not sure how to do any of the jobs ask your Suzuki dealer to do the main tenance CAUTION If you use your ATV under severe conditions it will need mainte nance more often than shown in the chart Operating your ATV under severe conditions causes more wear on your ATV Severe conditions include operating under frequent full throttle or in dusty wet sandy or mu...

Page 59: ...Hydrogen gas produced by batter ies can be hazardous Batteries produce flammable hydrogen gas which can explode if exposed to flames or sparks Keep flames and sparks away from the battery Never smoke when working near the battery CAUTION Exceeding the maximum charging rate for the ATV battery can dam age your ATV If you charge the battery at a rate too high it will decrease the life of the battery...

Page 60: ... heat range for your engine This may cause severe engine damage which may not be covered under warranty Use only the spark plugs listed below Consult your Suzuki dealer if you are not sure which spark plug is correct for your type of vehicle usage NGK DENSO REMARKS CR6E U20ESR N If the standard plug tends to run cold CR7E U22ESR N Standard CR8E U24ESR N If the standard plug tends to run hot CAUTIO...

Page 61: ...1 Start the engine and warm it up 2 Turn the throttle stop screw 1 in or out so that the engine idles at 1400 1600 r min 0 7 0 8 mm 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 en...

Page 62: ... 2 in or out to obtain the proper amount of outer cable free play 0 5 1 0 mm Measure choke cable free play by pulling on the outer cable 3 After adjusting the play tighten the lock nut 1 FUEL HOSE Replace the fuel hose every 4 years even if they appear to be in good con dition Damage from aging may not always be visible WARNING Operating the vehicle with an inadequate throttle cable play can be ha...

Page 63: ...1 Place the vehicle on the level ground 2 If the engine has been off for a week you can make sure that enough oil to start the engine remains in the crankcase Loosen the oil level check bolt 1 and see that the oil drips from the oil level check hole then retighten the bolt If the oil level is lower than the lower edge of the check hole while the vehicle is in vertical position have your Suzuki dea...

Page 64: ...e engine oil is not hot 8 Draw out the dipstick and check the oil level The level found on the dipstick should be between L Low and F Full lines If the oil level is below the L line add fresh oil into the filler hole until the oil level reaches the F line L F CAUTION Operating the vehicle with an incorrect amount of oil can dam age your ATV Too little or too much oil can dam age your engine Place ...

Page 65: ...the engine oil from the crankcase by removing the crank case drain plug 2 WARNING New and used oil can be hazard ous Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with used oil may irritate skin Keep new and used oil and used oil filters away from children and pets To minimize your exposure to used ...

Page 66: ... Pour fresh oil through the filler hole Approxi mately 2100 ml 2 2 1 8 US Imp qt of oil will be required NOTE Approximately 2000 ml 2 1 1 8 US Imp qt of oil will be required when changing oil only without replacing the oil filter CAUTION Failure to use the correct oil filter can damage your ATV Engine damage may occur if you use oil filter with the wrong design or thread specifications Be sure to ...

Page 67: ...ollowing procedure to remove the element and inspect it CAUTION Failure to use the correct oil can damage your ATV Engine damage may occur if you use oil that does not meet Suzuki s specifications Be sure to use the oil specified in the FUEL OIL AND ENGINE COOLANT RECOMMENDATION section WARNING Operating the engine without the air cleaner element in place can be hazardous A flame can spit back fro...

Page 68: ...to inspect the air cleaner element frequently if the vehicle is used in dusty wet or muddy con ditions can damage your ATV The air cleaner element can become clogged under these con ditions and engine damage may result Always check the air cleaner ele ment after riding in severe condi tions Clean or replace the element as necessary If water gets in the air cleaner case imme diately clean the eleme...

Page 69: ...oil 6 Clean any dirt or debris from inside the air cleaner case Be sure no dirt enters the carburetor 7 Reinstall the cleaned element in reverse order of removal Be sure that the element is securely in position and is properly sealed 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 ...

Page 70: ...ion the air cleaner element properly can damage your ATV Air can bypass the air cleaner ele ment if the element is not posi tioned properly This will cause the engine parts to wear more rap idly Be sure to position the air cleaner element properly WARNING Failure to properly dispose of the drained oil or gasoline can be haz ardous Oil and gasoline are flammable and are harmful if swallowed Be sure...

Page 71: ...cting the Drive Chain When inspecting the chain look for the following Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear Improper chain adjustment If you find anything wrong with the drive chain condition or adjustment correct the problem if you know how If necessary consult your authorized Suzuki dealer Damage to the drive chain means that the sprockets may als...

Page 72: ...flammable Children or pets may be harmed from con tact with kerosene Keep flames and smoking materi als away from kerosene Keep children and pets away from kero sene If swallowed do not induce vomiting Call a physician immedi ately Dispose of used kerosene properly Good Worn CAUTION Cleaning the chain with gasoline or commercial cleaning solvents can damage O rings and ruin the chain These fluids ...

Page 73: ... axle housing bolt 2 30 N m 3 0 kgf m 21 5 lb ft WARNING Failure to inspect the drive chain slack before each use of the vehi cle could be hazardous Too much chain slack can cause the chain to come off the sprock ets resulting in an accident or serious damage to the vehicle Inspect and adjust the drive chain slack before each use 30 40 mm WARNING Improper drive chain adjustment and bolts and nuts ...

Page 74: ... the radiator cap counter clockwise and remove it 2 Replenish the radiator with speci fied engine coolant described in the FUEL ENGINE OIL AND COOLANT RECOMMENDATION section Engine coolant level must be filled up to the bottom of the inlet hole 3 Tighten the radiator cap securely WARNING Engine coolant is extremely hot during and after engine operation You can be injured by scalding fluid or steam...

Page 75: ...ssure can be hazardous If you use improper tires or improper or uneven tire pressure you may lose control of the ATV Always use the size and type tires specified Always maintain proper tire pressure as described in this section 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 having an accident Replace the...

Page 76: ... the proper tools when repairing or replacing tires to prevent damage to the tire bead or wheel rims Have this work done by your Suzuki dealer or a qualified tire repair station When breaking the tire bead loose from the wheel be extremely careful not to damage the inner wheel sur face or the tire bead LOAD TIRE PRESSURE FRONT REAR Up to 110 kg 243 lbs 4 4 psi 30 kPa 0 30 kgf cm2 4 0 psi 27 5 kPa ...

Page 77: ...spect and maintain your ATV s brake sys tems can be hazardous Improper maintenance of the brakes increases your chances of having an accident Be sure to inspect the brakes before each use of the vehicle according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE WARNING Failure to properly inspect and maintain your ATV s brake sys tems can be...

Page 78: ...n be hazardous The use of any fluid except DOT4 brake fluid from a sealed con tainer can damage the brake sys tem 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 res ervoir full can be hazardous The brakes may not work correctly without the proper amount of brake fluid This could ...

Page 79: ...s of having an accident If you need to replace brake pads have your Suzuki dealer do this work Inspect and maintain the brake pads as recommended WARNING Riding this ATV after brake system repair or brake pedal replacement without pumping the brake lever pedal can be hazardous If you do not pump the brake lever pedal before starting you can not get enough braking per formance and may result in an ...

Page 80: ...ighten the adjuster 2 until resis tance is felt then loosen the adjuster 1 8 1 4 turn 7 Tighten the lock nut 1 while hold ing the adjuster in position 8 Tighten the lock nut 1 WARNING Failure to properly adjust the park ing brake can be hazardous If the brake grabs or fails to lock the wheels when engaged you may have an accident After adjusting the parking brake lift the rear wheels off the groun...

Page 81: ...ghtening 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 haz ardous If the wheel nuts are not properly tightened the wheel can come off causing an accident Be sure to tighten the wheel nuts to th...

Page 82: ... 1 and pull 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 nec essary 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 ...

Page 83: ...Remove the bulb 5 Put a new bulb in the headlight and then reinstall the socket and socket cover Headlight 12V 30 30W Brake light Taillight 12V 21 5W CAUTION Failure to use a light bulb with the correct wattage rating can dam age 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 CAUTION Touching the headlig...

Page 84: ...ll a new bulb push the bulb in firmly and turn it to the right while pushing in FUSE The main fuse is located under the seat One 20A spare fuse is located in the starter relay box The cooling fan fuse is located on the right side of the cooling fan One 10A spare fuse is located in the fuse box If any electrical system fails to oper ate then the fuses must be checked 20 ...

Page 85: ...teering shaft holder odometer cable choke cable etc 1 Brake lever holder 2 Throttle lever 3 Steering shaft holder 4 Brake pedal 5 Drive shaft joint spline Motor oil Grease 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 seriously damage the electrical system Always replace a blown fuse with a...

Page 86: ...6 1 6 TROUBLESHOOTING FUEL SYSTEM CHECK 6 2 IGNITION SYSTEM CHECK 6 3 ...

Page 87: ...seconds to turn the engine e Loosen the drain screw and check that the carburetor is filled back up with fuel f If fuel is reaching the carburetor the ignition system should be checked next CAUTION Failure to troubleshoot a problem correctly can damage your ATV Improper repairs or adjustments may damage the vehicle instead of fixing it Such damage may not be covered under warranty If you are not s...

Page 88: ... tank 2 Check to see that the spark plug is not fouled Remove the plug and clean it Replace it if neces sary 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 If necessary adjust it using a tachometer The correct idle speed is 1400 1600 r min WARNING Performing the spark test improp erly can be ...

Page 89: ......

Page 90: ...7 1 7 PREPARATION FOR WINTER RIDING ENGINE OIL CHANGE 7 2 ...

Page 91: ... the right oil for cold weather according to the chart in the FUEL OIL AND ENGINE COOLANT REC OMMENDATION 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 freezing even if the oil that is in the engine is the right type for colder temperatures ...

Page 92: ...8 1 8 TRANSPORTING TRANSPORTING 8 2 ...

Page 93: ...the carburetor 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 haz ardous Failure to properly secure the vehicle may result in an accident or damage to the vehicle When transporting the ATV lock the parking brake lever and tie down the vehicle securely with s...

Page 94: ...ch on fire 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 haz ard Dispose of drained fuel prop erly ...

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Page 96: ...9 1 9 CLEANING 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 ...

Page 97: ...m can reduce engine cooling conceal damage or increase wear of certain 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 dam age your ATV...

Page 98: ...ssure to remove the majority of dirt or other debris Hand wash your ATV with mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure even at remote areas such as link ages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughl...

Page 99: ...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 carbure tor 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 ...

Page 100: ... with rubber protectant Spray unpainted surfaces with rust preventative Coat painted surfaces with car wax MAINTENANCE DURING STORAGE Once a month recharge the battery The standard charging rate is 0 9A 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 outlined in this manual Remove the spar...

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Page 102: ...10 10 1 CONSUMER INFORMATION SERIAL NUMBER LOCATION 10 2 LOCATION OF LABELS 10 3 ...

Page 103: ...r 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 as shown in the illustration The engine serial number 2 is stamped on the right side of the crankcase assembly Write down the serial numbers here for your future reference Frame No Engine No ...

Page 104: ...the warnings labeled on your ATV Make sure you understand all of the labels Keep the labels on the ATV Do not remove them for any reason If a label comes off or becomes difficult to read you can get a replacement by contacting your Suzuki dealer 1 2 ...

Page 105: ...ntrol can result in severe injury or death ALWAYS maintain proper tire pressure as shown below NEVER exceed the Vehicle Load Capacity of 243 lbs 110 kg LOAD COLD TIRE PRESSURE UP TO 243 lbs REAR FRONT 4 4 psi 0 30 kgf cm2 REAR 4 0 psi 0 275 kgf cm2 110 kg TIRE SIZE FRONT AT22 7R10 AT20 10R 9 ...

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Page 107: ... TRAIN Clutch Wet multi plate type Transmission 5 forward and 1 reverse Gearshift pattern forward 1 down 4 up foot operated reverse Foot hand operated Primary reduction ratio 2 960 74 25 Gear ratios Low 2 538 33 13 2nd 1 666 30 18 3rd 1 238 26 21 4th 1 000 23 23 Top 0 846 22 26 Reverse 2 153 28 13 Final reduction ratio 2 857 40 14 Drive chain RK520SMOZ10S 96 Links CHASSIS Front suspension Independ...

Page 108: ...use 10A Headlight 12V 30 30W 2 Brake light Taillight 12V 21 5W Neutral indicator light 12V 3W Reverse indicator light 12V 3W Coolant temperature warning light 12V 3W CAPACITIES Fuel tank including reserve 10 0 L 2 6 2 2 US Imp gal reserve 2 7 L 0 7 0 6 US Imp gal Engine oil oil change 2000 ml 2 1 1 8 US Imp qt filter change 2100 ml 2 2 1 8 US Imp qt Coolant 1 2 L 1 3 1 1 US Imp qt ...

Page 109: ...EL HOSE 5 7 FUEL SYSTEM CHECK 6 2 FUEL TANK CAP 2 11 FUEL VALVE 2 10 FUSE 5 29 G GEARSHIFT LEVER 2 7 GENERAL LUBRICATION 5 30 I IDLE SPEED ADJUSTMENT 5 6 IGNITION SWITCH 2 5 IGNITION SYSTEM CHECK 6 3 INDICATOR LIGHTS 2 6 INSPECTION AFTER CLEANING 9 4 INSPECTION BEFORE RIDING 3 3 K KEY 2 4 L LEFT HANDLEBAR 2 8 LIGHT BULB REPLACEMENT 5 28 LOCATION OF LABELS 10 3 LOCATION OF PARTS 2 2 M MAINTENANCE D...

Page 110: ...LEBAR 2 9 S SEAT LOCK 2 13 SERIAL NUMBER LOCATION 10 2 SKIDDING OR SLIDING 3 15 SPARK ARRESTER 5 27 SPARK PLUG 5 5 STARTING OFF AND SHIFTING 3 8 STARTING THE ENGINE 3 7 STORAGE PROCEDURE 9 4 T THROTTLE CABLE ADJUSTMENT 5 7 THROTTLE LIMITER 2 10 TIRES 5 20 TOOL 5 4 TRANSPORTING 8 2 TURNING 3 14 W WASHING YOUR ATV 9 3 WHAT TO WEAR 3 5 WHAT YOU SHOULD KNOW BEFORE RIDING 3 2 Total page 110 ...

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