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Suzuki LT-A400 Service Manual

Suzuki LT-A400 Service Manual

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Vernon Rickards

January 21, 2025

fuel pump wont come when turn key on bike only cranks wont start take out plug pour little in put plug will start for few seconds

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1 comments:

Mr. Anderson

February 4, 2025

The Suzuki LT-A400 does not have an electric fuel pump; it uses a gravity-fed fuel system with a fuel valve. If the engine only cranks and does not start, the issue may be related to the fuel valve position or fuel reaching the carburetor. Ensure the fuel valve is in the "ON" or "RES" position (not "PRI") and verify that fuel flows properly to the carburetor. If fuel is reaching the carburetor, check the ignition system next.

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Summary of Contents for Suzuki LT-A400

Page 1 9 9 5 0 0 - 4 3 0 7 0 - 0 1 E...
Page 2 FOREWORD This manual contains an introductory description on the SUZUKI LT-A400/F, LT-F400/F and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
Page 3 TABLE OF CONTENTS Precautions............... 00-i Exterior Parts ............9D-1 Body Structure ............9E-1 Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........
Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Warning / Caution / Note........00-1...
Page 6 CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner...
Page 7 Precautions: 00-2 • Never reuse a circlip. When installing a • Before refitting the sealed coupler, make sure its seal new circlip, take care not to expand the rubber is positioned properly. The seal rubber may end gap larger than required to slip the possibly come off the position during disconnecting circlip over the shaft.
Page 8 00-3 Precautions: • Check the male connector for bend and female Switch connector for excessive opening. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc. prevent damage. CDI unit / Various sensors •...
Page 9 Precautions: 00-4 Battery • Never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its coupler is • Battery connection in reverse polarity is strictly disconnected. Otherwise, damage to electronic unit prohibited. Such a wrong connection will damage the may result.
Page 10 00-5 Precautions: 3) Using a test male terminal, check the female 2) Disconnect the coupler “B” and measure resistance terminals of the circuit being checked for contact between couplers “A” and “B-1”. tension. If no continuity is indicated, the circuit is open Check each terminal visually for poor contact between couplers “A”...
Page 11 Precautions: 00-6 3) Also, if measured values are as listed following, a 3) Measure resistance between terminal at one end of resistance (abnormality) exists which causes the circuit (“A” terminal in figure) and body ground. If voltage drop in the circuit between terminals “A” and continuity is indicated, there is a short circuit to “B”.
Page 12 00-7 Precautions: Using The Multi-Circuit Testers NOTE • Use the Suzuki multi-circuit tester set. • When connecting the multi-circuit tester, • Use well-charged batteries in the tester. use the needle pointed probe to the back side of the lead wire coupler and connect •...
Page 13: Table Of Contents
Chassis Bolt and Nut Inspection .......0B-19 Precautions............0B-1 Compression Pressure Check ......0B-21 Precautions for Maintenance ......0B-1 Oil Pressure Check ...........0B-21 General Description ..........0B-1 Automatic Clutch Inspection (LT-A400/F) ..0B-21 Recommended Fluids and Lubricants....0B-1 Specifications.............0B-22 Scheduled Maintenance ........0B-1 Tightening Torque Specifications......0B-22 Periodic Maintenance Schedule Chart....0B-1 Special Tools and Equipment ......0B-22...
Page 14 Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply WATER RESISTANCE GREASE.
Page 15 RH: Right Hand ROM: Read Only Memory SAE: Society of Automotive Engineers I827H1010005-01 Left Side Vehicle Side View B827H10101004 NOTE Difference between illustration and actual vehicle may exist depending on the markets. SUZUKI LT-A400/F (2008-model) Right Side I827H1010006-01 I827H1010003-01 Left Side I827H1010004-01...
Page 16 Use of SF/SG or SH/SJ in API with MA in JASO. pipe. The engine serial number “B” is located on the left Suzuki recommends the use of SAE 10W-40 engine oil. side of the crankcase. These numbers are required...
Page 17 General Information: 0A-4 BREAK-IN Procedures 1) Keep to these break-in engine speed limits: B827H10101008 Speed limits During manufacture only the best possible materials are Initial 500 km (300 miles): Less than 1/2 throttle used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts 2) Upon reaching an odometer reading of 500 km (300 to “BREAK-IN”...
Page 18 0A-5 General Information: Warning, Caution and Information Labels Location B827H10101011 12 13 17 18 I827H1010011-02 1. Certification plate (English) For P-24, 33 16. Gearshift label (French) For P-28 2. Information label (English) For P-33 17. Front carrier warning label (English) For P-24, 33 3.
Page 19 General Information: 0A-6 Component Location Electrical Components Location B827H10103001 LT-A400/F I827H1010007-01 1. Battery 6. Ignition switch 11. Starter motor 2. Main fuse 7. Output terminal 12. Brake light switch 3. Starter relay 8. Handlebar switch (LH) 13. Neutral switch 4. Neutral relay 9.
Page 20 0A-7 General Information: I827H1010008-02 16. Ignition coil 19. Regulator/Rectifier 22. Reverse diode 17. Cooling fan 20. CDI unit 23. Generator 18. Ignition/starter control relay 21. Neutral switch diode...
Page 21 General Information: 0A-8 LT-F400/F I827H1010009-02 1. Battery 6. Handlebar switch (LH) 11. Brake light switch 2. Main fuse 7. Parking brake switch 12. Starter motor 3. Starter relay 8. Burke light switch 13. Cooling fan thermo-switch 4. Neutral relay 9. Ignition switch 14.
Page 22 0A-9 General Information: I827H1010010-04 15. Ignition coil 18. Regulator/Rectifier 21. Neutral diode 16. Cooling fan 19. CDI unit 22. Generator 17. Ignition/starter control relay 20. Reverse switch 23. Neutral switch...
Page 23 General Information: 0A-10 Specifications Specifications B827H10107001 NOTE These specifications are subject to change without notice. LT-A400/F Dimensions and dry mass Item Specification Remark 2 160 mm (85.0 in) P-17, 24 Overall length 2 060 mm (81.1 in) P-28, 33 1 200 mm (47.2 in)
Page 24 0A-11 General Information: Chassis Item Specification Remark Front suspension Independent, double wishbone, coil spring, oil damped Rear suspension Swingarm type, coil spring, oil damped Front wheel travel 170 mm (6.7 in) Rear wheel travel 170 mm (6.7 in) Caster 3° Trail 14 mm (0.55 in) Toe-in...
Page 25 General Information: 0A-12 LT-F400/F Dimensions and dry mass Item Specification Remark 2 160 mm (85.0 in) P-17, 24 Overall length 2 060 mm (81.1 in) P-28,33 1 200 mm (47.2 in) P-17, 24 Overall width 1 145 mm (45.1 in) P-28,33 Overall height 1 220 mm (48.0 in)
Page 26: Specifications
0A-13 General Information: Chassis Item Specification Remark Front suspension Independent, double wishbone, coil spring, oil damped Rear suspension Swingarm type, coil spring, oil damped Front wheel travel 170 mm (6.7 in) Rear wheel travel 170 mm (6.7 in) Caster 3° Trail 14 mm (0.55 in) Toe-in...
Page 27 General Information: 0A-14 Special Tools and Equipment Special Tool B827H10108007 09900–06107 09900–06108 09900–20101 09900–20102 09900–20202 Snap ring pliers Snap ring pliers Vernier calipers (1/15 Vernier calipers (1/20 Micrometer (1/100 mm, 150 mm) mm, 200 mm) mm, 25 – 50 mm) 09900–20205 09900–20210 09900–20530...
Page 28 0A-15 General Information: 09915–64512 09915–74511 09916–10911 09916–14510 09916–14910 Compression gauge Oil pressure gauge set Valve lapper set Valve spring Valve spring compressor compressor attachment 09916–34542 09916–34570 09916–34580 09916–44310 09916–84511 Reamer handle Valve guide reamer Valve guide reamer Valve guide remover/ Tweezers (5.0 mm) (10.8 mm)
Page 29 General Information: 0A-16 09924–64510 09924–84521 09930–10121 09930–30104 09930–30141 Final driving gear Bearing installer set Spark plug wrench set Rotor remover slide Attachment A coupling holder shaft 09930–30721 09930–31921 09930–40113 09930–44541 09930–73190 Rotor remover Rotor remover Rotor holder Rotor holder Output shaft holder 09940–52861 09941–64511 09942–72410...
Page 30: Scheduled Maintenance
Engine oil and oil filter — Front differential gear oil (LT-A400F, LT-F400F)/Final — — gear oil Replace every 2 years. Throttle cable play Engine idle speed Drive belt (LT-A400/F) — Clutch (LT-F400/F) — — Drive shaft boots (LT-A400F, LT-F400F) Brakes — Brake fluid Replace every 2 years.
Page 31: Lubrication Points
• Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the vehicle has been operated under wet or rainy conditions. Lubricate exposed parts Every 1 000 km (600 miles, 3 months) LT-A400/F I827H1020033-02 1. Brake lever holder 4. Brake pedal : Apply grease.
Page 32 0B-3 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Inspection and Cleaning 4) Immerse the element in motor oil, and then squeeze B827H10206001 out the excess oil leaving the element slightly wet. Clean element Every 1 000 km (600 miles, 3 months) If the air cleaner is clogged with dust, intake resistance “A”...
Page 33 Maintenance and Lubrication: 0B-4 Exhaust Pipe Bolt and Muffler Bolt Inspection Valve Clearance Inspection and Adjustment B827H10206002 B827H10206003 Tighten exhaust pipe bolts, muffler bolt and nut Inspect valve clearance Initially at 200 km (100 miles, 1 month) and every 1 Initially at 200 km (100 miles, 1 month) and every 2 000 km (600 miles, 3 months) thereafter 000 km (1 200 miles, 6 months) thereafter...
Page 34: Special Tool
0B-5 Maintenance and Lubrication: 5) Turn the crankshaft until the piston reaches TDC on Adjustment the compression stroke by slowly pulling the recoil 1) If the clearance is out of specification, bring it into the starter rope. Pull the recoil starter rope until the line specified range using the special tool.
Page 35 Maintenance and Lubrication: 0B-6 Spark Plug Inspection and Cleaning Spark Plug Gap B827H10206005 1) Remove the spark plug. Refer to “Spark Plug Inspect spark plug Removal and Installation in Section 1H (Page 1H- Every 2 000 km (1 200 miles, 6 months) 3)”.
Page 36: Spark Arrester Cleaning
Every 1 000 km (600 miles, 3 months) Replace fuel line Every 4 years Inspect the fuel line in the following procedures: 1) Remove the left side cover. Refer to “Exterior Parts I827H1020006-01 Removal and Installation in Section 9D (Page 9D- [A] LT-A400/F [B] LT-F400/F 3)”.
Page 37 (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine suzuki automobile oil filter on this vehicle. I827H1020009-01 [A] LT-A400/F...
Page 38: Front Differential Gear Oil Inspection (Lt-A400F, Lt-F400F)
SH/SJ in API with MA in JASO. Tightening torque Necessary amount of engine oil Front drive (differential) gear oil level plug (a): 8 LT-A400/F N·m (0.8 kgf-m, 6.0 lb-ft) Oil change: 2 900 ml (3.1/2.6 US/lmpqt) Oil and filter change:3 100 ml (3.3/2.7 US/lmpqt) Tightening torque Engine overhaul:3 400 ml (3.6/3.0 US/lmpqt)
Page 39: Front Differential Gear Oil Replacement (Lt- A400F, Lt-F400F)
Maintenance and Lubrication: 0B-10 Front Differential Gear Oil Replacement (LT- 5) Tighten the oil drain plug (3) to the specified torque. A400F, LT-F400F) CAUTION B827H10206010 Replace front differential gear oil Replace the gasket washers with a new one. Every 2 years Tightening torque Replace the oil filter differential gear oil in the following Front drive (differential) gear oil drain plug (a):...
Page 40: Final Gear Oil Inspection
0B-11 Maintenance and Lubrication: 8) Install the front under cover. Refer to “Exterior Parts 4) Tighten the oil level plug (3) and oil filler plug (2) to Removal and Installation in Section 9D (Page 9D- the specified torque. 3)”. CAUTION Final Gear Oil Inspection Replace the gasket washers with new ones.
Page 41 Maintenance and Lubrication: 0B-12 3) Remove the oil filler plug (2) and oil level plug (3). 6) Pour fresh oil through the oil filler hole until it overflows from the oil level hole. when performing an oil change, the final gear case will hold about 350 ml (11.8/12.3 US/lmp oz) of oil.
Page 42: Throttle Cable Play Inspection And Adjustment
“a” at the throttle lever end is between 3 – 5 mm (0.12 – 0.20 in). 4) Tighten the lock-nut (2) while holding the adjuster (3). I827H1020024-01 Drive V-belt Inspection (LT-A400/F) B827H10206016 “ a” Inspect drive V-belt I827H1020038-02 Every 1 000 km (600 miles, 3 months) 5) Reinstall the boot (1) firmly.
Page 43: Clutch Inspection (Lt-F400
Maintenance and Lubrication: 0B-14 Clutch Inspection (LT-F400/F) 6) Fully open the throttle for two seconds and note the B827H10206031 maximum engine speed sustained during the test cycle. If the lock-up speed (r/min) does not coincide Inspect clutch system with the standard range, inspect the clutch shoe and Every 2 000 km (1200 miles, 6 months) clutch wheel.
Page 44: Front Brake System Inspection
0B-15 Maintenance and Lubrication: Front Brake System Inspection Front Brake Pad Inspection B827H10206018 The extent of front brake pad wear can be checked by observing the grooved limit line “A” on the pad. If the Inspect brake system wear exceeds the grooved limit line, replace the pads Initially at 200 km (100 miles, 1 month) and every 1 with new ones.
Page 45: Rear Brake Pedal / Rear Brake
Maintenance and Lubrication: 0B-16 Rear Brake Pedal / Rear Brake (Parking Brake) Rear Brake (Parking Brake) Lever Play Lever Inspection and Adjustment 1) After adjusting the brake pedal, check the rear brake B827H10206019 lever play “a”. The brake lever play “a” as measured NOTE at the lever holder should be between 3 –...
Page 46: Tire Inspection
0B-17 Maintenance and Lubrication: Rear Brake Lining Wear Limit This vehicle has brake lining wear limit indicator on the “a” rear brake. Inspect the wear of brake lining in the following procedures: 1) Make sure that the rear brake is properly adjusted. 2) While fully applying the rear brake, check that the extension line of index mark “A”...
Page 47: Steering System Inspection
Maintenance and Lubrication: 0B-18 Steering System Inspection Toe-In Adjustment B827H10206022 B827H10206023 Adjust the toe-out as follows: Inspect steering system 1) Loosen the lock-nuts (1), (2) on each tie-rod. Initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter CAUTION Steering should be adjusted properly for smooth turning The lock-nuts (2) have left-hand threads.
Page 48: Tightening Torque
0B-19 Maintenance and Lubrication: 5) After adjustment has been made, tighten the four lock-nuts to the specified torque. Tightening torque Tie-rod lock-nut (a): 29 N·m (2.9 kgf-m, 21.0 lb-ft) I827H1020054-02 Steering shaft lower nut 49 N⋅m (4.9 kgf-m, 35.5 lb-ft) Suspension arm pivot nut (Upper and lower) 65 N⋅m 6.5 kgf-m, I831G1020089-01 47.0 lb-ft)
Page 49 Maintenance and Lubrication: 0B-20 I827H1020057-02 I827H1020060-02 Steering knuckle pinch bolt (Upper and lower) 50 N⋅m 5.0 kgf-m, Footrest bolt (M8) 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 36.0 lb-ft) Footrest bolt (M10) 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) Tie-rod end nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) Brake pedal bolt 12 N⋅m (1.2 kgf-m, 8.5 lb-ft) Tie-rod lock nut 29 N⋅m (2.9 kgf-m, 21.0 lb-ft) I827H1020061-02...
Page 50: Compression Pressure Check
Refer to “Oil Pressure Check in Section 1E (Page 1E- Section 5A (Page 5A-7)”. 4)”. • Clutch shoe • Clutch wheel Automatic Clutch Inspection (LT-A400/F) • Movable drive and driven face B827H10206029 This vehicle is equipped with a centrifugal type automatic clutch.
Page 51: Specifications
The specified tightening torque is also described in the following. “Chassis Bolt and Nut Inspection (Page 0B-19)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 52 0B-23 Maintenance and Lubrication: 09900–25008 09900–26006 Multi-circuit tester set Engine tachometer (solar cell type) (Page 0B-13) / (Page 0B-13) / (Page 0B-14) / (Page 0B-14) / (Page 0B-21) (Page 0B-21) 09915–40610 09917–14910 Oil filter wrench Valve adjuster driver (Page 0B-8) / (Page 0B- (Page 0B-5)
Page 53: Service Data
Service Data: 0C-1 Service Data General Information Specifications Service Data (LT-A400/F) B827H10307001 Valve + Valve Guide Unit: mm (in) Item Standard Limit 30.6 (1.20) — Valve diam. 27.0 (1.06) — 0.05 – 0.10 (0.002 – 0.004) — Valve clearance (when cold) 0.22 –...
Page 54 0C-2 Service Data: Item Standard Limit — 0.180 (0.0071) Piston ring to groove clearance — 0.150 (0.0059) 1.01 – 1.03 (0.0398 – 0.0406) — Piston ring groove width 1.01 – 1.03 (0.0398 – 0.0406) — 2.01 – 2.03 (0.0791 – 0.0799) —...
Page 55 Service Data: 0C-3 Engine Oil Temp. Switch + Cooling Fan Thermo-switch Item Standard/Specification Limit OFF → ON Approx. 160 °C (320 °F) Engine oil temp. indicator light — ON → OFF Approx. 140 °C (284 °F) switch operating temperature — OFF →...
Page 56 0C-4 Service Data: Wattage Unit: W Specification Item P-17 Others ← 35 x 2 Headlight ← 35 x 2 ← Brake light/Taillight 21/5 ← Speedometer light ← Reverse indicator light ← Neutral indicator light ← Engine oil temp. indicator light High beam indicator light —...
Page 57 Service Data: 0C-5 Item Specification Note Including 16.0 L (4.2/3.5 US/lmp gal) Fuel tank capacity reserve reserve 2.9 L (0.8/0.6 US/lmp gal) Engine oil type SAE 10 W-40, API SF/SG or SH/SJ with JASO MA Change 2 900 ml (3.1/2.6 US/lmp qt) Engine oil capacity Filter change 3 100 ml (3.3/2.7 US/lmp qt)
Page 58 0C-6 Service Data: Item Standard Limit 81.930 – 81.945 (3.2256 – 3.2262) Piston diam. 81.880 (3.2236) Measure at 15 mm (0.6 in) from the skirt end. Cylinder distortion — 0.05 (0.002) Approx. 8.9 (0.35) 7.1 (0.28) Piston ring free end gap Approx.
Page 59 Service Data: 0C-7 Item Standard Limit 3.083 (37/12) — 1.933 (29/15) — Transmission 1.388 (25/18) — gear ratio 1.095 (23/21) — 0.913 (21/13) — Reverse 2.833 (34/12) — Transmission shift fork to groove 0.10 – 0.30 (0.004 – 0.012) 0.50 (0.020) clearance Transfer shift fork to groove 0.10 –...
Page 60 0C-8 Service Data: Item Specification Note 0.3 – 1.5 Ω Generator coil resistance B – B Generator no-load voltage 65 V (AC) and more at 5 000 r/min (When the engine is cold) Generator Max. output Approx. 225 W at 5 000 r/min Regulated voltage 13.5 –...
Page 61: Tightening Torque List (Lt-A400
Front/Rear drive gear oil type Hypoid gear oil SAE #90, API grade GL-5 Front drive differential) gear oil 300 ml (10.1/10.6 US/lmp oz) capacity Final gear oil capacity 350 ml (11.8/12.3 US/lmp oz) Tightening Torque List (LT-A400/F) B827H10307002 Engine Item N⋅m kgf-m lb-ft...
Page 62 0C-10 Service Data: Item N⋅m kgf-m lb-ft Oil pump drive gear bolt 58.0 Exhaust pipe nut 13.0 Exhaust pipe mounting bolt 16.5 Muffler mounting bolt 16.5 Muffler connecting bolt 16.5 Engine oil drain plug 16.5 Cooling fan thermo-switch 14.5 Engine oil temperature switch 16.5 Oil pressure regulator 16.5...
Page 63: Tightening Torque List (Lt-F400
Service Data: 0C-11 Item N⋅m kgf-m lb-ft Brake disc bolt 16.5 Brake caliper mounting bolt 19.0 18.0 Footrest mounting bolt 40.0 Rear brake cam lever nut Rear axle housing mounting bolt (Final gear case) 40.0 Rear axle housing mounting bolt (Swingarm) 43.5 Upper 25.5...
Page 64 0C-12 Service Data: Item N⋅m kgf-m lb-ft Muffler mounting bolt 16.5 Muffler connecting bolt 16.5 Engine oil drain plug 16.5 Drive bevel gear nut 10.0 72.5 Driven bevel gear nut 10.0 72.5 29.0 Engine mounting nut 40.0 Engine mounting bracket bolt 20.0 Rear output shaft nut 10.0...
Page 65 Service Data: 0C-13 Item N⋅m kgf-m lb-ft Rear brake cam lever nut Rear axle housing mounting bolt (Final gear case) 40.0 Rear axle housing mounting bolt (Swingarm) 43.5 Upper 25.5 Rear shock absorber mounting nut Lower 43.5 Rear swingarm pivot nut 10.2 74.0 Brake disc cover mounting bolt...
Page 66 0C-14 Service Data:...
Page 67 Precautions............1B-1 Bearing Removal and Installation .....1D-59 Precautions for Emission Control Devices ..1B-1 Specifications.............1D-66 General Description ..........1B-1 Service Data (LT-A400/F, LT-F400/F) ....1D-66 Carburetor System Description ......1B-1 Tightening Torque Specifications......1D-68 Repair Instructions ..........1B-2 Special Tools and Equipment ......1D-68 Crankcase Breather (PCV) Hose Inspection..1B-2 Recommended Service Material .......1D-68...
Page 68 Air Cleaner Element Inspection and Cleaning . 1G-22 Starter Driven Gear Bearing Removal and Specifications............ 1G-22 Installation ............1I-11 Service Data (LT-A400/F, LT-F400/F) ..... 1G-22 Starter Related Parts Inspection ......1I-11 Tightening Torque Specifications..... 1G-23 Starter Button Inspection........1I-12 Recoil Starter Components ........ 1I-12...
Page 69 Battery Charging ..........1J-11 Recoil Starter Inspection ........1I-15 Battery Removal and Installation ...... 1J-13 Battery Visual Inspection........1J-13 Specifications............1I-16 Service Data (LT-A400/F, LT-F400/F) ....1I-16 Specifications............. 1J-14 Tightening Torque Specifications....... 1I-16 Service Data (LT-A400/F, LT-F400/F) ....1J-14 Tightening Torque Specifications...... 1J-14 Special Tools and Equipment ......
Page 70: Precautions
1-1 Precautions: Precautions Engine Precautions Precautions for Engine B827H11000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.
Page 71: Engine General Information And Diagnosis
Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine Diagnostic Information and Procedures Engine Symptom Diagnosis B827H11104001 Condition Possible cause Correction / Reference Item Engine will not start or is Worn cylinder. Replace. hard to start Worn piston ring. Replace (Compression too low) Worn valve guide or improper valve...
Page 72 1A-2 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine idles poorly Valve clearance out of adjustment. Adjust. Poor seating of valves. Replace. Defective valve guides. Replace. Worn rocker arm or arm shaft. Replace. Defective generator. Replace.
Page 73: Emission Control Devices
If jet needle replacement is necessary, only replace it with a jet needle of the same type. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability.Adjusting, interfering with, improper...
Page 74: Repair Instructions
1B-2 Emission Control Devices: Repair Instructions Crankcase Breather (PCV) Hose Inspection Crankcase Breather (PCV) Hose Removal and B827H11206001 Installation Inspect the PCV hose in the following procedures: B827H11206002 Removal 1) Remove the right side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 1) Remove the right side cover.
Page 75: Engine Mechanical
Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Throttle Cable Routing Diagram B827H11402001 “D” “C” “E” “F” INSIDE “a” “A” “B” “H” “G” “ b ” I827H1140304-02 1. Clamp 12. Clamp : Bind the front brake switch lead wire and throttle cable with the clamp. : Bind the starter cable with the clamp.
Page 76: Diagnostic Information And Procedures
1D-2 Engine Mechanical: 11. Clamp “H”: Pass the breather hose to outside of the cable. : Bind the rear brake cable with the clamp. Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 4) Keep the throttle lever in the fully-opened position. B827H11404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-1)”.
Page 77: Repair Instructions
Refer to “Movable / Fixed Continuously Variable Fixed drive face Automatic Transmission Drive Face Parts Inspection Automatic Transmission (LT-A400/F) Removal and Installation in in Section 5A (Page 5A-15)”. Removal and Installation in Section 5A (Page 5A-7)”. Section 5A (Page 5A-7)”.
Page 78 Section 5A (Page 5A-7)”. Refer to “V-belt Type Refer to “V-belt Type Continuously Variable Refer to “Drive V-belt Continuously Variable Drive V-belt (LT-A400/F) Automatic Transmission Inspection in Section 5A Automatic Transmission Removal and Installation in (Page 5A-15)”. Removal and Installation in Section 5A (Page 5A-7)”.
Page 79: Air Cleaner Element Inspection And Cleaning
Engine Mechanical: 1D-5 Air Cleaner Element Removal and Installation Air Cleaner Box Removal and Installation B827H11406002 B827H11406004 Removal Removal 1) Remove the seat. Refer to “Exterior Parts Removal 1) Remove the rear fender. Refer to “Exterior Parts and Installation in Section 9D (Page 9D-3)”. Removal and Installation in Section 9D (Page 9D- 3)”.
Page 80: Engine Assembly Removal
Removal and Installation in Section 9D (Page 9D- 3)”. • Under covers. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. 4) Remove the V-belt cooling ducts (1). (LT-A400/F) Refer to “V-belt Cooling Duct Removal and Installation (LT-A400/F) in Section 5A (Page 5A-6)”. I827H1140236-01 8) Disengage the gearshift link arm (5).
Page 81 Engine Mechanical: 1D-7 10) Remove the transfer gearshift arm (7). 15) Disconnect the cooling fan thermo-switch lead wire coupler (15) and oil temperature switch coupler (16). I827H1140238-02 11) Disconnect the gear position switch lead wire I827H1140242-01 coupler (8), CKP sensor lead wire coupler (9) and 16) Remove the brake pedal (17).
Page 82 1D-8 Engine Mechanical: 18) Remove the muffler and exhaust pipe. 20) Remove the engine mounting bracket (20). I827H1140245-01 I827H1140249-01 21) Remove the engine mounting bolts and nuts. WARNING Care should be taken not to drop the engine accidentally when the engine mounting bolts and nuts are removed.
Page 83: Engine Assembly Installation
Engine Mechanical: 1D-9 Engine Assembly Installation NOTE B827H11406014 The engine mounting nuts are self-locking. Reinstall the engine in the reverse order of removal. Pay Once the nut has been removed, it is no attention to the following points: longer any use. Be sure to use new nuts, and then tighten them to the specified torque.
Page 84: Engine Top Side Disassembly
1D-10 Engine Mechanical: • After finishing the engine installation, check the Cam Chain Tension Adjuster following items: 1) Remove the spring holder bolt (1) and spring. – Throttle cable play 2) Remove the O-ring, cam chain tension adjuster (2) Refer to “Throttle Cable Play Inspection and and gasket (3).
Page 85 Engine Mechanical: 1D-11 Cylinder Head Cover Cam Shaft 1) Remove the valve timing inspection caps (1). 1) Flatten the lock washer. 2) Remove the cam chain sprocket bolts and lock washer. 3) Remove the cam chain tensioner bolt. I827H1140005-01 2) Remove the cylinder head cover. I827H1140008-01 4) Drop the camshaft sprocket to the camshaft groove “A”.
Page 86 1D-12 Engine Mechanical: Cylinder Head 2) Remove the cam chain guide (2). 1) Remove the cylinder head nuts. 3) Remove the cylinder (3). I827H1140011-01 I827H1140014-02 2) Remove the cylinder head bolts. 4) Remove the dowel pins and gasket (4). NOTE The cylinder head bolts must be loosened diagonally and evenly.
Page 87: Engine Top Side Assembly
• Place a cloth beneath the piston, install the circlip (1). • Apply bond lightly to the crankcase mating points. CAUTION : Sealant 99000–31140 (SUZUKI BOND Use new piston pin circlips (1) to prevent No.1207B or equivalent) circlip failure which will occur when it is bent.
Page 88 1D-14 Engine Mechanical: • Hold each piston ring with properly position, insert the NOTE piston into the cylinder. • The rounded side of the washer (2) should • Tighten the cylinder base nuts temporarily. be positioned upside. • Apply engine oil to the both sides of CAUTION washers (2) and thread of the cylinder When installing the cylinder and cylinder...
Page 89 Engine Mechanical: 1D-15 • Tighten the cylinder head nuts to the specified torque. • Install the C-ring (1) and cam chain tensioner (2). • Install the camshaft and camshaft sprocket. Tightening torque Cylinder head nut (8 mm) (Initial): 10 N·m (1.0 kgf- CAUTION m, 7.0 lb-ft) Install the camshaft sprocket so that the...
Page 90 • Clean the mating surface of the cylinder head and head cover before mating. • Install the dowell pins to the cylinder head. • Apply bond to the camshaft end cap. : Sealant 99000–31140 (SUZUKI BOND I827H1140029-01 No.1207B or equivalent) I827H1140030-01 1.
Page 91 Engine Mechanical: 1D-17 • Apply bond to the mating surface of the cylinder head : Sealant 99000–31140 (SUZUKI BOND cover. No.1207B or equivalent) I827H1140034-01...
Page 92 • With the spring holder bolt and spring removed from the cam chain tension adjuster, release locking of the : Grease 99000–25010 (SUZUKI SUPER ratchet mechanism (1) and push the push rod all the GREASE A or equivalent) way in.
Page 93 Engine Mechanical: 1D-19 • Fit a new gasket (2). Recoil Starter • Install the recoil starter assembly (1). CAUTION • Apply a small quantity of thread lock to the bolts and Use new gasket to prevent oil leakage. tighten them to the specified torque. : Thread lock cement 99000–32110 •...
Page 94: Cylinder Head Cover Disassembly And Assembly
1D-20 Engine Mechanical: Spark Plug 4) Remove each rocker arm (3) and wave washer (4). • Install the spark plug. Special tool : 09930–10121 (Spark plug wrench set) Tightening torque Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft) I827H1140043-01 Assembly •...
Page 95: Cylinder Head Cover Relate Parts Inspection
Engine Mechanical: 1D-21 Cylinder Head Cover Relate Parts Inspection 2) Measure each rocker arm shaft out side diameter B827H11406041 using the micrometer. If the diameter exceeds the Refer to “Engine Top Side Disassembly (Page 1D-10)”. limit, replace the rocker arm shaft with a new one. Refer to “Engine Top Side Assembly (Page 1D-13)”...
Page 96: Cylinder Head Disassembly And Assembly
1D-22 Engine Mechanical: Cylinder Head Disassembly and Assembly 6) Remove the oil seal with long-nose pliers. B827H11406042 7) Remove the valve spring seat. Disassembly 8) Remove other valves in the same manner. CAUTION NOTE Be sure to identify each removed part as to Remove of valves completes ordinary its location, and lay the parts out in groups disassembling work.
Page 97: Cylinder Head Related Parts Inspection
Engine Mechanical: 1D-23 • Insert the valves, with their stems coated with molybdenum oil solution all around and along the full stem length without any break. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) CAUTION When inserting each valve, take care not to damage the lip of the stem seal.
Page 98 1D-24 Engine Mechanical: Valve Stem Runout Valve Face Wear Support the valve with V-blocks as shown, and check its Visually inspect each valve face for wear or damage. If runout with the dial gauge. The valve must be replaced if any abnormal wear is found, replace the respective the runout exceeds the limit.
Page 99 Engine Mechanical: 1D-25 Valve Stem Wear Valve Spring If valve stem is worn down to the limit, as Measured with The force of the coil spring keeps the valve seat tight. A a micrometer. where the clearance is found to be in weakened spring results in reduced engine power output excess of the limit indicated replace the valve, if the stem and often accounts for the chattering noise coming from...
Page 100: Valve Guide Replacement
1D-26 Engine Mechanical: Valve Seat Width 2) Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve 1) Visually check for valve seat width on each valve seat and face for burrs or other things that could face.
Page 101 Engine Mechanical: 1D-27 4) Re-finish the valve guide holes in the cylinder head 9) After installing the valve guides, refinish their guiding with the reamer and handle. bores using the reamer. Be sure to clean and oil the guides after reaming. Special tool : 09916–34580 (Valve guide reamer (10.8 Special tool...
Page 102: Valve Seat Repair
1D-28 Engine Mechanical: Valve Seat Repair Camshaft Inspection B827H11406027 B827H11406018 The valve seats (1) for both the intake and exhaust The camshaft should be checked for wear and also for valves are machined to three different angles. The seat runout of cams and journals if the engine has been contact surface is cut at 45°.
Page 103 Engine Mechanical: 1D-29 NOTE If the camshaft journal oil clearance exceeds the limit, measure the outside diameter of the camshaft. Replace To properly measure the oil clearance with either the cylinder head set or camshaft if it the plastigauge, all gasket material must be clearance is incorrect.
Page 104: Cam Chain Tension Adjuster Inspection
1D-30 Engine Mechanical: Cam Chain Tension Adjuster Inspection Cam Chain Guide Inspection B827H11406020 B827H11406022 The cam chain tension adjuster is maintained at the Inspect the cam chain guide in the following procedures: proper tension automatically. 1) Remove the cam chain guides. Refer to “Engine Top 1) Remove the cam chain tension adjuster.
Page 105: Piston Ring Removal And Installation
Engine Mechanical: 1D-31 Cylinder Bore Installation Inspect the cylinder wall for any scratches, nicks or other NOTE damage.Measure the cylinder bore diameter at six places. • When installing the piston ring, be careful not to damage the piston. Special tool : 09900–20530 (Cylinder gauge set) •...
Page 106: Piston And Piston Ring Inspection
1D-32 Engine Mechanical: b) Install the 2nd ring (3) and 1st ring (4) to piston. Piston and Piston Ring Inspection B827H11406032 Piston Diameter NOTE Using the micrometer, measure the piston outside 1st ring (4) and 2nd ring (3) differ in shape. diameter at the place shown in figure.
Page 107 Engine Mechanical: 1D-33 Piston Ring-to-groove Clearance Piston Ring Free End Gap and Piston Ring End Gap Using the thickness gauge, measure the side clearances Before installing piston rings, measure the free end gap of the 1st and 2nd piston rings. If any of the clearances of each ring using vernier calipers.
Page 108: Engine Bottom Side Disassembly
Piston Pin and Pin Bore Engine Bottom Side Disassembly B827H11406033 Using a small bore gauge, measure the piston pin bore LT-A400/F inside diameter, using the micrometer, measure the piston pin outside diameter. If the reading exceeds NOTE following limit, replace both piston and piston pin.
Page 109 Remove the oil filter with the special tool. Transfer Gearshift System Special tool Remove the transfer gearshift related parts. Refer to (A): 09915–40610 (Oil filter wrench) “Transfer Gearshift Shaft No. 2 / Gearshift Cam Plate Removal and Installation (LT-A400/F) in Section 3C (Page 3C-17)”. I827H1140105-01 I827H1140101-02...
Page 110 1D-36 Engine Mechanical: Automatic Transmission Oil Pump Remove the automatic transmission component parts 1) Remove the oil pump drive gear bolt with holding the (1). Refer to “V-belt Type Continuously Variable oil pump driven gear (1) using the special tool. Automatic Transmission Removal and Installation in 2) Remove the washer (2) and oil pump drive gear (3) Section 5A (Page 5A-7)”.
Page 111 5) Remove the front output shaft (5) and rear output • The crankshaft must remain in the left shaft (6). (LT-A400F) crankcase half. 6) Remove the rear output shaft (6). (LT-A400) Special tool (A): 09920–13120 (Crankcase separating tool) I827H1140117-01...
Page 112 1D-38 Engine Mechanical: Balancer Drive Bevel Gear and Output Shaft Remove the drive bevel gear (1) and output shaft. Refer 1) Remove the balancershaft driven gear (1). to “Transfer Removal and Installation (LT-F400/F) in 2) Remove the key (2). Section 3C (Page 3C-7)”. I827H1140118-01 I827H1140257-01 3) Remove the balancershaft with the special tools.
Page 113 Engine Mechanical: 1D-39 Speedometer Gearbox Stater Idle Gear Remove the speedometer gearbox (1) and gasket (2). Remove the starter idle gear No.1, (1) and No.2 (2). I827H1140122-01 I827H1140126-01 Transfer shift cam stopper Transfer Gearshift System Remove the bolt, spring and transfer shift cam stopper Remove the transfer related parts.
Page 114 1D-40 Engine Mechanical: Gearshift System Oil Filter Remove the oil filter with the special tool. 1) Remove the gearshift cam plate guide (1). Special tool (A): 09915–40610 (Oil filter wrench) I827H1140132-01 2) Remove the gearshift shaft (2) and gearshift cam plate (3).
Page 115 Engine Mechanical: 1D-41 6) Remove the pin (6) and washer (7). 3) Remove the generator rotor (1) with the special tool. 7) Remove the oil pump (8). Special tool 8) Remove the dowel pins. (C): 09930–30721 (Rotor remover) I827H1140138-01 I827H1140141-01 Generator Rotor Starter Driven Gear 1) Remove the generator rotor bolt with the special tool.
Page 116 1D-42 Engine Mechanical: 2) Remove the crankcase bolts. Gearshift Cam Remove the transfer reverse gearshift cam assembly (1), gearshift cam (2) and gearshift forks (3). I827H1140144-01 I827H1140147-01 Transmission 1) Remove the reverse idle gear assembly (1). I827H1140145-01 3) Separator the crankcase with the special tool. NOTE •...
Page 117: Engine Bottom Side Assembly
Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling. I827H1140258-01 LT-A400/F CAUTION Always keep the drive belt, drive face and driven face away from any greasy matter. Output Shaft and Drive Bevel Gear •...
Page 118 Transfer / Gearshift • Install the front output shaft (1) and rear output shaft (2). (LT-A400F) • Install the rear output shaft (2). (LT-A400) I827H1140261-01 • Install the gearshift cam stopper. Refer to “Transfer Gearshift Shaft No. 2 / Gearshift Cam Plate Removal...
Page 119 Engine Mechanical: 1D-45 “A” “A” “A” “B” I827H1140156-01 I827H1140262-01 • Install the washers (4), bearing (5) and gearshift shaft • Install the transfer input shaft assembly (11). (6). • Install the washer (7). I827H1140159-01 • Install the shaft (12), spacer (13) and bearing (14). •...
Page 120 1D-46 Engine Mechanical: • Apply bond to the mating surface of the left crankcase. LT-A400F LT-A400 I827H1140162-02 • Assemble the crankcase within few minutes. • Tighten the crankcase bolts to the specified torque. NOTE • Tighten the larger diameter crankcase bolts first and then smaller ones diagonally and evenly.
Page 121 Engine Mechanical: 1D-47 • Install the oil pump driven gear (4) as shown in the • Tighten the oil pump drive gear bolt to the specified figure. torque with the special tool. Tightening torque Oil pump drive gear bolt: 80 N·m (8.0 kgf-m, 58.0 lb-ft) Special tool (A): 09930–40113 (Rotor holder)
Page 122 Install the transfer gearshift related parts. Refer to “Transfer Gearshift Shaft No. 2 / Gearshift Cam Plate • Install the oil filter. Refer to “Engine Oil and Filter Removal and Installation (LT-A400/F) in Section 3C Replacement in Section 0B (Page 0B-7)”. (Page 3C-17)”.
Page 123 (Page 1J-5)”. Starter Cup • Apply grease to the to the O-ring and lip of the oil seal. • Install the starter cup (1). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1140176-01 Speedometer Gearbox • Apply grease to the sliding part of the gear.
Page 124 1D-50 Engine Mechanical: Starter Motor Balancer • Install the starter motor (1). Refer to “Starter Motor • Install the balancershaft (1). Removal and Installation in Section 1I (Page 1I-3)”. • Install the key (2). I827H1140180-01 I827H1140181-01 • Install the balancershaft driven gear (3) with aligning LT-F400/F the punch marks.
Page 125 Engine Mechanical: 1D-51 • Install the C-ring (3). • Install the reverse idle gear shaft (6). • Install the snap ring (7), washer (8) and spacer (9). NOTE Special tool Be sure to fit the pin “A” on the bearings into : 09900–06107 (Snap ring pliers) the groove of the crankcase.
Page 126 NOTE • Each fork has own embossed letters. • Face the letter upward (to the right side). I827H1140191-01 • Apply bond to the mating surface of the right crankcase. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) LT-F400 LT-F400F I827H1140163-01...
Page 127 Engine Mechanical: 1D-53 • Assemble the crankcase within few minutes. Starter Driven Gear • Tighten the crankcase bolts to the specified torque. • Install the starter driven gear (1). • Install the key (2) NOTE NOTE Tighten the larger diameter crankcase bolts first and then smaller ones diagonally and Degrease the tapered portion of the evenly.
Page 128 1D-54 Engine Mechanical: Oil Pump • Install the pin (5). • Install the dowel pins. • Install the oil pump drive gear (6) and washer (7). • Install the oil pump (1). • Apply thread lock to the oil pump drive gear bolt. •...
Page 129 Engine Mechanical: 1D-55 Oil Filter • Install the spring to the gearshift cam shaft properly. • Install the oil filter with the special tool. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-7)”. Special tool (A): 09915–40610 (Oil filter wrench) I827H1520029-01 •...
Page 130 I827H1140207-01 Generator cover • Apply a bond lightly to the groove of the lead wire • Install the dowel pins and new gasket (1). grommet. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) I827H1140217-01 • Install the generator cover. NOTE I827H1140208-01 Fit the clamp to the bolt “A”.
Page 131 (2). • Install the starter cup (1). • Tighten the bolt (2) to the specified torque. : Grease 99000–25010 (SUZUKI SUPER Tightening torque GREASE A or equivalent) Transfer gearshift cam stopper bolt (a): 22 N·m ( 2.2 kgf-m, 16.0 lb-ft)
Page 132: Conrod And Crankshaft Inspection
1D-58 Engine Mechanical: Conrod and Crankshaft Inspection Conrod Big End Side Clearance B827H11406035 1) Check the conrod big end side clearance with the Refer to “Engine Bottom Side Disassembly (Page 1D- thickness gauge. 34)”. Special tool Conrod Small End I.D. (A): 09900–20803 (Thickness gauge) Measure the conrod small end inside diameter with the Conrod big end side clearance...
Page 133: Width Between Crankshaft Webs
Engine Mechanical: 1D-59 Width Between Crankshaft Webs LT-A400/F right crankcase B827H11406036 Measure the width between crankshaft webs “a”. Width between crankshaft webs “a” Standard: 59.9 – 60.1 mm (2.36 – 2.37 in) I827H1140272-01 LT-F400/F left crankcase “a” I705H1140149-04 Crankshaft Oil Seal Inspection B827H11406037 Check the oil seals for damage.
Page 134: Bearing Removal And Installation
4) Remove other bearings with the special tool. Special tool Bearing Removal and Installation (C): 09913–70210 (Bearing installer set) B827H11406039 Removal LT-A400/F Left crankcase 1) Remove the retainers. I827H1140279-01 LT-A400/F Right crankcase 1) Remove the transfer countershaft bearing with the I827H1140276-01 special tool.
Page 135 Engine Mechanical: 1D-61 2) Remove the other bearings with the special tool. 3) Remove the other bearings with the special tool. Special tool Special tool (C): 09913–70210 (Bearing installer set) (B): 09913–70210 (Bearing installer set) I827H1140281-01 I827H1140284-02 LT-F400/F left Crankcase LT-F400/F right crankcase 1) Remove the retainers.
Page 136 (A): 09913–70210 (Bearing installer set) (B): 09913–70210 (Bearing installer set) (C): 09921–20240 (Bearing remover set) I827H1140286-03 I827H1140289-02 LT-A400/F generator cover 1) Remove the magnet stator. Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”. 2) Remove the oil seal retainer. I827H1140290-03 6) Remove the oil seal.
Page 137 3) Remove the oil seal (1) with the special tool. Special tool (A): 09913–50121 (Oil seal remover) 4) Remove the spacer (2). I827H1140311-01 Installation LT-A400/F right crankcase Install the bearings with the special tool. CAUTION Use the suitable size attachment for each bearing. I827H1140308-01 5) Remove the bearings with the special tools.
Page 138 1D-64 Engine Mechanical: LT-A400/F left crankcase LT-F400/F right crankcase 1) Install the bearings with the special tool. 1) Install the bearings with the special tool. CAUTION CAUTION Use the suitable size attachment for each Use the suitable size attachment for each bearing.
Page 139 Engine Mechanical: 1D-65 LT-F400/F left crankcase LT-A400/F Generator cover 1) Install the bearings with the special tool. CAUTION CAUTION The removed bearings and oil seals must be replaced with new ones. Use the suitable size attachment for each bearing. Special tool (A): 09913–70210 (Bearing installer set)
Page 140 When installing the oil seals, the stamped (A): 09913–70210 (Bearing installer set) mark on the oil seal faces outside. • Install the bearing with the special tool. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1140312-01 • Install the bearings with the special tool.
Page 141: Specifications
• Install the oil seal with the special tool. Special tool (A): 09913–70210 (Bearing installer set) NOTE When installing the oil seals, the stamped mark on the oil seal faces outside. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1140295-03 I827H1140294-03 I827H1140314-01 Specifications...
Page 142 1D-68 Engine Mechanical: Camshaft + Cylinder Head Unit: mm (in) Item Standard Limit Cam height IN. & EX. 33.130 – 33.170 (1.3043 – 1.3059) 32.830 (1.2925) φ 22 0.032 – 0.066 (0.0013 – 0.0026) 0.150 (0.0059) Camshaft journal oil clearance φ...
Page 143: Special Tools And Equipment
The specified tightening torque is also described in the following. “Engine Assembly Installation (Page 1D-9)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 144: Special Tool
1D-70 Engine Mechanical: Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1D-13) / equivalent (Page 1D-16) / (Page 1D-17) / (Page 1D-48) / (Page 1D-52) / (Page 1D-56) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030...
Page 145 Engine Mechanical: 1D-71 09900–20607 09900–20701 Dial gauge (1/100 mm, 10 Magnetic stand (Page 1D-24) / (Page 1D-24) / (Page 1D-24) / (Page 1D-24) / (Page 1D-24) / (Page 1D-24) / (Page 1D-29) / (Page 1D-29) / (Page 1D-58) / (Page 1D-58) / (Page 1D-58) (Page 1D-58) 09900–20803...
Page 146 1D-72 Engine Mechanical: 09915–63311 09915–64512 Compression gauge Compression gauge attachment (Page 1D-2) (Page 1D-2) 09916–10911 09916–14510 Valve lapper set Valve spring compressor (Page 1D-26) (Page 1D-22) / (Page 1D-23) 09916–14910 09916–34542 Valve spring compressor Reamer handle attachment (Page 1D-22) / (Page 1D-27) / (Page 1D-23) (Page 1D-27)
Page 147 Engine Mechanical: 1D-73 09930–31921 09930–40113 Rotor remover Rotor holder (Page 1D-41) / (Page 1D-36) / (Page 1D-43) (Page 1D-40) / (Page 1D-47) / (Page 1D-54) 09930–44541 09940–52861 Rotor holder Front fork oil seal installer (Page 1D-41) / (Page 1D-44) (Page 1D-53)
Page 148: Engine Lubrication System
Engine Precautions Precautions for Engine Oil B827H11500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”. Schematic and Routing Diagram Engine Lubrication System Chart Diagram B827H11502001 LT-A400/F ROCKER ROCKER ARM CAMSHAFT CAMSHAFT CAMSHAFT ARM (IN) SHAFT (IN) JOURNAL (L)
Page 149 Engine Lubrication System: 1E-2 LT-F400/F I827H1150002-01...
Page 150: Cylinder Head Cooling System Chart Diagram
1E-3 Engine Lubrication System: Cylinder Head Cooling System Chart Diagram B827H11502002 CYLINDER HEAD COOLING CYLINDER HEAD (EX) ORIFICE OIL FILTER OIL COOLER OIL PUMP OIL SUMP FILTER I827H1150003-01...
Page 151: Diagnostic Information And Procedures
Oil pressure specification LT-A400/F: 110 – 150 kPa (1.1 – 1.5 kgf/cm , 16 – 21 psi) at 3 000 r/min, Oil temp. at 60 °C (140 °F) LT-F400/F: 60 – 100 kPa (0.6 – 1.0 kgf/cm , 9 –...
Page 152: Repair Instructions
CAUTION B827H11506002 Refer to “Engine Oil and Filter Replacement in Section Use new O-ring to prevent oil leakage. 0B (Page 0B-7)”. : Grease 99000–25010 (SUZUKI SUPER Oil Sump Filter Removal and Installation GREASE A or equivalent) B827H11506003 Removal 1) Remove the engine protector. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 153: Oil Sump Filter Inspection And Cleaning
1) Drain the engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-7)”. 2) Remove the drive V-belt inner cover. (LT-A400/F). Refer to “Clutch Shoe Removal and Installation in Section 5A (Page 5A-16)”. Remove the clutch cover. (LT-F400/F). Refer to “Clutch Removal and Installation (LT-F400/F) in...
Page 154 1E-7 Engine Lubrication System: 3) Remove the oil pump drive gear (1) with holding the 7) Remove the dowel pins. oil pump driven gear (2) using the special tool. Special tool (A): 09930–40113 (Rotor holder) I827H1150016-01 Installation Install the oil pump and oil pump drive gear in the I827H1150013-01 reverse order of removal.
Page 155: Oil Pump Inspection
I827H1150019-01 3) Install the oil pump. Refer to “Oil Pump Drive Gear / I827H1150018-01 • Install the drive V-belt covers. (LT-A400/F). Refer to Oil Pump Removal and Installation (Page 1E-6)”. “Clutch Shoe Removal and Installation in Section 5A (Page 5A-16)”.
Page 156: Oil Cooler And Oil Hose Components
1E-9 Engine Lubrication System: Oil Cooler And Oil Hose Components B827H11506009 I827H1150048-02 1. Oil cooler : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Oil cooler fin guard net : Apply grease. 3. Oil hose (inlet) : Apply thread lock. 4. Oil hose (outlet) : Do not reuse.
Page 157: Oil Cooler / Oil Cooler Hose Removal And Installation
Engine Lubrication System: 1E-10 Oil Cooler Inspection 4) Remove the oil cooler (1). Inspect the oil cooler for oil leakage. If any defects are found, replace the oil cooler with a new one. If the fins are bent or dented, repair them by carefully straightening them with the blade of a small screwdriver.
Page 158: Oil Cooler Cleaning
1E-11 Engine Lubrication System: • Install the oil cooler. • Tighten the oil cooler hose bolts (oil cooler side) (2) to the specified torque. Tightening torque Oil cooler hose bolt (oil cooler side) (b): 10 N·m ( 1.0 kgf-m, 7.0 lb-ft) I827H1150030-01 •...
Page 159: Cooling Fan Components
Engine Lubrication System: 1E-12 Cooling Fan Components B827H11506012 I827H1150049-01 1. Cooling fan assembly : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) Cooling Fan Inspection NOTE B827H11506013 Inspect the cooling fan in the following procedures: • When making this test, it is not necessary to remove the cooling fan.
Page 160: Cooling Fan Removal And Installation
1E-13 Engine Lubrication System: Cooling Fan Removal and Installation 2) Disconnect the cooling fan thermo-switch lead wire B827H11506014 coupler (1). Removal 1) Remove the left inner fenders. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. 2) Disconnect the cooling fan motor lead wire coupler (1).
Page 161: Cooling Fan Thermo-Switch Inspection
Engine Lubrication System: 1E-14 Cooling Fan Thermo-Switch Inspection Engine Oil Temperature Switch Removal and B827H11506016 Installation Inspect the cooling fan thermo-switch in the following B827H11506017 procedures: Removal 1) Remove the cooling fan thermo-switch. Refer to 1) Remove the left side of the front inner fender. Refer “Cooling Fan Thermo-switch Removal and to “Exterior Parts Removal and Installation in Section Installation (Page 1E-13)”.
Page 162: Engine Oil Temperature Switch Inspection
1E-15 Engine Lubrication System: Engine Oil Temperature Switch Inspection Oil Pressure Regulator Removal and B827H11506018 Installation Inspect the engine oil temperature switch in the following B827H11506019 procedures: Removal 1) Remove the engine oil temperature switch. Refer to 1) Remove the generator cover. Refer to “Generator “Engine Oil Temperature Switch Removal and Removal and Installation in Section 1J (Page 1J-5)”.
Page 163: Oil Pressure Regulator Inspection
Inspect the operation of the oil pressure regulator by pushing the piston with a proper bar. If the piston does not operate, replace the oil pressure regulator with a new one. I827H1150045-01 Specifications Service Data (LT-A400/F) B827H11507001 Oil Pump Item Standard Limit 110 –...
Page 164: Tightening Torque Specifications
“Oil Cooler And Oil Hose Components (Page 1E-9)” “Cooling Fan Components (Page 1E-12)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 165 Engine Lubrication System: 1E-18 09930–40113 Rotor holder (Page 1E-7) / (Page 1E-...
Page 166: Fuel System
1G-1 Fuel System: Fuel System Engine Precautions Precautions for Fuel System B827H11700001 WARNING Gasoline is highly flammable and explosive. Extreme care must be taken. Keep heat, sparks and flames away from gasoline. General Description I.D. No. Location B827H11701002 Each carburetor has an I.D. number “A” printed on its body. “A”...
Page 167: Fuel System Description
Fuel System: 1G-2 Fuel System Description B827H11701001 Fuel System The fuel system consists of a fuel tank, fuel filter, fuel valve, vacuum hose, fuel hose and carburetor assembly. When there is negative pressure (vacuum) in the combustion chamber, the fuel is able to flow from the fuel tank, through the fuel valve and then to the carburetor assembly.
Page 168 1G-3 Fuel System: Fuel Valve When the engine is not operating, the fuel valve (1) is kept closed by the tension of the spring (2), which closes the fuel passageway and stops the flow of fuel to the carburetor. When the engine has started, negative pressure (vacuum) “A” is generated in the combustion chamber and reaches the diaphragm through a passage in the carburetor’s main bore and the vacuum hose.
Page 169 Fuel System: 1G-4 Diaphragm and Piston Operation The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve (1). The piston valve moves according to the negative pressure present on the downstream side of the venturi “A”.
Page 170 1G-5 Fuel System: Slow System This system supplies fuel during engine operation when the throttle valve (1) is closed or slightly opened. The fuel from the float chamber (2) is metered by the slow jet (3) where it mixes with air coming in through the slow air jet (4). This mixture, rich with fuel, then goes up through the passage to the pilot screw (5).
Page 171 Fuel System: 1G-6 Main System As the throttle valve (1) is opened, engine speed rises and negative pressure in the venturi “A” increases. This causes the piston valve (2) to move upward. The fuel in the float chamber (3) is metered by the main jet (4). The metered fuel enters the needle jet (5), mixes with the air admitted through the main air jet (6) and forms an emulsion.
Page 172 1G-7 Fuel System: Starter (Enricher) System Pulling the starter (enricher) plunger causes fuel to be drawn into the starter circuit from the float chamber (1). The starter jet (2) meters this fuel. The fuel then flows into the fuel pipe (3) and mixes with the air coming from the float chamber (1).
Page 173 Fuel System: 1G-8 Transient Enrichment System The transient enrichment system is a device which keeps fuel/air mixture ratio constant in order not to generate unstable combustion when the throttle grip is returned suddenly during high speed driving. For normal operation, sum of the air (1) and (2) keeps proper fuel/air mixture ratio.
Page 174 1G-9 Fuel System: Float System The float (1) and needle valve (2) work in conjunction with one another. As the float (1) moves up and down, so does the needle valve (2). When there is a high fuel level in the float chamber (3), the float (1) rises and the needle valve (2) pushes up against the valve seat.
Page 175: Schematic And Routing Diagram
Fuel System: 1G-10 Schematic and Routing Diagram Carburetor Hose Routing Diagram B827H11702001 “A” I827H1170040-02 1. Vacuum hose 3. Air vent hose [A]: Intake pipe side 2. Fuel hose “A” Clamp end should face downward. [B]: Air cleaner side...
Page 176: Diagnostic Information And Procedures
1G-11 Fuel System: Diagnostic Information and Procedures Carburetor Symptom Diagnosis B827H11704001 Condition Possible cause Correction / Reference Item Starting difficulty Clogged starter jet. Clean. Clogged starter jet passage. Clean. Air leaking from joint between starter Tighten, adjust or replace gasket. body and carburetor.
Page 177: Repair Instructions
Fuel System: 1G-12 Repair Instructions Fuel Tank Construction B827H11706018 “ a ” I827H1170041-02 1. Fuel tank upper cover “a”: 29 mm (1.14 in) 2. Fuel tank : 4.6 N⋅m (0.46 kg-f, 3.5 lb-ft) 3. Fuel tank cushion : Do not reuse. 4.
Page 178: Fuel Tank Removal And Installation
1G-13 Fuel System: Fuel Tank Removal and Installation 6) Remove the fuel tank backward. B827H11706009 7) Drain fuel completely. Removal WARNING • Keep away from fire or spark. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. 1) Remove the side covers.
Page 179: Fuel Filter Inspection And Cleaning
Fuel System: 1G-14 Installation Fuel Level Gauge Removal and Installation B827H11706021 Install the fuel valve in the reverse order of removal. Pay Removal attention to the following points: WARNING WARNING Gasoline is very explosive. Extreme care Replace the gasket washers (1) and gasket must be taken.
Page 180: Fuel Level Gauge Inspection
1G-15 Fuel System: Fuel Level Gauge Inspection Starter Cable Removal and Installation B827H11706007 B827H11706025 Inspect the fuel level gauge as follows: Removal 1) Inspect the float (1) of the fuel gauge assembly 1) Remove the front fender. Refer to “Exterior Parts moves smoothly.
Page 181: Carburetor Components
Fuel System: 1G-16 Carburetor Components B827H11706027 I827H1170042-02 1. Top cap 9. Spring 17. Needle jet 24. Float pin 2. Spring retainer 10. Holder 18. Needle jet holder 25. Pilot screw 3. Jet needle 11. Cap 19. Main jet 26. O-ring 4.
Page 182: Carburetor Assembly Removal And Installation
1G-17 Fuel System: Carburetor Assembly Removal and Installation 7) Disconnect the starter cable (5). B827H11706028 WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. Removal 1) Turn the fuel valve ON position. 2) Remove the side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”.
Page 183 Fuel System: 1G-18 3) Remove the carburetor top cap (8). 6) Remove the O-ring (15). CAUTION Do not use compressed air on the carburetor body before removing the diaphragm; this may damage the diaphragm. I827H1170005-02 7) Remove the throttle stop screw (16). I827H1170002-02 4) Remove the spring (9), spring retainer (10), spacer (11), jet needle (12) and diaphragm (13).
Page 184 1G-19 Fuel System: 9) Remove the following parts. Pilot Screw Removal (For Tampering Plug Type) Because harsh cleaning solvents can damage the O-ring • Main jet (20) seals in the pilot system, the pilot system components • Needle jet holder (21) should be removed before cleaning.
Page 185: Carburetor Assembly
• Apply thin coat of the grease to new pilot screw O- Replace the O-ring with a new one. ring. CAUTION Replace the O-ring with new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1170011-01 • Install the diaphragm. NOTE...
Page 186: Float Height Inspection And Adjustment
1G-21 Fuel System: Float Height Inspection and Adjustment Carburetor Inspection and Cleaning B827H11706031 B827H11706032 Inspect and adjust the float height in the following Refer to “Carburetor Assembly (Page 1G-20)” and procedures: “Carburetor Disassembly (Page 1G-17)”. 1) Remove the carburetor assembly. Refer to Carburetor Parts “Carburetor Assembly Removal and Installation Check the following items for any damage or clogging.
Page 187: Engine Idle Speed Inspection
Section 1D (Page 1D-5)”. Air Cleaner Element Inspection and Cleaning B827H11706036 Refer to “Air Cleaner Element Inspection and Cleaning in Section 0B (Page 0B-3)”. Specifications Service Data (LT-A400/F, LT-F400/F) B827H11707001 Injector + Fuel Pump + Fuel Pressure Regulator Specification Item P-17, 24, 28 P-33 ←...
Page 188: Tightening Torque Specifications
The specified tightening torque is also described in the following. “Fuel Tank Construction (Page 1G-12)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 189: Ignition System
Ignition System: 1H-1 Ignition System Engine Schematic and Routing Diagram Ignition System Diagram B827H11802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-4)”. Emergency switch Engine Ignition Fuse (E-17) stop switch switch Fuse CDI unit Wave form Ignition power arrangment source circuit circuit...
Page 190: No Spark Or Poor Spark
1H-2 Ignition System: Condition Possible cause Correction / Reference Item Spark plug quickly Worn piston ring. Replace. becomes fouled with oil Worn piston. Replace. or carbon Worn cylinder. Rebore or replace. Excessive valve-stem to valve-stem to Replace. valve-guide clearance. Worn valve stem oil seals. Replace.
Page 191: Repair Instructions
Ignition System: 1H-3 Repair Instructions Spark Plug Removal and Installation B827H11806001 Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch. 1) Turn the ignition switch OFF. 2) Remove the left side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”.
Page 192 1H-4 Ignition System: 4) Connect the multi-circuit tester with the peak voltage 6) Repeat the b) procedure few times and measure the adaptor as follows: highest peak voltage. If the voltage is lower than standard range, inspect CAUTION the ignition coil and the CKP sensor. Before using the multi-circuit tester and peak Ignition coil primary peak voltage voltage adaptor, refer to the appropriate...
Page 193: Ignition Coil Removal And Installation
Ignition System: 1H-5 Ignition Coil Removal and Installation 3) Connect the multi-circuit tester with the peak voltage B827H11806010 adaptor as follows: Remove CAUTION 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-13)”. Before using the multi-circuit tester and peak 2) Disconnect the spark plug cap.
Page 194: Ckp Sensor Removal And Installation
1H-6 Ignition System: CKP Sensor Resistance 3) Disconnect the handlebar switch coupler (1) (Yellow). 1) Remove the left side cover and left footrest mudguard. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. 2) Disconnect the CKP sensor coupler (1). I827H1180009-01 4) Inspect the engine stop switch for continuity with a tester.
Page 195: Specifications
Note N⋅m kgf-m lb-ft Spark plug (Page 1H-3) Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment Special Tool B827H11808001 09900–25008 09930–10121...
Page 196: Starting System
1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B827H11902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-4)”. Engine Emergency Starter Ignition stop switch button switch (E-17) switch Fuse Fuse Neutral relay Starter motor Neutral Ignition/ indicator...
Page 197: Starter Motor Will Not Run
Starting System: 1I-2 Starter Motor will not Run B827H11904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transfer to neutral. Go to step 2. Go to step 3. 2) Turn on the ignition switch with the engine stop switch in the “RUN”...
Page 198: Repair Instructions
Removal • Apply grease to the starter motor O-ring. 1) Turn the ignition switch OFF and disconnect the : Grease 99000–25010 (SUZUKI SUPER battery (–) lead wire. Refer to “Battery Removal and GREASE A or equivalent) Installation in Section 1J (Page 1J-13)”.
Page 199: Starter Motor Disassembly And Assembly
• Apply a small quantity of moly paste to the armature engine ground lead wire (2) and starter motor lead shaft. wire mounting nut (3) to the specified torque. Refer to : Moly paste 99000–25140 (SUZUKI Moly “Wiring Harness Routing Diagram in Section 9A paste or equivalent) (Page 9A-8)”.
Page 200: Starter Relay Removal And Installation
1I-5 Starting System: Carbon Brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush holder set with a new one. Measure the length “a” of the carbon brushes using a vernier calipers.
Page 201: Starter Relay Inspection
Starting System: 1I-6 6) Disconnect the starter motor lead wire (4) and battery (+) lead wire (5). To starter motor To battery 7) Remove the starter relay. (–) “A” “B” I823H1190040-02 3) Measure the relay coil resistance between the terminals using the multi-circuit tester. If the I827H1190011-02 resistance is not within the specified value, replace Installation...
Page 202: Neutral Relay Inspection
1I-7 Starting System: 3) Remove the neutral relay (1). 2) Disconnect the neutral switch diode (1). I827H1190012-01 I827H1190013-02 [A] LT-A400/F [B] LT-F400/F Installation Install the neutral relay in the reverse order of removal. 3) Measure the voltage between the “A” and “B”...
Page 203: Ignition / Starter Control Relay Removal And Installation
) to “D”) and check the continuity between “A” and “B”. If there is no continuity, replace the ignition/ Gear Position Switch Inspection starter control relay with a new one. B827H11906013 LT-A400/F Special tool Inspect the gear position switch in the following : 09900–25008 (Multi-circuit tester set) procedures: Tester knob indication 1) Remove the rear fender.
Page 204: Starter Clutch Removal And Installation
1I-9 Starting System: 2) Disconnect the gear position switch coupler (1). 3) Inspect the gear position switch for continuity with the tester. If any abnormality is found, replace the gear position switch with a new one. Refer to “Gear Position (GP) Switch Removal and Installation (LT- F400/F) in Section 5B (Page 5B-7)”.
Page 205 Starting System: 1I-10 6) Hold the generator rotor with the special tool and remove the starter clutch bolts. Special tool (A): 09930–44541 (Rotor holder) I718H1190031-01 • Install the guide to the generator rotor. NOTE The arrow mark “B” must face the engine side.
Page 206: Starter Driven Gear Bearing Removal And Installation
1I-11 Starting System: Starter Driven Gear Bearing Removal and Starter Related Parts Inspection B827H11906016 Installation Refer to “Starter Clutch Removal and Installation B827H11906015 (Page 1I-9)”. Removal 1) Remove the starter driven gear. Refer to “Starter Starter Clutch Clutch Removal and Installation (Page 1I-9)”. 1) Install the starter driven gear onto the starter clutch.
Page 207: Starter Button Inspection
Starting System: 1I-12 Starter Idle Gear 2) Disconnect the handlebar switch coupler (1) Inspect the starter idle gear No.1 (1) and No.2 (2) for (Yellow). wear or damage. If any damage is found, replace it with a new one. I827H1180009-01 3) Measure the voltage between Y/G and O lead wires.
Page 208: Recoil Starter Assembly Removal And Installation
1I-13 Starting System: Recoil Starter Assembly Removal and Recoil Starter Disassembly and Assembly B827H11906020 Installation Refer to “Recoil Starter Assembly Removal and B827H11906019 Installation (Page 1I-13)”. Removal 1) Remove the left side cover and left footrest Disassembly mudguard. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 209 I831G1190052-02 • Apply grease to the spiral spring. 5) Hook the rope to groove “A” of the reel (11). : Grease 99000–25010 (SUZUKI SUPER 6) Turn the rope on the reel (11) properly. GREASE A or equivalent) 7) Remove the reel (11).
Page 210: Recoil Starter Inspection
• Install the ratchet related parts. Recoil Starter Inspection • Apply grease to the shaft and ratchet guide. B827H11906021 : Grease 99000–25010 (SUZUKI SUPER Ratchet Set GREASE A or equivalent) Inspect the ratchet set for wear or damage. If any defects are found, replace the ratchet set with a new one.
Page 211: Specifications
The specified tightening torque is also described in the following. “Starter Motor Components (Page 1I-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 212: Special Tool
1I-17 Starting System: NOTE Required service material is also described in the following. “Starter Motor Components (Page 1I-3)” “Recoil Starter Components (Page 1I-12)” Special Tool B827H11908002 09900–20102 09900–25008 Vernier calipers (1/20 mm, Multi-circuit tester set 200 mm) (Page 1I-5) (Page 1I-5) / (Page 1I-6) (Page 1I-6) / (Page 1I-...
Page 213: Charging System
Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B827H11A02001 Ignition switch Main fuse Battery Generator Regulator/rectifier I827H11A0001-01 Component Location Charging System Components Location B827H11A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-6)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B827H11A04001 Condition...
Page 214: Battery Runs Down Quickly
1J-2 Charging System: Condition Possible cause Correction / Reference Item Unstable charging Lead wire insulation frayed due to Repair or replace. vibration, resulting in intermittent short- circuiting. Internally short-circuited generator. Replace. Defective regulator/rectifier. Replace. Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace.
Page 215: Repair Instructions
Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection Regulated Voltage Inspection B827H11A06001 B827H11A06002 Inspect the battery current leakage in the following Inspect the regulated voltage in the following procedures: procedures: 1) Turn the ignition switch OFF. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 216: Generator Inspection
1J-4 Charging System: Generator Inspection No-load Performance B827H11A06003 1) Remove the left side cover and left footrest Generator Coil Resistance mudguard. Refer to “Exterior Parts Removal and 1) Remove the left side cover and left footrest Installation in Section 9D (Page 9D-3)”. mudguard.
Page 217: Generator Removal And Installation
Charging System: 1J-5 Generator Removal and Installation 8) Disengage the gearshift link arm (4) (LT-F400/F) and B827H11A06004 transfer gearshift arm (5). Removal 1) Disconnect the (–) battery lead wire. Refer to “Battery Removal and Installation (Page 1J-13)”. 2) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-7)”.
Page 218 1J-6 Charging System: 12) Remove the generator cover (10). 15) Install the special tool (attachment) to the crankshaft end. Special tool (B): 09930–31921 (Rotor remover) I827H11A0013-01 13) Remove the gasket (11) and dowel pins. I827H11A0016-01 16) Remove the generator rotor (12) with the special tool.
Page 219 Charging System: 1J-7 18) Remove the generator stator (15) along with the • Degrease the tapered portion “A” of generator rotor CKP sensor (16). assembly and “B” of the crankshaft. Use nonflammable cleaning solvent to wipe off oily or greasy matter to make these surfaces completely dry. •...
Page 220 • Apply grease to the sliding part of the speedometer CAUTION gearbox. Fit the clamp to the bolt “C”. Refer to “Wiring : Grease 99000–25010 (SUZUKI SUPER Harness Routing Diagram in Section 9A GREASE A or equivalent) (Page 9A-8)”. • Fit new gasket (7).
Page 221 • Connect the oil hose. Refer to “Oil Cooler / Oil Cooler Hose Removal and Installation in Section 1E (Page 1E-10)”. • Apply grease to new O-ring and oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION I827H11A0029-01 Replace the O-ring with a new one.
Page 222: Regulator / Rectifier Inspection
1J-10 Charging System: Regulator / Rectifier Inspection B827H11A06005 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch OFF. 2) Remove the rear fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. 3) Disconnect the coupler and remove the regulator/rectifier (1). I827H11A0035-01 4) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table.
Page 223: Battery Components
Charging System: 1J-11 Battery Components 2) Remove the caps (2) from the electrolyte container. B827H11A06006 NOTE • Do not remove or pierce the sealed areas “B” of the electrolyte container. • After filling the electrolyte completely, use the removed cap (2) as sealing caps of battery-filler holes.
Page 224 1J-12 Charging System: 5) Make sure that air bubbles (4) rise to the top of each electrolyte container, and leave in this position for about more than 20 minutes. I718H11A0027-01 Correct I649G11A0042-03 NOTE If no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times.
Page 225: Battery Removal And Installation
Charging System: 1J-13 Battery Recharging Battery Removal and Installation B827H11A06008 Removal CAUTION 1) Remove the seat. Refer to “Exterior Parts Removal Do not remove the caps on the battery top and Installation in Section 9D (Page 9D-3)”. while recharging. 2) Remove the battery stay (1). 3) Disconnect the battery (–) lead wire (2).
Page 226: Specifications
27.5 (Page 1J-9) Recoil starter mounting bolt (Page 1J-9) Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material B827H11A08001...
Page 227 Charging System: 1J-15 09930–31921 09930–44541 Rotor remover Rotor holder (Page 1J-6) (Page 1J-6) / (Page 1J-...
Page 228: Exhaust System
1K-1 Exhaust System: Exhaust System Engine Precautions Precautions for Exhaust System B827H11B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.
Page 229: Muffler / Exhaust Pipe Removal And Installation
Exhaust System: 1K-2 Muffler / Exhaust Pipe Removal and Installation 5) Remove the exhaust pipe (3). B827H11B06002 NOTE Removal Support the exhaust pipe to prevent it from 1) Remove the right inner fender. Refer to “Exterior falling. Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 230: Exhaust System Inspection
1K-3 Exhaust System: • Tighten the Exhaust pipe nuts (3) and exhaust pipe mounting bolt (4) to the specified torque. Tightening torque Exhaust pipe nut (a): 18 N·m (1.8 kgf-m, 13.0 lb-ft) Exhaust pipe mounting bolt (b): 23 N·m (2.3 kgf- m, 16.5 lb-ft) I827H11B0009-01 Exhaust System Inspection...
Page 231: Specifications
(Page 1K-3) NOTE The specified tightening torque is also described in the following. “Exhaust System Components (Page 1K-1)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”.
Page 232 1K-5 Exhaust System:...
Page 233 Front / Rear Wheel Removal and Installation ..2D-3 Steering Knuckle End Removal and Tire Removal and Installation......2D-3 Installation............2B-10 Specifications............2D-5 Front Suspension Upper / Lower Arm Bushing Service Data (LT-A400/F, LT-F400/F) ....2D-5 Removal and Installation......... 2B-11 Tightening Torque Specifications......2D-5 Specifications.............2B-12...
Page 234: Precautions
2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B827H12000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.
Page 235: Suspension General Diagnosis
Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B827H12104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn hub bearings. Replace. Defective or incorrect tire. Replace.
Page 236: Front Suspension
2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Suspension Components B827H12206001 I827H1220045-05 1. Front shock absorber 10. Bushing : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 2. Upper suspension arm 11. Knuckle end : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) 3.
Page 237: Front Suspension Assembly Construction
Front Suspension: 2B-2 8. Outer dust seal 17. Tie rod end nut 9. Lower suspension arm : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft) Front Suspension Assembly Construction B827H12206002 I827H1220001-04 1. Front shock absorber mounting bolt (Upper) 10. Front hub nut : 65 N⋅m (6.5 kgf-m, 47.0 lb-ft) 2.
Page 238: Front Suspension Inspection
2B-3 Front Suspension: Front Suspension Inspection Tightening torque B827H12206004 Front shock absorber mounting bolt (upper) (a): Refer to “Suspension Inspection in Section 0B 55 N·m (5.5 kgf-m, 40.0 lb-ft) (Page 0B-19)”. Front shock absorber mounting nut (lower) (b): 60 N·m (6.0 kgf-m, 43.5 lb-ft) Front Shock Absorber Inspection B827H12206005 Inspect the front shock absorber for damage and oil...
Page 239 Install the steering knuckle in the reverse order of removal. Pay attention to the following points: • Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1220007-01 7) Disengage the tie-rod end with the special tool.
Page 240 • Apply grease to the spline of wheel hub and lip of dust tighten the tie-rod end nut to the specified torque. seal. Tightening torque : Grease 99000–25010 (SUZUKI SUPER Tie-rod end nut (b): 29 N·m (2.9 kgf-m, 21.0 lb-ft) GREASE A or equivalent) • Install new cotter pin (1).
Page 241: Front Wheel Hub / Steering Knuckle Related Parts Inspection
Front Suspension: 2B-6 • Tighten the front hub nut to the specified torque. Front Wheel Hub Bearing Inspect the inner race play of the front wheel hub Tightening torque bearings by hand while they are in the steering knuckle. Front hub nut (d): 110 N·m (11.0 kgf-m, 79.5 lb-ft) Rotate the inner races by hand to inspect for abnormal •...
Page 242 Pay attention to the following points: • Apply grease to the bearings and the lip of the dust seals before installing them. I827H1220019-01 : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1220018-01 I827H1220020-01...
Page 243: Front Suspension Upper / Lower Arm Removal And Installation
Front Suspension: 2B-8 • Install the steering knuckle dust seals using the 4) Remove the brake hose clamp (2). special tool. CAUTION Removed oil seal must be replaced with a new one. Special tool (A): 09913–70210 (Bearing installer set) I827H1220023-01 5) Remove the front shock absorber mounting bolt (lower) (3).
Page 244: Front Suspension Arm Related Parts Inspection
2B-9 Front Suspension: Installation 7) Tighten each nut to the specified torque. Tightening torque 1) Apply thread lock to the suspension arm pivot bolts Suspension arm pivot nut (upper) (a): 65 N·m ( (lower). 6.5 kgf-m, 47.0 lb-ft) Suspension arm pivot nut (lower) (b): 65 N·m ( : Thread lock cement 99000–32030 6.5 kgf-m, 47.0 lb-ft) (THREAD LOCK CEMENT SUPER 1303 or...
Page 245: Steering Knuckle End Removal And Installation
Front Suspension: 2B-10 Suspension Arm Drive Shaft Cover (LT-A400F, LT-F400F) Inspect the suspension arm for wear or damage. If any Inspect the drive shaft cover for damage. If any damages are found, replace the suspension arm with a damages are found, replace the drive shaft cover with a new one.
Page 246: Front Suspension Upper / Lower Arm Bushing Removal And Installation
2B-11 Front Suspension: Front Suspension Upper / Lower Arm Bushing Installation Removal and Installation B827H12206014 1) Install the knuckle end with the special tool. Refer to “Front Suspension Upper / Lower Arm Removal and Installation (Page 2B-8)”. Special tool (A): 09913–70210 (Bearing installer set) Removal Remove the front suspension arm bushing using a hydraulic press and suitable tools.
Page 247: Specifications
“Front Suspension Components (Page 2B-1)” “Front Suspension Assembly Construction (Page 2B-2)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material...
Page 248: Special Tool
2B-13 Front Suspension: Special Tool B827H12208002 09900–06107 09913–50121 Snap ring pliers Oil seal remover (Page 2B-10) / (Page 2B-6) (Page 2B-11) 09913–70210 09923–74511 Bearing installer set Bearing remover (Page 2B-7) / (Page 2B- (Page 2B-7) 8) / (Page 2B-11) 09930–30104 09942–72410 Rotor remover slide shaft Tie rod end remover...
Page 249: Rear Suspension
Rear Suspension: 2C-1 Rear Suspension Suspension Repair Instructions Rear Suspension Components B827H12306001 I827H1230011-01 1. Rear shock absorber 5. Rear shock absorber mounting lower : 102 N⋅m (10.2 kgf-m, 74.0 lb-ft) 2. Swingarm 6. Swingarm pivot nut : Apply thread lock to thread part. 3.
Page 250: Rear Shock Absorber Removal And Installation
2C-2 Rear Suspension: Rear Shock Absorber Removal and Installation Rear Suspension Inspection B827H12306003 B827H12306004 Refer to “Suspension Inspection in Section 0B Removal (Page 0B-19)”. 1) Place the vehicle on level ground and support the Rear Shock Absorber Inspection vehicle with a jack. B827H12306005 Inspect the rear shock absorber for damage and oil CAUTION...
Page 251: Swingarm Inspection
Rear Suspension: 2C-3 • Install the final gear assembly. Refer to “Final Gear Assembly Removal and Installation in Section 3B (Page 3B-21)”. • Install the rear wheels. Refer to “Front / Rear Wheel Removal and Installation in Section 2D (Page 2D-3)”. Swingarm Inspection B827H12306018 Inspect the swingarm in the following procedures:...
Page 252: Swingarm Bushing Removal And Installation
The specified tightening torque is also described in the following. “Rear Suspension Components (Page 2C-1)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 253: Wheels And Tires
Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B827H12400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of vehicle control. •...
Page 254: Repair Instructions
2D-2 Wheels and Tires: Repair Instructions Front and Rear Wheel Components B827H12406001 I827H1240004-02 1. Front tire 6. Rear tire : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Cotter pin 7. Cotter pin : 12 N⋅m (1.2 kgf-m, 8.5 lb-ft) 3. Front wheel hub 8.
Page 255: Front / Rear Wheel Removal And Installation
Wheels and Tires: 2D-3 Front / Rear Wheel Removal and Installation • Tighten the wheel set nuts to the specified torque. B827H12406002 NOTE NOTE Tighten the wheel set nuts diagonally. Make sure that the vehicle is supported securely. Tightening torque Wheel set nut (Front and rear) (a): 60 N·m (6.0 Removal kgf-m, 43.5 lb-ft)
Page 256 2D-4 Wheels and Tires: 4) Separate the tire from the rim using a set of tire 3) Mount the tire on the rim by hand as shown in the levers and rim protectors. figure. CAUTION When using the tire levers, do not scratch or hit the sealing portion (hump) of the wheel or it may cause air-leakage.
Page 257: Specifications
The specified tightening torque is also described in the following. “Front and Rear Wheel Components (Page 2D-2)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”.
Page 258 2D-6 Wheels and Tires:...
Page 259 Transfer Cable Removal and Installation (LT- Specifications.............3A-11 A400F, LT-F400F)...........3B-33 Tightening Torque Specifications...... 3A-11 Specifications.............3B-34 Special Tools and Equipment ......3A-11 Service Data (LT-A400/F, LT-F400/F) ....3B-34 Recommended Service Material ....... 3A-11 Tightening Torque Specifications......3B-34 Special Tool ............3A-11 Special Tools and Equipment ......3B-35 Recommended Service Material .......3B-35 Differential..........
Page 260 Tightening Torque Specifications......3C-22 Transfer Gearshift Cam Components (LT- Special Tools and Equipment ......3C-23 F400/F) ............3C-11 Recommended Service Material .......3C-23 Gearshift System Construction (LT-A400/F) ..3C-12 Special Tool ............3C-23 Gearshift System Construction (LT-F400/F) ..3C-12 Propeller Shafts ........3D-1 Transfer Gearshift Cam Disassembly and Assembly (LT-A400/F) ........3C-13...
Page 261: Precautions
Precautions: Precautions Driveline / Axle Precautions Precautions for Driveline / Axle B827H13000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train.
Page 262: 3A-1 Drive Chain / Drive Train / Drive Shaft
3A-1 Drive Chain / Drive Train / Drive Shaft: Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Shaft Symptom Diagnosis B827H13104001 Condition Possible cause Correction / Reference Item Noisy Drive Shaft Worn drive shaft joints. Replace.
Page 263: Front Drive Shaft Assembly Removal And Installation (Lt-A400F, Lt-F400F)
1) Remove the boot band of the differential side joint. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I831G1310005-01...
Page 264 3A-3 Drive Chain / Drive Train / Drive Shaft: 2) Slide the boot toward the center of the front drive 6) Remove the boot band of the small diameter side. shaft and remove the stopper ring from the outer race. I831G1310011-02 Assembly CAUTION...
Page 265 Drive Chain / Drive Train / Drive Shaft: 3A-4 3) Install the new snap ring to the cage. 5) Insert the cage into the outer race and install the new stopper ring to the groove of the outer race. CAUTION CAUTION Replace the snap ring with a new one.
Page 266: Front Drive Shaft Inspection (Lt-A400F, Lt- F400F)
3A-5 Drive Chain / Drive Train / Drive Shaft: 8) Install a circlip (2) into the groove of front drive shaft Front Drive Shaft Inspection (LT-A400F, LT- spline. F400F) B827H13106004 Inspect the front drive shaft in the following procedures: CAUTION 1) Remove the front drive shaft assembly.
Page 267: Rear Axle Components
Drive Chain / Drive Train / Drive Shaft: 3A-6 Rear Axle Components B827H13106005 I827H1310025-02 1. Dust seal 6. Rear axle housing (LH) : 55 N⋅m (5.5 kgf-m, 40 lb-ft) 2. Snap ring 7. Rear axle (RH) : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 3.
Page 268: Rear Axle Construction
3A-7 Drive Chain / Drive Train / Drive Shaft: Rear Axle Construction B827H13106009 I827H1310009-01 1. Swingarm pivot nut 8. Brake panel bolt : Apply grease. 2. Rear shock absorber nut (Upper) : 102 N⋅m (10.2 kgf-m, 74.0 lb-ft) : Apply silicon grease. 3.
Page 269 Pay attention to the following points: 7) Remove the rear axle housing mounting bolt and • Apply grease to the rear axle shaft spline. nuts (4) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) NOTE Overall length of RH axle shaft is shorter than LH axle shaft.
Page 270: Rear Axle / Axle Housing Inspection
3A-9 Drive Chain / Drive Train / Drive Shaft: • Install the trailer towing (1) and tighten the rear axle Rear Axle Housing housing bolts (2) to the specified torque. Inspect the rear axle housing for distortion or damages. If any damages are found, replace the rear axle housing Tightening torque with a new one.
Page 271: Rear Axle Housing Disassembly And Assembly
• Apply grease to the hub bearings and dust seal lip before installing them. Special tool (A): 09913–50121 (Oil seal remover) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1310020-01 I827H1310017-01 • Install the hub bearings with the special tool.
Page 272: Specifications
“Rear Axle Components (Page 3A-6)” “Rear Axle Construction (Page 3A-7)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material...
Page 273 Drive Chain / Drive Train / Drive Shaft: 3A-12 09913–50121 09913–70210 Oil seal remover Bearing installer set (Page 3A-10) (Page 3A-10) / (Page 3A-11) 09921–20240 Bearing remover set (Page 3A-10)
Page 274: Differential
3B-1 Differential: Differential Driveline / Axle Diagnostic Information and Procedures Drive Train Symptom Diagnosis B827H13204001 Condition Possible cause Correction / Reference Item Engine noisy (Noise Worn or damage drive and driven bevel Replace. seems to come from front/ gears. rear output shaft bevel Excessive backlash.
Page 275: Repair Instructions
Differential: 3B-2 Repair Instructions Front Drive (Differential) Components (LT-A400F, LT-F400F) B827H13206001 I827H1320118-02 1. Front drive (differential) gear case 8. 2WD/4WD shifting fork shaft : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Shim(-s) (RH) 9. 2WD/4WD shifting cable guide : Apply grease. 3.
Page 276: Front Drive (Differential) Construction (Lt-A400F, Lt-F400F)
3B-3 Differential: Front Drive (Differential) Construction (LT-A400F, LT-F400F) B827H13206002 “A” I827H1320001-02 1. Shim : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply thread lock to the thread part. 2. Front drive (differential) case cover bolt : Apply grease. : Apply bond to mating surface. “A”: Mating surface : Apply water resistance grease.
Page 277: Front Drive (Differential) Gear Oil Level Inspection (Lt-A400F, Lt-F400F)
Differential: 3B-4 I827H1320002-02 1. Propeller shaft boot : Apply water resistance grease. : P-24 only : 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) : Apply thread lock to the thread part. : Apply grease. Front Drive (Differential) Gear Oil Level 4) Hold the inboard joint (1) of the drive shaft and tug the drive shaft horizontally.
Page 278: Front Drive (Differential) Assembly Disassembly And Assembly (Lt-A400F, Lt- F400F)
3B-5 Differential: 6) Remove the front drive (differential) mounting bolts. • Connect the transfer cable. • Apply thread lock to the front drive (differential) mounting bolts and tighten the nuts to the specified torque. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent) Tightening torque Front drive (differential) gear case mounting nut...
Page 279 Differential: 3B-6 2) Remove the front drive (differential) case cover (1). 4) Remove the bearings from the front differential gear assembly with a commercially available bearing NOTE puller. Use the special tool to remove the cover from NOTE housing if necessary. If there is no abnormal condition, the bearing Special tool removal is not necessary.
Page 280 3B-7 Differential: 6) Remove the snap ring (4) out of its groove and slide 9) Remove the snap ring (5). it towards the shifting sleeve. Special tool : 09900–06108 (Snap ring pliers) 10) Remove the bearing. NOTE Use the special tool if necessary. Special tool (B): 09913–50121 (Oil seal remover) I827H1320015-01...
Page 281 Differential: 3B-8 14) Remove the bearing from the pinion gear with the 17) Remove the bearings by tapping with the special tool special tool. and hammer. Special tool NOTE (E): 09913–70210 (Bearing installer set) If there is no abnormal condition, the bearing removal is not necessary.
Page 282 Replace the removed oil seal with a new one. Special tool (A): 09913–70210 (Bearing installer set) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1320028-01 • Install the bearing onto the shaft with the special tool. Special tool (A): 09913–70210 (Bearing installer set)
Page 283 (A): 09913–70210 (Bearing installer set) Replace the snap ring with a new one. • Apply grease to the seal lip groove. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Apply 4 – 5 gram of water resistance grease to the outside of seal lip groove.
Page 284 (4) between the shifting sleeve and splines of universal joint. CAUTION Replace the removed C-rings with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool (A): 09913–70210 (Bearing installer set) I827H1320036-01 •...
Page 285 • Install the shims (5) to the gear case and cover. with the special tool. • Apply grease to the oil seal lips. Special tool (A): 09913–70210 (Bearing installer set) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the oil seals with new ones. I827H1320041-02 •...
Page 286: Front Drive (Differential) Related Parts Inspection (Lt-A400F, Lt-F400F)
3B-13 Differential: • Tighten the front drive (differential) case cover bolts to 2WD/4WD Shifting Sleeve the specified torque. Inspect the 2WD/4WD shifting sleeve for wear or damage. If any defects are found, replace the 2WD/4WD Tightening torque shifting sleeve with new one. Front drive (differential) gear case cover bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) I831G1320054-01...
Page 287: Universal Joint Bearing / Pinion Gear Pilot Bearing Inspection
Differential: 3B-14 Insert the universal joint to the bearing and check the Pinion Gear play by turning the universal joint, as shown. If excessive Inspect the pinion gear for wear or damage. play is noted, replace the bearing with a new one. Inspect the pinion gear bearing for abnormal noise and smooth rotation.
Page 288: Front Drive (Differential) Gear Shim Inspection And Selection (Lt-A400F, Lt-F400F)
3B-15 Differential: Breather Rubber Case 2) Make sure that the front drive (differential) case Inspect the breather rubber case (1) for wear or damage. cover bolts are tightened to the specified torque. If any defects are found, replace the breather rubber Tightening torque case with a new one.
Page 289 Differential: 3B-16 5) Remove the dial gauge and turn the front drive Left Side Shim Selection (differential) gear 120°, then measure the backlash. 1) Disassemble the front drive (differential) assembly. Repeat this procedure once more and compare the Refer to “Front Drive (Differential) Assembly difference of the three measurements.
Page 290 3B-17 Differential: 4) Install the front drive (differential) case cover and 7) Select the proper size of shim(-s) from the table, tighten the bolts to the special torque diagonally. according the compressed solder thickness. List of shims (for left side) NOTE Part No.
Page 291 Differential: 3B-18 3) Install the left and right side shims and front drive 5) Rotate the front drive (differential) gear several turns (differential) assembly. in each direction. This will provide a contact pattern on the coated teeth of front drive (differential) gear. 6) Remove the front drive (differential) gear and compare the coated teeth to the examples shown in [A], [B] and [C].
Page 292: Final Gear Components
3B-19 Differential: Final Gear Components B827H13206012 I827H1320119-02 1. Final gear case cover 8. Final drive gear : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Shim(-s) (RH) 9. Rear drive shaft : Apply silicone grease. 3. Final driven gear 10. Final gear coupling : Apply water resistant grease.
Page 293: Final Gear Construction
Differential: 3B-20 Final Gear Construction B827H13206013 I827H1320063-04 1. Shim(-s) (LH) : 80 N⋅m (8.0 kgf-m, 58.0 lb-ft) : Apply silicone grease. 2. Shim(-s) (RH) : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply water resistance grease. 3. Final drive gear shim(-s) : 33 N⋅m (3.3 kgf-m, 24.0 lb-ft) : Apply hypoid gear oil.
Page 294: Final Gear Oil Level Inspection
3B-21 Differential: I827H1320064-02 : 33 N⋅m (3.3 kgf-m, 24.5 lb-ft) : 33 N⋅m (3.3 kgf-m, 24.5 lb-ft) : Apply hypoid gear oil. : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Apply grease. Final Gear Oil Level Inspection 4) Remove the rear axle housing mounting bolts from B827H13206014 the swingarm.
Page 295 Pay attention to the following points: • Coat the new O-rings with grease and install them into the grooves in the gear case and cover. • Apply grease to the spline of the axles. : Grease 99000–25010 (SUZUKI SUPER I827H1320073-01 GREASE A or equivalent) I827H1320070-01...
Page 296: Final Gear Assembly Disassembly And Assembly
3B-23 Differential: • Install the final gear case assembly to the frame. 2) Unlock the final gear coupling nut. • Apply thread lock to the rear axle housing mounting nuts and tighten the nuts to the specified torque. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent) Tightening torque...
Page 297 Differential: 3B-24 5) Unlock the bearing lock-nut. 8) Remove the final gear case cover bolts diagonally and evenly. 9) Pry up the final gear case cover with 5 mm screws “A”. “A” I827H1320078-01 6) Remove the bearing lock-nut with the special tool. Special tool I827H1320080-02 (C): 09924–41830 (Bearing retainer wrench)
Page 298 3B-25 Differential: 12) Remove the bearing out of the final gear case cover with the special tool. Special tool (D): 09913–70210 (Bearing installer set) NOTE If there is no abnormal condition, the bearing removal is not necessary. I827H1320086-01 15) Remove the spacer and bearing from the final drive gear shaft with a commercially available bearing puller or hydraulic press.
Page 299 Differential: 3B-26 Assembly • Install new oil seals into the gear case and case cover Assemble the final drive in the reverse order of with the special tool. disassembly. Pay attention to the following points: • Apply gear oil to the new oil seal lips. Special tool CAUTION (A): 09913–70210 (Bearing installer set)
Page 300 • Install the shims, final drive gear assembly. bond to the mating surface of the cover. • Tighten new final drive gear lock-nut to the specified torque with the special tool. : Grease 99000–25100 (SUZUKI SILICONE GREASE or equivalent) CAUTION : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent)
Page 301: Final Gear Related Parts Inspection
Final Gear Related Parts Inspection • Apply silicone grease to the O-ring. B827H13206018 Refer to “Final Gear Assembly Removal and Installation : Grease 99000–25100 (SUZUKI SILICONE (Page 3B-21)” and “Final Gear Assembly Disassembly GREASE or equivalent) and Assembly (Page 3B-23)”.
Page 302 3B-29 Differential: Final Drive / Final Driven Gear Oil Seal Final Drive Gear / Bearing Inspect the oil seals for damage or wear. If any defect Inspect the final drive gear for wear or damage. Inspect are found, replace the oil seal with a new one. the final drive gear bearing for abnormal noise and smooth rotation.
Page 303: Final Gear Backlash Inspection And Shim Adjustment
Differential: 3B-30 Breather Rubber Case 3) Install the left side shim(-s) and final driven gear. Inspect the breather rubber case (1) for wear or damage. Special tool If any defects are found, replace the breather rubber (A): 09900–20607 (Dial gauge (1/100 mm, 10 case with a new one.
Page 304 3B-31 Differential: Right Side Shim Selection 3) Remove the final gear case cover. 1) Put a few pieces of solder (1) (O.D.: 1.2 – 1.5 mm 4) Measure the thickness of compressed solder with (0.05 – 0.06 in) x L: 6 mm (0.24 in)) on the back side the micrometer.
Page 305 Differential: 3B-32 • Install the left and right side shims (2) and final driven gear assembly (1). • Install the final gear case cover, and then tighten the bolts to the specified torque diagonally. Tightening torque Final gear case cover bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) NOTE At this time, it is not necessary to install the...
Page 306: Transfer Cable Inspection And Adjustment (Lt-A400F, Lt-F400F)
3B-33 Differential: Transfer Cable Inspection and Adjustment (LT- 3) Loosen the lock-nut (2). A400F, LT-F400F) 4) Turn in the adjuster (3) fully so that the cable obtains B827H13206021 enough play. Set the transfer selection lever to 4WD position and inspect that there is no play in the cable. If there is any play in the cable, adjust it in the following procedures.
Page 307: Specifications
“Front Drive (Differential) Construction (LT-A400F, LT-F400F) (Page 3B-3)” “Final Gear Components (Page 3B-19)” “Final Gear Construction (Page 3B-20)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”.
Page 308: Special Tools And Equipment
3B-35 Differential: Special Tools and Equipment Recommended Service Material B827H13208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3B-9) / (Page 3B- equivalent 10) / (Page 3B-11) / (Page 3B-12) / (Page 3B-22) SUZUKI SILICONE GREASE or P/No.: 99000–25100...
Page 309 Differential: 3B-36 09913–70210 09921–20210 Bearing installer set Bearing remover (Page 3B-8) / (Page 3B- (Page 3B-8) 8) / (Page 3B-9) / (Page 3B-9) / (Page 3B- 9) / (Page 3B-10) / (Page 3B-10) / (Page 3B-11) / (Page 3B-12) / (Page 3B-12) / (Page 3B-25) / (Page 3B-26) /...
Page 310: Transfer
3C-1 Transfer: Transfer Driveline / Axle Diagnostic Information and Procedures Transfer Symptom Diagnosis (LT-A400/F) B827H13304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn transfer input/output shaft.
Page 311: Repair Instructions
Transfer: 3C-2 Repair Instructions Transfer Components (LT-A400/F) B827H13306001 I827H1330001-02 1. Washer 14. Washer 27. Bearing 2. Reverse idle gear 15. Lock washer 28. High driven gear 3. Bearing 16. Lock washer 29. Washer 4. Reverse idle gear shaft 17. Spacer 30.
Page 312: Transfer Components (Lt-F400
3C-3 Transfer: Transfer Components (LT-F400/F) B827H13306017 I827H1330002-03 1. Washer 7. Transfer selecting dog 13. Transfer idle gear 2. Transfer low gear 8. Washer 14. Washer 3. Bushing 9. Transfer high gear 15. Transfer output shaft 4. Bearing 10. Washer 16. Transfer driven gear 5.
Page 313: Transfer Removal And Installation
Transfer: 3C-4 Transfer Removal and Installation (LT-A400/F) 8) Remove the transfer gearshift cam assembly (9). B827H13306002 Removal 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D (Page 1D-6)”. 2) Remove the engine top side. Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-10)”.
Page 314 3C-5 Transfer: 12) Remove the washer (11) and drive bevel gear (12). Installation Install the transfer in the reverse order of removal. Pay 13) Remove the shim (13). attention to the following points: CAUTION Apply engine oil to each gears and shafts. •...
Page 315 • Install the gearshift fork (5), reverse gearshift fork (6) tighten the drive bevel gear nut to the specified and transfer counter shaft assembly. Refer to torque. “Transfer Construction (LT-A400/F) (Page 3C-8)”. NOTE CAUTION Each gearshift fork has own embossed The removed drive bevel gear nut must be letters “A”...
Page 316: Transfer Removal And Installation
3C-7 Transfer: Transfer Removal and Installation (LT-F400/F) 9) Remove the bushing (8) and washer (9). B827H13306018 Removal 1) Remove the generator cover. Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”. 2) Remove the washer and transfer idle gear (1) with bearings.
Page 317: Transfer Construction (Lt-A400
I827H1330025-01 Spline offset part “A” of the gear faces • Install the generator cover. Refer to “Generator crankcase side. Removal and Installation in Section 1J (Page 1J-5)”. Transfer Construction (LT-A400/F) B827H13306003 I827H1330026-01 1. Transfer input shaft 2. Transfer countershaft 3. Reverse idle gear...
Page 318: Transfer Disassembly And Assembly (Lt- A400
Special tool original position. (A): 09921–20240 (Bearing remover set) Disassembly Disassemble the transfer countershaft and reverse idle gear. Refer to “Transfer Removal and Installation (LT-A400/F) (Page 3C-4)” and “Transfer Components (LT-A400/F) (Page 3C-2)”. Assembly NOTE • When reassembling the driven gears,...
Page 319 Transfer: 3C-10 Transfer Gearshift Cam Components (LT-A400/F) B827H13306005 I827H1330027-03 1. Spacer 10. Transfer gearshift shaft No. 1 19. Washer 2. Transfer shift gear 11. Washer 20. Gearshift cam plate 3. Return spring 12. Circlip 21. Gearshift cam stopper 4. Transfer gearshift shaft No. 2 13.
Page 320 3C-11 Transfer: Transfer Gearshift Cam Components (LT-F400/F) B827H13306019 I827H1330028-03 1. Transfer gearshift cam stopper set 8. OIl seal 15. Transfer gearshift shaft No. 1 2. Gasket 9. Washer 16. Spring 3. Washer 10. Gearshift cam plate 17. Washer 4. Snap ring 11.
Page 321 Transfer: 3C-12 Gearshift System Construction (LT-A400/F) B827H13306006 I827H1330029-01 1. Transfer gearshift shaft No. 1 2. Transfer counter shaft Gearshift System Construction (LT-F400/F) B827H13306020 I827H1330030-01 1. Transfer gearshift shaft No. 1 2. Reverse gearshift cam shaft...
Page 322: Transfer Gearshift Cam Disassembly And
• When installing a new snap ring (1), pay attention to Assembly (LT-A400/F) its direction. Fit it to the side where the thrust is as B827H13306007 shown in the figure. Refer to “Transfer Removal and Installation (LT-A400/F) (Page 3C-4)”. “A” Disassembly CAUTION Identify the position of each removed part.
Page 323 Transfer: 3C-14 Transfer Gearshift Cam Disassembly and • When installing a new snap ring (1), pay attention to Assembly (LT-F400/F) its direction. Fit it to the side where the thrust is as B827H13306021 shown in the figure. Refer to “Transfer Removal and Installation (LT-F400/F) (Page 3C-7)”.
Page 324: Transfer Related Parts Inspection
3C-15 Transfer: Transfer Related Parts Inspection (LT-A400/F) Gearshift Fork Thickness B827H13306010 Measure the gearshift fork thickness using the vernier Refer to “Transfer Removal and Installation (LT-A400/F) calipers. (Page 3C-4)” and “Transfer Disassembly and Assembly Special tool (LT-A400/F) (Page 3C-9)”. (A): 09900–20102 (Vernier calipers (1/20 mm,...
Page 325: Gear Position (Gp) Switch Inspection
B827H13306012 Refer to “Gear Position Switch Inspection in Section 1I (Page 1I-8)”. I827H1330062-01 Gear Position (GP) Switch Removal and Installation (LT-A400/F) B827H13306013 Removal 1) Turn the ignition switch OFF. 2) Remove the rear fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-...
Page 326: Gear Position (Gp) Switch Removal And Installation (Lt-F400
Refer to “Gear Position (GP) Switch Removal and Installation (LT-F400/F) in Section 5B (Page 5B-7)”. Transfer Gearshift Shaft No. 2 / Gearshift Cam I827H1330037-02 Plate Removal and Installation (LT-A400/F) 5) Remove the gearshift cam plate (9) and washer (10). B827H13306014 Removal 1) Drain engine oil.
Page 327 Transfer: 3C-18 6) Remove the spring (11) and gearshift cam stopper • Install the washer (2) and gearshift cam stopper plate (12). (3). NOTE • Align the gearshift cam pin “A” with the gearshift cam stopper plate hole “B”. I827H1330039-02 “B”...
Page 328: Gearshift Linkage Inspection (Lt-A400
Install the oil seal in the reverse order of removal. Pay B827H13306015 attention to the following points: Refer to “Transfer Gearshift Shaft No. 2 / Gearshift Cam Plate Removal and Installation (LT-A400/F) (Page 3C- CAUTION 17)”. The removed oil seal must be replaced with Gearshift Shaft new one.
Page 329: Transfer Range Lever Components
Transfer: 3C-20 Transfer Range Lever Components (LT-A400/F) Transfer Range Lever Removal and Installation B827H13306024 B827H13306026 Removal 1) Keep the vehicle on a level ground. 2) Remove the front fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”.
Page 330: Transfer Range Lever Disassembly And Assembly
“Transfer Range Lever Removal and Installation (Page 3C-20)”. 2) Disassemble the transfer range lever assembly as shown in the transfer range lever components. Refer to “Transfer Range Lever Components (LT-A400/F) (Page 3C-20)” and “Transfer Range Lever I827H1330058-01 Components (LT-F400/F) (Page 3C-20)”.
Page 331: Specifications
Color Position I827H1330060-01 L and R I827H1330061-02 4) After finishing the reverse switch inspection, reinstall the removed parts. Specifications Service Data (LT-A400/F) B827H13307001 Drive Train Unit: mm (in) Except ratio Item Standard Limit Automatic transmission ratio Variable change (2.938 – 0.813) —...
Page 332: Tightening Torque Specifications
“Transfer Range Lever Components (LT-A400/F) (Page 3C-20)” “Transfer Range Lever Components (LT-F400/F) (Page 3C-20)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 333: Propeller Shafts
Propeller Shafts: 3D-1 Propeller Shafts Driveline / Axle Repair Instructions Front Output Shaft Components B827H13406001 LT-A400/F I827H1340001-05 1. Front output shaft (LT-A400F) 4. Shim(-s) : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear output shaft 5. Driven bevel gear : Apply grease.
Page 334 3D-2 Propeller Shafts: LT-F400/F I827H1340003-02 1. Front output shaft (LT-F400F) 4. Shim(-s) : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear output shaft 5. Driven bevel gear : Apply grease. 3. Drive bevel gear 6. Shim(-s) : Do not reuse.
Page 335: Output Shaft Removal And Installation
Propeller Shafts: 3D-3 Output Shaft Removal and Installation B827H13406002 Removal 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D (Page 1D-6)”. 2) Remove the engine top side. Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-10)”. 3) Separate the crankcase.
Page 336: Rear Output Shaft Disassembly And Assembly (Lt-A400
• Assemble the engine. Refer to “Engine Bottom Side Assembly in Section 1D (Page 1D-43)” and “Engine Top Side Assembly in Section 1D (Page 1D-13)”. Rear Output Shaft Disassembly and Assembly (LT-A400/F) B827H13406016 Refer to “Output Shaft Removal and Installation (Page 3D-3)”.
Page 337 Propeller Shafts: 3D-5 4) Remove the C-rings (3) from the universal joint (4). 9) Remove the washer, joint yoke (5), oil seal (6), bearing (7) and shim (8). I827H1340020-01 5) Remove the bearings by tapping them with the I827H1340024-01 special tool and hammer. Assembly Special tool Assemble the rear output shaft in the reverse order of...
Page 338 • After the backlash and tooth contact have been checked or adjusted, stake the nut with a center • Install the oil seal to the joint yoke. punch. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the removed oil seal with a new one.
Page 339: Rear Output Shaft Disassembly And Assembly (Lt-F400
Propeller Shafts: 3D-7 • After reassembling the universal joint, check the joint • Stake the nut with a center punch. movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. I827H1340035-01 Rear Output Shaft Disassembly and Assembly I827H1340032-01 •...
Page 340 3D-8 Propeller Shafts: 3) Remove the washer, bearing (1) and driven bevel 8) With the rear output shaft held immovable with a gear (2). vise, remove the nut. I827H1340038-02 I827H1340042-01 4) Remove the C-rings (3) from the universal joint (4). 9) Remove the washer, joint yoke (5), oil seal (6), bearing (7) and shim (8).
Page 341 • After the backlash and tooth contact have been checked or adjusted, stake the nut with a center • Install the oil seal to the joint yoke. punch. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION Replace the removed oil seal with a new one.
Page 342: Front Output Shaft Disassembly And Assembly (Lt-A400F, Lt-F400F)
3D-10 Propeller Shafts: • After reassembling the universal joint, check the joint • Stake the nut with a center punch. movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. I827H1340053-01 Front Output Shaft Disassembly and Assembly I827H1340050-02 •...
Page 343: Rear Output Shaft Related Parts Inspection
• Install new oil seal to the front output shaft. Rear Output Shaft Inspect the rear output shaft for wear or damage. If any : Grease 99000–25010 (SUZUKI SUPER defects are found, replace the rear output shaft with a GREASE A or equivalent) new one.
Page 344 If any defects are found, replace the bearing with a new one. I827H1340057-01 I827H1340089-01 I827H1340086-01 I827H1340059-02 [A]: LT-A400/F [B]: LT-F400/F [A]: LT-A400/F [B]: LT-F400/F Rear Output Shaft Oil Seal Visually inspect the oil seal for damage, with particular Universal Joint attention given to the lip.
Page 345: Front Output Shaft Related Parts Inspection (Lt-A400F, Lt-F400F)
Propeller Shafts: 3D-13 Insert the universal joint to the bearing and check the Front Output Shaft Bearing (LT-A400F, LT-F400F) play by turning the universal joint, as shown. If excessive Inspect the front output shaft bearing for abnormal noise play is noted, replace the bearing with a new one. and smooth rotation.
Page 346 3D-14 Propeller Shafts: • Install the transfer output shaft assembly (1) with a plastic mallet. I827H1340063-01 6) Remove the washer (1) and drive bevel gear (2). 7) Remove the shim (3). I827H1340066-01 • Install the shim (2), drive bevel gear (3) and washer (4).
Page 347: Drive Bevel Gear Removal And Installation (Lt-F400
Propeller Shafts: 3D-15 • After the backlash and tooth contact have been 7) Remove the washer (1) and drive bevel gear (2). checked or adjusted, stake the nut with a center 8) Remove the shim (3). punch. I827H1340072-01 I827H1340069-01 9) Remove the transfer output shaft (4) with a plastic mallet.
Page 348: Driven And Drive Bevel Gear Shim Inspection And Adjustment
Tightening torque Drive bevel gear nut (a): 100 N·m (10.0 kgf-m, 72.5 lb-ft) I827H1340079-01 [A]: LT-A400/F [B]: LT-F400/F I827H1340076-01 • After the backlash and tooth contact have been checked or adjusted, stake the nut with a center punch.
Page 349 24945-03G50-118 1.175 mm (0.046 in) 24945-03G50-120 1.200 mm (0.047 in) I827H1340080-01 24945-03G50-123 1.225 mm (0.048 in) [A]: LT-A400/F [B]: LT-F400/F 24945-03G50-125 1.250 mm (0.049 in) 24945-03G50-128 1.275 mm (0.050 in) 3) Measure the backlash by turning the drive bevel 24945-03G50-130 1.300 mm (0.051 in)
Page 350 3D-18 Propeller Shafts: Tooth Contact CAUTION Make sure to check the backlash after the tooth contact has been adjusted, since it may have changed. Adjust the tooth contact and backlash until they are both within specification. If the correct tooth contact cannot be maintained when adjusting the backlash, replace the rear output shaft drive Incorrect (Contact at tooth top)
Page 351 (0.0217 in) 025: 0.25 mm 3) Install the drive bevel gear. Refer to “Drive Bevel 0.30+0.30=0.60 mm (0.0098 in) Gear Removal and Installation (LT-A400/F) (0.0236 in) (Page 3D-13)”. 0.30+0.35=0.65 mm 4) Install the rear output shaft. Refer to “Rear Output Combined (0.0256 in)
Page 352: Driven And Drive Bevel Gear Shim Adjustment Information
3D-20 Propeller Shafts: Driven and Drive Bevel Gear Shim Adjustment Information B827H13406023 LT-A400/F I827H1340082-01 1. Driven bevel gear shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Drive bevel gear shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft)
Page 353 Propeller Shafts: 3D-21 LT-F400/F I827H1340083-01 1. Driven bevel gear shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Drive bevel gear shim : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) : Do not reuse...
Page 354: Specifications
“Front Output Shaft Components (Page 3D-1)” “Driven and Drive Bevel Gear Shim Adjustment Information (Page 3D-20)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 355 Propeller Shafts: 3D-23 09900–20701 09913–70210 Magnetic stand Bearing installer set (Page 3D-17) (Page 3D-5) / (Page 3D- 6) / (Page 3D-8) / (Page 3D-9) 09920–53740 09921–21910 Clutch sleeve hub holder Bearing holder (Page 3D-13) / (Page 3D-16) (Page 3D-14) 09930–73190 Output shaft holder (Page 3D-15) / (Page 3D-16)
Page 356 3D-24 Propeller Shafts:...
Page 357 Recommended Service Material .......4C-10 Rear Brake Pedal Removal and Installation ..4A-12 Parking Brake .......... 4D-1 Specifications.............4A-13 Service Data (LT-A400/F, LT-F400/F) ....4A-13 Schematic and Routing Diagram ......4D-1 Tightening Torque Specifications...... 4A-14 Parking / Rear Brake Cable Routing Diagram ..4D-1 Special Tools and Equipment ......4A-14...
Page 358 4-ii Table of Contents Parking / Rear Brake Lever Inspection and Specifications ............4D-3 Adjustment ............4D-1 Tightening Torque Specifications......4D-3 Parking / Rear Brake Lever Removal and Special Tools and Equipment ......4D-3 Installation ............4D-1 Recommended Service Material ......4D-3 Parking / Rear Brake Cable Removal and Installation ............4D-3...
Page 359: Precautions
Precautions: Precautions Brake Precautions Precautions for Brake System B827H14000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B827H14000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.
Page 360: Brake Control System And Diagnosis
4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B827H14102001 “D” “C” “A” “C” “E” “ a ” “B” “F” “C” “C” “C” “G” I827H1410035-04 1. Front brake master cylinder “a”: 21°...
Page 361: Brake Cable Routing Diagram
Brake Control System and Diagnosis: 4A-2 Brake Cable Routing Diagram B827H14102002 “D” “C” “E” “F” “a” INSIDE “A” “B” “H” “ b ” “G” I827H1410036-06 1. Clamp 12. Clamp : Bind the front brake switch lead wire and throttle cable with the clamp. : Bind the starter cable with the clamp.
Page 362: Diagnostic Information And Procedures
4A-3 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brake Symptom Diagnosis B827H14104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads or lining. Replace. Oil adhesion on engaging surface of Clean disc and pads.
Page 363: Rear Brake Light Switch Inspection
Brake Control System and Diagnosis: 4A-4 2) Inspect the switch for continuity with a tester. Rear Brake Light Switch Inspection and If any abnormality is found, replace the front brake Adjustment light switch with a new one. Refer to “Front Brake B827H14106004 Inspection Master Cylinder / Brake Lever Disassembly and...
Page 364: Parking / Rear Brake Light Switch Inspection
4A-5 Brake Control System and Diagnosis: Parking / Rear Brake Light Switch Inspection Air Bleeding from Front Brake Fluid Circuit B827H14106005 B827H14106009 Inspect the parking/rear brake light switch in the Air trapped in the brake fluid circuit acts like a cushion to following procedures: absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full...
Page 365: Brake Fluid Replacement
Brake Control System and Diagnosis: 4A-6 4) Loosen the air bleeder valve by turning it a quarter of Brake Fluid Replacement B827H14106010 a turn so that the brake fluid runs into the receptacle, CAUTION this will remove the tension of the brake lever causing it to touch the handlebar grip.
Page 366: Front Brake Hose Removal And Installation
4A-7 Brake Control System and Diagnosis: 6) Close the air bleeder valve (1) and disconnect the 3) Remove the front brake hoses as shown in the front clear hose. brake hose routing diagram. Refer to “Front Brake Hose Routing Diagram (Page 4A-1)”. Tightening torque Front brake air bleeder valve (a): 6 N·m (0.6 kgf- Installation...
Page 367: Front Brake Master Cylinder Components
Brake Control System and Diagnosis: 4A-8 Front Brake Master Cylinder Components B827H14106013 I827H1410039-02 1. Reservoir cap 7. Brake hose union bolt : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 2. Diaphragm 8. Brake lever : Apply silicone grease. 3. Plate 9. Brake lever pivot bolt : Apply brake fluid.
Page 368 4A-9 Brake Control System and Diagnosis: 4) Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid. “A” 5) Remove the brake hose union bolt (2) and disconnect the brake hose. “B”...
Page 369: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly
Brake Control System and Diagnosis: 4A-10 Front Brake Master Cylinder / Brake Lever 4) Remove the following parts from the master cylinder. Disassembly and Assembly • Secondary cup (7) B827H14106015 • Piston (8) Refer to “Front Brake Master Cylinder Assembly Removal and Installation (Page 4A-8)”.
Page 370: Front Brake Master Cylinder Parts Inspection
• Apply grease to the brake lever pivot bolt. • Apply grease to the contact point between piston and brake lever. I649G1410027-02 : Grease 99000–25100 (SUZUKI Silicone Piston Grease or equivalent) Inspect the piston surface for any scratches or other damage.
Page 371: Rear Brake Pedal Construction
Brake Control System and Diagnosis: 4A-12 Rear Brake Pedal Construction B827H14106017 I827H1410037-03 1. Rear brake pedal 4. Brake light switch spring : 12 N⋅m (1.2 kgf-m, 8.5 lb-ft) 2. Rear brake light switch 5. Rear brake pedal pivot nut : Apply grease. 3.
Page 372: Specifications
Replace the O-rings with new ones. • After installing the rear brake pedal, check the rear brake pedal free travel. Refer to “Rear Brake Pedal / : Grease 99000–25010 (SUZUKI SUPER Rear Brake (Parking Brake) Lever Inspection and GREASE A or equivalent) Adjustment in Section 0B (Page 0B-16)”.
Page 373: Tightening Torque Specifications
“Front Brake Master Cylinder Components (Page 4A-8)” “Rear Brake Pedal Construction (Page 4A-12)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 374: Front Brakes
4B-1 Front Brakes: Front Brakes Brake Precautions Precautions for Front Brakes B827H14200001 WARNING When servicing the front brake system, place the vehicle on a level ground and support the vehicle with a jack. NOTE The right and left calipers, brake pads and discs are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side.
Page 375: Front Brake Pad Inspection
Front Brakes: 4B-2 Front Brake Pad Inspection 6) Install the new brake pads. B827H14206002 Refer to “Front Brake System Inspection in Section 0B CAUTION (Page 0B-15)”. Replace the brake pads as a set, otherwise braking performance will be adversely Front Brake Pad Replacement affected.
Page 376: Front Brake Caliper Removal And Installation
4B-3 Front Brakes: 9) Apply a small quantity of thread lock to the front Front Brake Caliper Removal and Installation B827H14206004 brakes caliper mounting bolts (2). : Thread lock cement 99000–32030 Removal (THREAD LOCK CEMENT SUPER 1303 or 1) Remove the front wheel assembly. Refer to “Front / equivalent) Rear Wheel Removal and Installation in Section 2D (Page 2D-3)”.
Page 377: Front Brake Caliper Disassembly And Assembly
Front Brakes: 4B-4 Installation Front Brake Caliper Disassembly and Assembly B827H14206005 Install the brake caliper in the reverse order of removal. Refer to “Front Brake Caliper Removal and Installation Pay attention to the following points: (Page 4B-3)”. • Apply a small quantity of thread lock to the front brake caliper mounting bolts (1).
Page 378 4B-5 Front Brakes: 5) Place a rag over the brake caliper piston to prevent it Assembly from popping out and then force out the piston using Assemble the caliper in the reverse order of compressed air. disassembly. Pay attention to the following points: •...
Page 379: Front Brake Caliper Parts Inspection
• Apply silicon grease to the two pins. Boots Inspect the boots for damage or wear. If any defects are : Grease 99000–25100 (SUZUKI SILICONE found, replace them with new ones. GREASE or equivalent) • Install the caliper holder (6) to the brake caliper (7).
Page 380: Front Brake Disc Removal And Installation
4B-7 Front Brakes: Brake Pad Mounting Pin Front Brake Disc Removal and Installation B827H14206007 Inspect the brake pad mounting pins for wear or other damage. If any defects are found, replace the mounting Removal pins with new ones. 1) Remove the front wheel assembly. Refer to “Front / Rear Wheel Removal and Installation in Section 2D (Page 2D-3)”.
Page 381: Front Brake Disc Inspection
3) Remount the front brake caliper. Refer to “Front 3) Remount the front brake caliper. Refer to “Front Brake Caliper Removal and Installation (Page 4B- Brake Caliper Removal and Installation (Page 4B- 3)”. 3)”. Specifications Service Data (LT-A400/F, LT-F400/F) B827H14207001 Brake Unit: mm (in) Item Standard Limit Front brake disc thickness 3.3 –...
Page 382: Tightening Torque Specifications
The specified tightening torque is also described in the following. “Front Brake Components (Page 4B-1)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 383: Rear Brakes
Rear Brakes: 4C-1 Rear Brakes Brake Precautions Precautions for Rear Brake B827H14300001 WARNING When servicing the rear brake system, place the vehicle on a level ground and support the vehicle with a jack. Schematic and Routing Diagram Rear Brake Breather Hose Routing Diagram B827H14302001 “A”...
Page 384: Repair Instructions
4C-2 Rear Brakes: Repair Instructions Rear Brake Components B827H14306001 “A” I827H1430039-03 1. Rear hub 7. Brake anchor panel : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 2. O-ring 8. Brake cam lever : Apply grease. 3. Dust seal 9. Rear brake drain plug : Apply silicone grease 4.
Page 385: Rear Brake Construction
Rear Brakes: 4C-3 Rear Brake Construction B827H14306007 “A” I827H1430034-02 1. Drum cover 8. Brake anchor panel : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 2. Brake drum 9. Brake camshaft : Apply grease. 3. O-ring 10. Brake cam lever : Apply silicone grease. 4.
Page 386 4C-4 Rear Brakes: 4) Disconnect the brake cables by removing the 8) Remove the rear hub (6) and dust seal (7) from the adjuster nuts (3). drum cover (5). NOTE If there are wear or damage, remove the dust seal (7). Refer to “Rear Brake Related Parts Inspection (Page 4C-8)”.
Page 387 Pay attention to the following points: I827H1430010-03 • Apply grease to the O-rings and brake camshaft. 14) Remove the O-ring (12). CAUTION Replace the O-rings with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1430011-02 I827H1430014-02...
Page 388 • Install the brake camshaft (1) and washer (2). • Apply bond to the mating surface of the brake panel. • Install the spring (3) with the spring end hooked to the : Sealant 99000–31230 (SUZUKI BOND hole on the brake panel. No.1216B or equivalent) •...
Page 389 If grease gets on the lining, brake slippage will result. • Apply grease to the spline on the rear axle. : Grease 99000–25010 (SUZUKI SUPER : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) GREASE A or equivalent)
Page 390: Rear Brake Related Parts Inspection
4C-8 Rear Brakes: • Assemble the drum cover (11) and rear hub (13). • Tighten the rear hub nut (16) to the specified torque. Tightening torque Rear hub nut (c): 121 N·m (12.1 kgf-m, 87.5 lb-ft) • Install the new cotter pin into the rear axle. CAUTION Replace the cotter pin with a new one.
Page 391: Specifications
The specified tightening torque is also described in the following. “Rear Brake Components (Page 4C-2)” “Rear Brake Construction (Page 4C-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”.
Page 392: Special Tools And Equipment
4C-10 Rear Brakes: Special Tools and Equipment Recommended Service Material B827H14308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 4C-5) / (Page 4C- equivalent 7) / (Page 4C-7) SUZUKI SILICONE GREASE or P/No.: 99000–25100...
Page 393: Parking Brake
Parking Brake: 4D-1 Parking Brake Brake Schematic and Routing Diagram Parking / Rear Brake Cable Routing Diagram B827H14402001 Refer to “Brake Cable Routing Diagram in Section 4A (Page 4A-2)”. Repair Instructions Parking / Rear Brake Lever Components B827H14406003 I827H1440001-03 1. Brake lever stopper 4.
Page 394: Parking / Rear Brake Lever Removal And Installation
Pay attention to the following points: B827H14406004 • Apply grease to the brake lever pivot bolt. Removal : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) 1) Disconnect the brake cable (1) from the brake lever. NOTE • Align the slit of lock-nut (2) with the slit of adjuster (3).
Page 395: Parking / Rear Brake Cable Removal And Installation
The specified tightening torque is also described in the following. “Parking / Rear Brake Lever Components (Page 4D-1)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 396 4D-4 Parking Brake:...
Page 397 Automatic Transmission......5A-1 Disassembly and Assembly (LT-F400/F) ..5B-5 Transmission Reverse Gearshift Cam Schematic and Routing Diagram......5A-1 Disassembly and Assembly (LT-F400/F) ..5B-6 Drive Train Operation (LT-A400/F) ..... 5A-1 Transmission Related Parts Inspection (LT- Diagnostic Information and Procedures....5A-4 F400/F)..............5B-7 Automatic Transmission Symptom Diagnosis..5A-4 Gear Position (GP) Switch Inspection (LT- Repair Instructions ..........5A-5...
Page 398 5-ii Table of Contents Specifications.............5C-10 Special Tools and Equipment ......5C-11 Service Data (LT-F400/F) .........5C-10 Recommended Service Material .......5C-11 Tightening Torque Specifications......5C-10 Special Tool ............5C-11...
Page 399: Precautions
Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B827H15000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 400: Automatic Transmission
5A-1 Automatic Transmission: Automatic Transmission Transmission / Transaxle Schematic and Routing Diagram Drive Train Operation (LT-A400/F) B827H15102001 High Gear I827H1510001-01 1. Conrod 4. Transfer input shaft 7. Output drive gear 2. Crankshaft 5. High driven gear 8. Output driven gear/Drive bevel gear 3.
Page 401: Low Gear
Automatic Transmission: 5A-2 Low Gear I827H1510002-01 1. Conrod 4. Transfer input shaft 7. Output drive gear 2. Crankshaft 5. Low driven gear 8. Output driven gear/Drive bevel gear 3. Drive V-belt 6. High/Low gear selection dog 9. Driven bevel gear/Output shaft...
Page 402 5A-3 Automatic Transmission: Reverse Gear I827H1510003-01 1. Conrod 5. Reverse idle gear 9. Output driven gear/Drive bevel gear 2. Crankshaft 6. Reverse driven gear 10. Driven bevel gear/Output shaft 3. Drive V-belt 7. Reverse gear dog 4. Transfer input shaft 8.
Page 403: Diagnostic Information And Procedures
Automatic Transmission: 5A-4 Diagnostic Information and Procedures Automatic Transmission Symptom Diagnosis B827H15104001 Condition Possible cause Correction / Reference Item Excessive engine noise Gear worn or abnormal contact. Replace. Spline worn. Replace. Bearing worn or burned. Replace. V-belt slipping V-belt slipping. Replace.
Page 404: Repair Instructions
5A-5 Automatic Transmission: Repair Instructions Automatic Transmission Components B827H15106001 I827H1510004-03 1. Clutch shoe assembly 13. Spacer 25. Movable driven face 2. One way clutch 14. Movable driven plate 26. Oil seal 3. Clutch wheel 15. Damper 27. Drive V-belt 4. Bearing 16.
Page 405: V-Belt Cooling Duct Removal And Installation
4. Outlet cooling duct connector V-belt Cooling Duct Removal and Installation 4) Remove the rear fender. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- (LT-A400/F) B827H15106003 3)”. 5) Loosen the clamp screws and remove the connector Removal (3) and outlet belt cooling duct (4).
Page 406: Clutch Engagement And Lock-Up Speed Inspection
(A): 09930–40113 (Rotor holder) Duct Construction (Page 5A-6)”. 2) Install the removed parts. Clutch Engagement and Lock-up Speed Inspection B827H15106004 Refer to “Automatic Clutch Inspection (LT-A400/F) in Section 0B (Page 0B-21)”. V-belt Type Continuously Variable Automatic Transmission Removal and Installation B827H15106005 Removal...
Page 407 • Apply grease in the groove of fixed driven face. oily or greasy matter and make its surfaces completely dry. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1510013-01 I827H1510015-01 • Install the movable driven face assembly.
Page 408 5A-9 Automatic Transmission: Movable Drive Face • Tighten the movable driven face nut to the specified torque with the special tool. • Install the movable drive face assembly (1). Tightening torque CAUTION Movable driven face nut (a): 115 N·m (11.5 kgf- Degrease the movable drive face assembly m, 83.0 lb-ft) (1).
Page 409: Movable Drive Face Disassembly And Assembly
2) Apply grease to the lip of oil seals and inside grease 3) Remove the rollers (3). groove “A” of the movable drive face. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION • Wipe off any excess grease thoroughly.
Page 410: Movable Driven Face Disassembly And Assembly
5A-11 Automatic Transmission: 4) Assemble the dampers (3) to the movable drive plate Movable Driven Face Disassembly and (4). Assembly B827H15106007 1) Hold the movable driven face assembly (1) with the special tool and vise, loosen the movable driven face ring nut with the special tool.
Page 411 Automatic Transmission: 5A-12 3) Remove the movable driven face ring nut (2). 6) Remove the spring seat (5). WARNING Since a high spring force applies to the movable driven face, care must be used so as not to cause the movable driven face to come off abruptly.
Page 412 If there are no abnormal conditions, the oil CAUTION seal removal is not necessary. Replace the O-rings (1) with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) CAUTION • Wipe off any excess grease thoroughly. • Take care not to apply grease to the contact surface of the drive V-belt.
Page 413 Automatic Transmission: 5A-14 • Install the pins and rollers. • Compress the spring with the special tool. Special tool (B): 09922–31430 (Clutch spring compressor) NOTE Make sure to insert the spring end “E” into the slot “F” of the special tool as shown in the figure.
Page 414: Drive V-Belt Inspection
5A-15 Automatic Transmission: Drive V-belt Inspection Roller B827H15106008 Inspect each roller and their sliding surface for wear or Inspect that the drive belt is free from any greasy damage. substance. If any defects are found, replace the rollers as a set. Inspect the contact surface of the drive belt for cracks or damage and measure the width of the drive belt with the NOTE...
Page 415: Movable / Fixed Driven Face Parts Inspection
Automatic Transmission: 5A-16 Movable / Fixed Driven Face Parts Inspection O-ring and Oil Seal B827H15106010 Inspect the O-rings and oil seals for wear or damage. If any defects are found, replace the O-rings and oil Movable / Fixed Driven Face seals with new ones.
Page 416 5A-17 Automatic Transmission: 6) Remove the gasket (5) and dowel pins. Installation Install the clutch shoe in the reverse order of removal. 7) Remove the one way clutch (6). Pay attention to the following points: • Install the clutch shoe assembly. •...
Page 417: V-Belt Outer Cover Bearing Removal And Installation
Automatic Transmission: 5A-18 • Install the dowel pins and new gasket (3). V-belt Outer Cover Bearing Removal and Installation CAUTION B827H15106021 Removal Use new gasket to prevent oil leakage. 1) Remove the V-belt outer cover. Refer to “V-belt Type Continuously Variable Automatic Transmission Removal and Installation (Page 5A-7)”.
Page 418: V-Belt Inner Cover Disassembly And Assembly
Installation • Apply grease to the rip of the oil seal. Installation is in the reverse order of removal. Pay : Grease 99000–25010 (SUZUKI SUPER attention to the following points: GREASE A or equivalent) • Install the bearing with the special tool.
Page 419 Automatic Transmission: 5A-20 3) Remove the retainers (3). Assembly Assembly is in the reverse order of disassembly. Pay attention to the following points: • Install the oil seal with the special tool. CAUTION • The removed oil seal must be replaced with a new one.
Page 420: Clutch Related Parts Inspection
I827H1510074-01 • Apply grease to the O-ring and oil seal lip. • Install the collar (1). : Grease 99000–25010 (SUZUKI SUPER I831G1510084-01 GREASE A or equivalent) Check the depth of the grooves on the clutch shoes. If...
Page 421: Specifications
“ a ” I831G1510087-01 “a”: play I827H1510079-01 One Way Clutch 1) Install the one way clutch (1) into the clutch wheel. Specifications Service Data (LT-A400/F) B827H15107001 Clutch Unit: mm (in) Item Standard Limit Clutch wheel I.D.
Page 422: Tightening Torque Specifications
The specified tightening torque is also described in the following. “Automatic Transmission Components (Page 5A-5)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 423: Special Tool
Automatic Transmission: 5A-24 Special Tool B827H15108002 09900–06108 09900–20101 Snap ring pliers Vernier calipers (1/15 mm, 150 mm) (Page 5A-18) (Page 5A-15) 09913–70210 09917–23711 Bearing installer set Ring nut wrench (Page 5A-10) / (Page 5A-11) / (Page 5A-13) / (Page 5A-14) (Page 5A-19) / (Page 5A-19) / (Page 5A-20) /...
Page 424: Manual Transmission
5B-1 Manual Transmission: Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis (LT-F400/F) B827H15204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Gear worn or rubbing. Replace. seems to come from the Badly worn splines. Replace.
Page 425: Repair Instructions
Manual Transmission: 5B-2 Repair Instructions Transmission Components (LT-F400/F) B827H15206001 I827H1520031-02 1. Reverse gear dog 7. 2nd driven gear 13. 2nd drive gear 2. Reverse driven gear 8. Driveshaft 14. Reverse idle gear 3. 1st driven gear 9. Countershaft 15. Reverse idle shaft 4.
Page 426: Transmission Removal And Installation (Lt- F400
5B-3 Manual Transmission: Transmission Removal and Installation (LT- Installation Install the transmission related parts in the reverse order F400/F) of removal. Pay attention to the following points: B827H15206002 Removal • Install the gearshift forks (1), (2), (3) and (4) as shown 1) Remove the engine assembly from the frame.
Page 427: Transmission Construction
Manual Transmission: 5B-4 • Install the reverse idle gear shaft (5). • Install the reverse idle gear (9) and washer (10). • Install the snap ring (6), washer (7) and spacer (8). Special tool : 09900–06107 (Snap ring pliers) I827H1520008-01 I827H1520007-01 Transmission Construction B827H15206004...
Page 428: Countershaft Gear / Driveshaft Gear
5B-5 Manual Transmission: Countershaft Gear / Driveshaft Gear Assembly Assemble the transmission in the reverse order of Disassembly and Assembly (LT-F400/F) disassembly. Pay attention to the following points: B827H15206005 Refer to “Transmission Removal and Installation (LT- F400/F) (Page 5B-3)”. NOTE Before installing the gears, coat lightly Disassembly engine oil to the shafts and gears.
Page 429: Transmission Reverse Gearshift Cam
Manual Transmission: 5B-6 • Fit the special tool and install the 2nd drive gear using Assembly a hydraulic press. When assembling the reverse gearshift cam, pay attention to the following points: Special tool (A): 09913–70210 (Bearing installer set) CAUTION • Never reuse a snap ring. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed.
Page 430: Transmission Related Parts Inspection (Lt- F400
5B-7 Manual Transmission: Transmission Related Parts Inspection (LT- Gearshift Fork Thickness Measure the gearshift fork thickness using the vernier F400/F) calipers. B827H15206007 Refer to “Transmission Removal and Installation (LT- Special tool F400/F) (Page 5B-3)” and “Countershaft Gear / (A): 09900–20102 (Vernier calipers (1/20 mm, Driveshaft Gear Disassembly and Assembly (LT-F400/F) 200 mm)) (Page 5B-5)”.
Page 431: Gear Position (Gp) Switch Removal And Installation (Lt-A400
5) Remove the gear position switch (2). Gear Position (GP) Switch Removal and Installation (LT-A400/F) B827H15206020 Refer to “Gear Position (GP) Switch Removal and Installation (LT-A400/F) in Section 3C (Page 3C-16)”. Gearshift Lever Removal and Installation (LT- F400/F) B827H15206017 Removal 1) Remove the left footrest mudguard.
Page 432: Gearshift Lever Height Inspection And Adjustment (Lt-F400
Replace the O-rings with new ones. Inspect and adjust the gearshift lever height in the following procedures: : Grease 99000–25010 (SUZUKI SUPER 1) Inspect the gearshift lever height “a” between the GREASE A or equivalent) pedal top face and footrest.
Page 433: Gearshift Shaft / Gearshift Cam Plate Components (Lt-F400
Manual Transmission: 5B-10 Gearshift Shaft / Gearshift Cam Plate Components (LT-F400/F) B827H15206019 I827H1520032-02 1. Gearshift fork (for reverse gear) 7. Gearshift cam plate : Apply thread lock to thread part. 2. Gearshift fork (for 1st driven 3rd driven 8. Gearshift cam : Apply thread lock to thread part.
Page 434: Gearshift Shaft / Gearshift Cam Plate Removal And Installation (Lt-F400
5B-11 Manual Transmission: Gearshift Shaft / Gearshift Cam Plate Removal 6) Remove the spring (5) and gearshift cam stopper (6). and Installation (LT-F400/F) B827H15206011 Removal 1) Drain engine oil 2) Remove the clutch assembly. Refer to “Clutch Removal and Installation (LT-F400/F) in Section 5C (Page 5C-3)”.
Page 435: Gearshift Linkage Inspection (Lt-F400
Manual Transmission: 5B-12 • Apply a small quantity of thread lock to the gearshift • Install the gearshift shaft assembly while aligning the shaft stopper (2) and tighten it to the specified torque. spring ends with the gearshift shaft stopper. : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent)
Page 436: Gearshift Shaft Oil Seal Removal And Installation (Lt-A400
5B-13 Manual Transmission: Gearshift Shaft Oil Seal Removal and Installation Install the oil seal in the reverse order of removal. Pay Installation (LT-A400/F) attention to the following points: B827H15206022 Removal CAUTION • Remove the generator cover. Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”.
Page 437: Tightening Torque Specifications
The specified tightening torque is also described in the following. “Gearshift Shaft / Gearshift Cam Plate Components (LT-F400/F) (Page 5B-10)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 438: Clutch
5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B827H15300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Diagnostic Information and Procedures Clutch System Symptom Diagnosis B827H15304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn splines of crankshaft or inner race.
Page 439: Repair Instructions
Clutch: 5C-2 Repair Instructions Clutch Components (LT-F400/F) B827H15306014 I827H1530001-01 1. Bearing 7. Clutch driven plate 13. Clutch wheel 2. Clutch release plate 8. Clutch pressure plate : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3. Clutch spring 9. Collar : 145 N⋅m (14.5 kgf-m, 105.0 lb-ft) 4.
Page 440: Clutch Removal And Installation (Lt-F400
5C-3 Clutch: Clutch Removal and Installation (LT-F400/F) 6) Remove the washer (3), clutch release arm (4) and B827H15306016 clutch release roller guide (5). Remove 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-7)”. 2) Remove the right footrest mudguard.
Page 441 Clutch: 5C-4 9) Unlock the clutch sleeve hub nut. 12) Remove the thrust washer (9), thrust washer (10) and spacer (11). I827H1530008-01 10) Remove the clutch sleeve hub nut using the special I827H1530011-01 tool. Installation Special tool Install the clutch components in the reverse order of (A): 09920–53730 (Clutch sleeve hub removal.
Page 442 5C-5 Clutch: • Install the collar (3) onto the primary driven gear • Stake the clutch sleeve hub nut with a center punch. assembly. I827H1530017-01 • Install the one-way clutch with the “OUT SIDE” letters I827H1530014-01 • Install the clutch sleeve hub assembly into the primary “A”...
Page 443: Clutch Related Parts Inspection (Lt-F400
• Install the clutch springs and clutch release plate. • Apply grease to the O-ring and install the clutch adjuster cap. • Tighten the clutch spring bolts diagonally. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1530020-01 • Install the dowel pins and new gasket (4).
Page 444 5C-7 Clutch: Measure the claw width of drive plates with a vernier Clutch Sleeve Hub and Primary Driven Gear calipers. Replace the drive plates found to have worn Assembly down to the limit. Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the Special tool clutch plates.
Page 445: Clutch Cover Disassembly And Assembly
Clutch: 5C-8 Clutch Wheel 2) Install the clutch shoe (3) onto the clutch wheel and Inspect the clutch wheel for any abnormal surface turn the clutch shoe by hand to inspect the one way damage. Measure the inside diameter of the clutch clutch for a smooth movement.
Page 446 5C-9 Clutch: 2) Remove the snap ring (1) with the special tool. • Install the snap ring with the special tool. Special tool Special tool : 09900–06108 (Snap ring pliers) : 09900–06108 (Snap ring pliers) NOTE CAUTION If there is no abnormal noise, the bearing Removed snap ring must be replaced with a removal is not necessary.
Page 447: Clutch Release Roller Inspection (Lt-F400
(Page 5C-6) NOTE The specified tightening torque is also described in the following. “Clutch Components (LT-F400/F) (Page 5C-2)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”.
Page 448 5C-11 Clutch: Special Tools and Equipment Recommended Service Material B827H15308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5C-6) equivalent NOTE Required service material is also described in the following. “Clutch Components (LT-F400/F) (Page 5C-2)”...
Page 449 Installation ............6B-5 Steering General Diagnosis....6A-1 Steering Parts Inspection ........6B-10 Specifications.............6B-11 Diagnostic Information and Procedures....6A-1 Service Data (LT-A400/F, LT-F400/F) ....6B-11 Steering Symptom Diagnosis......6A-1 Tightening Torque Specifications......6B-11 Steering / Handlebar........ 6B-1 Special Tools and Equipment ......6B-12 Recommended Service Material .......6B-12 Repair Instructions ..........6B-1...
Page 450: Precautions
6-1 Precautions: Precautions Steering Precautions Precautions for Steering B827H16000001 Refer to “General Precautions in Section 00 (Page 00-1)”.
Page 451: Steering General Diagnosis
Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B827H16104001 Condition Possible cause Correction / Reference Item Heavy Steering Distorted steering shaft. Replace. Improper front wheel alignment. Adjust. Insufficiently lubricated. Lubricate. Not enough pressure in tires. Adjust.
Page 452: Steering / Handlebar
6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Steering / Handlebars Components B827H16206001 “A” “A” I827H1620049-02 1. Handlebars 6. Steering shaft 11. Dust seal : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Handle grip 7. Steering shaft bushing 12.
Page 453: Steering Assembly Construction
Steering / Handlebar: 6B-2 Steering Assembly Construction B827H16206008 I827H1620001-03 1. Steering shaft 6. O-ring : 49 N⋅m (4.9 kgf-m, 35.5 lb-ft) 2. Tie-rod 7. Cotter pin : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) 3. Tie-rod end nut 8. Handlebar clamp bolt : Apply grease.
Page 454: Handlebars Removal And Installation
6B-3 Steering / Handlebar: Handlebars Removal and Installation 5) Remove the left switch box (5) and rear brake lever B827H16206003 holder clamp bolt (6). Removal 1) Remove the speedometer cover. Refer to “Speedometer Removal and Installation in Section 9C (Page 9C-2)”. 2) Remove the throttle lever case (1), front brake master cylinder (2) and right grip (3).
Page 455 Steering / Handlebar: 6B-4 Installation • Tighten the handlebar clamp bolts (3) to the specified Install the handlebars in the reverse order of removal. torque. Pay attention to the following points: NOTE • Insert the rear brake lever holder (1) and starter lever First tighten the handlebar clamp bolts (3) (2) onto the handlebars.
Page 456: Handlebars Inspection
3)”. 3) Remove the cooling fan (1) and inlet cooling duct (2) I827H1620015-01 (LT-A400/F). Refer to “Cooling Fan Removal and • Install the right grip as the same manner of left grip. Installation in Section 1E (Page 1E-13)” and “V-belt •...
Page 457 Steering / Handlebar: 6B-6 Tie-rod 4) Remove the tie-rod end (3), lock-nut (1) and (2) from the tie-rod (4). 1) Remove cotter pins and tie-rod end nuts and washers. I827H1620022-02 Steering Shaft I827H1620019-01 1) Remove the speedometer and handlebars. Refer to “Speedometer Removal and Installation in Section 9C (Page 9C-2)”...
Page 458 6B-7 Steering / Handlebar: 5) Remove the steering shaft holders (1) and dust seals 9) Remove the steering shaft bushing (8) using the (2). special tools and suitable socket wrench “A”. NOTE If there are wear or damage, remove the steering shaft bushing (8).
Page 459 6B-8 • Apply grease to the steering shaft bushing (1). • Apply grease to the dust seals before installing the steering shaft. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I827H1620030-02 •...
Page 460 6B-9 Steering / Handlebar: • Tighten the steering shaft lower nut to the specified • Tighten the tie-rod end nuts to the specified torque. torque. Tightening torque Tightening torque Tie-rod end nut (a): 29 N·m (2.9 kgf-m, 21.0 lb-ft) Steering shaft lower nut (b): 49 N·m (4.9 kgf-m, •...
Page 461: Steering Parts Inspection
Steering / Handlebar: 6B-10 • Check the steering moves smoothly. Tie-rod End Inspect the tie-rod ends for smooth movement. If there • Check the wiring harness routing, cable routing and are any abnormalities, replace the tie-rod ends with new brake hose routing. Refer to “Wiring Harness Routing ones.
Page 462: Tightening Torque Specifications
The specified tightening torque is also described in the following. “Steering / Handlebars Components (Page 6B-1)” “Steering Assembly Construction (Page 6B-2)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”.
Page 463: Special Tools And Equipment
Steering / Handlebar: 6B-12 Special Tools and Equipment Recommended Service Material B827H16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-5) / (Page 6B- equivalent 8) / (Page 6B-8) / (Page 6B-8) /...
Page 464 6B-13 Steering / Handlebar:...
Page 465 Horn Removal and Installation (For P-17, 24)..9C-4 Wiring Harness Routing Diagram......9A-8 Specifications............9C-4 Specifications.............9A-10 Service Data (LT-A400/F, LT-F400/F) ....9C-4 Service Data (LT-A400/F, LT-F400/F) ....9A-10 Special Tools and Equipment ......9C-4 Tightening Torque Specifications...... 9A-10 Special Tool ............9C-4 Lighting Systems........9B-1 Exterior Parts ...........
Page 466: Precautions
9-1 Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B827H19000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B827H19003001 Refer to “Electrical Components Location in Section 0A (Page 0A-6)”.
Page 467: Wiring Systems
Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram B827H19102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-4)”.
Page 468 9A-2 Wiring Systems: LT-A400 (P-28, 33), LT-A400F (P-24) I827H1910903-03...
Page 469 Wiring Systems: 9A-3 LT-A400F (P-17) I827H1910904-03...
Page 470 9A-4 Wiring Systems: LT-A400F (P-28, 33) I827H1910905-03...
Page 471 Wiring Systems: 9A-5 LT-F400 (P-24, 28, 33), LT-F400F (P-24) I827H1910906-03...
Page 472 9A-6 Wiring Systems: LT-F400/F (P-17) I827H1910907-03...
Page 473 Wiring Systems: 9A-7 LT-F400F (P-28, 33) I827H1910908-03...
Page 474: Wiring Harness Routing Diagram
9A-8 Wiring Systems: Wiring Harness Routing Diagram B827H19102002 “A” “B” “D” “E” “C” “G” “ a ” “F” I827H1910901-06 1. Clamp 16. Cooling fan thermo-switch and engine oil temperature switch lead wire : Bind the handlebar switch lead wire, parking/rear brake light switch lead wire and horn button lead wire (P-17, 24) with the clamp.
Page 475 “ b ” “ a ” “A” “ c” “ c ” I827H1910902-01 1. Clamp : 7.0 N⋅m (0.7 kgf-m, 5.0 lb-ft) 2. GP switch (LT-A400/F) : 140 N⋅m (14.0 kgf-m, 101.0 lb-ft) 3. GP switch (LT-F400/F) “a”: Within 60°...
Page 476: Specifications
NOTE The specified tightening torque is also described in the following. “Wiring Harness Routing Diagram (Page 9A-8)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”.
Page 477: Lighting Systems
Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Construction B827H19206001 I827H1920001-02 1. Headlight housing 2. Grommet 3. Yellow tape (LH) White tape (RH)
Page 478: Front Side Reflector Construction
9B-2 Lighting Systems: Front Side Reflector Construction B827H19206015 I827H1920003-01 1. Front side reflector (P-28 only) : 1.8 N⋅m (0.18 kgf-m, 1.5 lb-ft) 2. Bracket stopper : 3.3 N⋅m (0.33 kgf-m, 2.5 lb-ft)
Page 479: Headlight Components
Lighting Systems: 9B-3 Headlight Components B827H19206002 I827H1920004-01 1. Headlight bulb (12 V 35/35 W x2) Headlight Removal and Installation 2) Remove the headlight with the housing (2). B827H19206003 Removal 1) Disconnect the headlight coupler (1). I827H1920006-03 I827H1920005-01...
Page 480: Headlight Bulb Replacement
9B-4 Lighting Systems: 3) Remove the headlight (3) from the housing. I827H1920009-01 4) Reinstall the removed parts. I827H1920007-01 NOTE Installation Install the headlight in the reverse order of removal. Pay Properly fit the socket cover and headlight attention to the following point: housing cover.
Page 481: Rear Combination Light Components
Lighting Systems: 9B-5 Rear Combination Light components B827H19206009 I827H1920002-01 1. Brake light / Taillight bulb (12 V 21/5 W) Rear Combination Light Removal and 2) Remove the rear combination light assembly (2). Installation B827H19206010 Removal 1) Remove the rear combination light coupler (1). I827H1920012-01 I827H1920011-01...
Page 482: Rear Combination Light Bulb Replacement
9B-6 Lighting Systems: Installation Reversing Light Bulb Replacement (For P-17) B827H19206012 Install the rear combination light in the reverse order of CAUTION removal. • If you touch the bulb with your bare hands, Rear Combination Light Bulb Replacement clean the bulb with a cloth moistened with B827H19206011 alcohol or soapy water to prevent CAUTION...
Page 483: Dimmer Switch Inspection
The specified tightening torque is also described in the following. “Front Side Reflector Construction (Page 9B-2)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment...
Page 484: Combination Meter / Fuel Meter / Horn
9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories Repair Instructions Speedometer Components B827H19306001 I827H1930001-01 1. Speedometer 3. Speedometer light bulb (12V 1.7 W) 5. Indicator light bulb (12V 3.4 W) 2.
Page 485: Speedometer Removal And Installation
Combination Meter / Fuel Meter / Horn: 9C-2 Speedometer Removal and Installation 6) Disconnect the speedometer light socket (7) and B827H19306002 remove the speedometer. Removal 1) Remove the indicator light lenses (1). 2) Remove the speedometer cover bolts and ignition switch ring nut (2).
Page 486: Speedometer Disassembly And Assembly
9C-3 Combination Meter / Fuel Meter / Horn: Installation Speedometer light bulb / Indicator light bulb Install the speedometer in the reverse order of removal. Replacement Pay attention to the following points: B827H19306016 Refer to “Speedometer Removal and Installation • Rout the speedometer cable properly. Refer to (Page 9C-2)”.
Page 487: Specifications
Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication Continuity ( Color Position PUSH I831G1930024-03 3) Connect the horn connectors. Specifications Service Data (LT-A400/F, LT-F400/F) B827H19307001 Wattage Unit: W Specification Item P 24, 28, 33 P-17 ← Speedometer light High beam indicator light —...
Page 488: Exterior Parts
9D-1 Exterior Parts: Exterior Parts Body and Accessories Repair Instructions Rear Fender Heat Shield Construction B827H19406002 “A” “ a ” I827H1940003-02 1. Rear fender heat shield “A”: Do not cover the hole with the heat shield 2. Rear fender “a”: 0 mm (0 in)
Page 489: Fastener Removal And Installation
Exterior Parts: 9D-2 Fastener Removal and Installation Type B B827H19406004 Removal Type A 1) Pry up the head of fastener center piece (1) with a Removal screw driver. 1) Depress the head of fastener center piece (1). 2) Pull out the fastener “A”. 2) Pull out the fastener (2).
Page 490: Exterior Parts Removal And Installation
9D-3 Exterior Parts: Exterior Parts Removal and Installation B827H19406005 Seat Removal Unlock and remove the seat. I827H1940007-01 Installation Installation is in the reverse order of removal. Fuel Tank Upper Cover Refer to “Fuel Tank Removal and Installation in Section I827H1940004-01 1G (Page 1G-13)”.
Page 491 Exterior Parts: 9D-4 Inner Fender Front Under Cover Removal Removal Remove the inner fender (1) (LH/RH) by removing the Remove the front under cover (1). following screw and fasteners. I827H1940013-02 I827H1940010-01 I827H1940014-02 I827H1940011-01 Installation Installation is in the reverse order of removal. I827H1940012-01 Installation Installation is in the reverse order of removal.
Page 492 9D-5 Exterior Parts: Engine Under Cover 7) Disconnect the headlight couplers (2). Removal 8) Remove the front fender with the headlight Remove the engine under cover (1). assemblies. I827H1940015-01 I827H1940018-03 I827H1940021-01 I827H1940019-03 9) Remove the headlight assemblies from the front Installation fender.
Page 493 Exterior Parts: 9D-6 Rear Fender Removal 1) Remove the rear carrier. Refer to “Rear Carrier Removal and Installation in Section 9E (Page 9E-4)”. 2) Remove the CDI unit (1) from the bracket. I827H1940023-01 3) Remove the side covers. 4) Remove the footrest mudguards. 5) Remove the battery (2).
Page 494: Body Structure
9E-1 Body Structure: Body Structure Body and Accessories Repair Instructions Body Frame Construction B827H19506001 I827H1950001-03 1. Frame 3. Battery plate : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) 2. Engine mounting upper bracket : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) Footrest Construction B827H19506002 I827H1950002-03 1.
Page 495: Footrest Removal And Installation
Body Structure: 9E-2 Footrest Removal and Installation Installation B827H19506003 Install the footrest in the reverse order of removal. Pay attention to the following point: Removal • Install the gearshift lever assembly to the footrest. (LT- 1) Remove the footrest mudguard. Refer to “Exterior F400/F LH).
Page 496: Carrier Construction
9E-3 Body Structure: Carrier Construction B827H19506004 I827H1950005-04 1. Front carrier : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) : Apply thread lock to the thread part. 2. Rear carrier : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft)
Page 497: Front Carrier Removal And Installation
Body Structure: 9E-4 Front Carrier Removal and Installation Rear Carrier Removal and Installation B827H19506005 B827H19506006 Removal Removal • Remove the front carrier (1) by removing the bolts (2). • Remove the rear carrier (1) by removing the bolts and screw. I827H1950007-01 I827H1950010-01 I827H1950008-01...
Page 498: Front Grip Bar Construction
9E-5 Body Structure: Front Grip Bar Construction B827H19506007 I827H1950006-03 1. Front grip bar : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) Front Grip Bar Removal and Installation B827H19506008 Removal 1) Remove the front under cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”.
Page 499: Trailer Towing Removal And Instruction
Body Structure: 9E-6 Installation Trailer Towing Removal and Instruction B827H19506010 Install the front grip bar in the reverse order of removal. Removal Pay attention to the following point: Remove the trailer towing (1) by removing the bolts. • Tighten the front grip bar mounting bolts to the specified torque.
Page 500: Specifications
“Carrier Construction (Page 9E-3)” “Front Grip Bar Construction (Page 9E-5)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A400/F) in Section 0C (Page 0C-9)”. Special Tools and Equipment Recommended Service Material...
Page 501 Prepared by December, 2007 Part No. 99500-43070-01E Printed in Japan...
Page 502 Printed in Japan...

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Lt-a400f Lt-f400 Lt-f400f

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