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Suzuki LT-A400 Service Manual

Summary of LT-A400

  • Page 1

    Printed in japan k8 9 9 5 0 0 - 4 3 0 7 0 - 0 1 e k8.

  • 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 wi...

  • Page 3

    00 0 1 2 3 4 5 6 7 8 9 10 11 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ....................

  • Page 5

    Table of contents 00- i 00 section 00 contents precautions precautions ...............................................00-1 precautions........................................................... 00-1 warning / caution / note..................................... 00-1 general precautions .................

  • Page 6

    00-1 precautions: precautions precautions precautions warning / caution / note b827h10000001 please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the message...

  • Page 7

    Precautions: 00-2 • never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. • use a torque wrench to ti...

  • Page 8

    00-3 precautions: • check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc. Clamp • clamp the wire harness at such positions as indicated in “wiring harness routing diagram in section 9a (page 9a-8)”. • bend ...

  • Page 9

    Precautions: 00-4 battery • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi systems instantly when reverse power is applied. • removing any battery terminal of a running engine is strictly prohibited. The moment such removal...

  • Page 10

    00-5 precautions: 3) using a test male terminal, check the female terminals of the circuit being checked for contact tension. Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each termin...

  • Page 11

    Precautions: 00-6 3) also, if measured values are as listed following, a resistance (abnormality) exists which causes the voltage drop in the circuit between terminals “a” and “b”. Voltage between “a” and body ground: approx. 5 v “b” and body ground: approx. 5 v – 2 v voltage drop “c” and body groun...

  • Page 12

    00-7 precautions: using the multi-circuit testers • use the suzuki multi-circuit tester set. • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Special tool (a): 09900–25008 (multi-circuit tester set) using the testers • incorrectly connecting the (...

  • Page 13

    Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 symbols .............................................................. 0a-1 abbreviations .....................

  • Page 14

    0a-1 general information: general information general information general description symbols b827h10101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Abbreviations b827h10...

  • Page 15

    General information: 0a-2 m: max: maximum mil: malfunction indicator lamp (led) min: minimum n: nox: nitrogen oxides o: ohc: over head camshaft p: pcv: positive crankcase ventilation (crankcase breather) r: rh: right hand rom: read only memory s: sae: society of automotive engineers vehicle side vie...

  • Page 16

    0a-3 general information: vehicle identification number b827h10101005 the frame serial number or v.I.N. (vehicle identification number) “a” is stamped on the left side of the rear frame pipe. The engine serial number “b” is located on the left side of the crankcase. These numbers are required especi...

  • Page 17

    General information: 0a-4 break-in procedures b827h10101008 during manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The...

  • Page 18

    0a-5 general information: warning, caution and information labels location b827h10101011 2 23 1 24 26 21 22 8 9 16 15 7 3 17 18 6 10 20 19 5 4 25 12 13 14 11 [a] [b] [d] [c] i827h1010011-02 1. Certification plate (english) for p-24, 33 16. Gearshift label (french) for p-28 2. Information label (engl...

  • Page 19

    General information: 0a-6 component location electrical components location b827h10103001 lt-a400/f 1 3 5 6 7 8 11 10 12 13 14 15 4 2 9 i827h1010007-01 1. Battery 6. Ignition switch 11. Starter motor 2. Main fuse 7. Output terminal 12. Brake light switch 3. Starter relay 8. Handlebar switch (lh) 13....

  • Page 20

    0a-7 general information: 16 17 18 19 21 22 23 20 i827h1010008-02 16. Ignition coil 19. Regulator/rectifier 22. Reverse diode 17. Cooling fan 20. Cdi unit 23. Generator 18. Ignition/starter control relay 21. Neutral switch diode.

  • Page 21

    General information: 0a-8 lt-f400/f 1 3 5 6 8 10 11 12 13 14 4 2 7 9 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 swi...

  • Page 22

    0a-9 general information: 23 15 16 17 18 21 22 19 20 i827h1010010-04 15. Ignition coil 18. Regulator/rectifier 21. Neutral diode 16. Cooling fan 19. Cdi unit 22. Generator 17. Ignition/starter control relay 20. Reverse switch 23. Neutral switch.

  • Page 23

    General information: 0a-10 specifications specifications b827h10107001 note these specifications are subject to change without notice. Lt-a400/f dimensions and dry mass engine drive train item specification remark overall length 2 160 mm (85.0 in) p-17, 24 2 060 mm (81.1 in) p-28, 33 overall width 1...

  • Page 24

    0a-11 general information: chassis electrical capacities 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...

  • Page 25

    General information: 0a-12 lt-f400/f dimensions and dry mass engine drive train item specification remark overall length 2 160 mm (85.0 in) p-17, 24 2 060 mm (81.1 in) p-28,33 overall width 1 200 mm (47.2 in) p-17, 24 1 145 mm (45.1 in) p-28,33 overall height 1 220 mm (48.0 in) wheelbase 1 270 mm (5...

  • Page 26

    0a-13 general information: chassis electrical capacities 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...

  • Page 27

    General information: 0a-14 special tools and equipment special tool b827h10108007 09900–06107 snap ring pliers 09900–06108 snap ring pliers 09900–20101 vernier calipers (1/15 mm, 150 mm) 09900–20102 vernier calipers (1/20 mm, 200 mm) 09900–20202 micrometer (1/100 mm, 25 – 50 mm) 09900–20205 micromet...

  • Page 28

    0a-15 general information: 09915–64512 compression gauge 09915–74511 oil pressure gauge set 09916–10911 valve lapper set 09916–14510 valve spring compressor 09916–14910 valve spring compressor attachment 09916–34542 reamer handle 09916–34570 valve guide reamer (5.0 mm) 09916–34580 valve guide reamer...

  • Page 29

    General information: 0a-16 09924–64510 final driving gear coupling holder 09924–84521 bearing installer set 09930–10121 spark plug wrench set 09930–30104 rotor remover slide shaft 09930–30141 attachment a 09930–30721 rotor remover 09930–31921 rotor remover 09930–40113 rotor holder 09930–44541 rotor ...

  • Page 30

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance b827h10200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak...

  • Page 31

    Maintenance and lubrication: 0b-2 lubrication points b827h10205002 proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots and wipe off an...

  • Page 32

    0b-3 maintenance and lubrication: repair instructions air cleaner element inspection and cleaning b827h10206001 clean element every 1 000 km (600 miles, 3 months) if the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an increase i...

  • Page 33

    Maintenance and lubrication: 0b-4 exhaust pipe bolt and muffler bolt inspection b827h10206002 tighten exhaust pipe bolts, muffler bolt and nut initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter check the exhaust pipe bolts, muffler bolts and nuts to the spec...

  • Page 34

    0b-5 maintenance and lubrication: 5) turn the crankshaft until the piston reaches tdc on the compression stroke by slowly pulling the recoil starter rope. Pull the recoil starter rope until the line (4) on the generator rotor is aligned with the mark (5) on the crankcase. 6) remove the valve timing ...

  • Page 35

    Maintenance and lubrication: 0b-6 spark plug inspection and cleaning b827h10206005 inspect spark plug every 2 000 km (1 200 miles, 6 months) heat range 1) remove the spark plug. Refer to “spark plug removal and installation in section 1h (page 1h- 3)”. 2) check spark plug heat range by observing ele...

  • Page 36

    0b-7 maintenance and lubrication: spark arrester cleaning b827h10206006 clean spark arrester every 2 000 km (1 200 miles, 6 months) clean the spark arrester in the following procedures: 1) remove the spark arrester (1) from the muffler. 2) clean the spark arrester with a brush. Warning ! Only clean ...

  • Page 37

    Maintenance and lubrication: 0b-8 4) check the oil level on the dipstick. If the level is below low level line “a”, add oil to full level line “b”. If the level is above full level line “b”, drain oil to full level line “b”. Note when inspecting the oil level, the oil filler cap threads are not run ...

  • Page 38

    0b-9 maintenance and lubrication: 7) install the new oil filter. Turn it by hand until you feel that the oil filter o-ring contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to the specified torque) using the special tool. Note to properly tighten the oil filte...

  • Page 39

    Maintenance and lubrication: 0b-10 front differential gear oil replacement (lt- a400f, lt-f400f) b827h10206010 replace front differential gear oil every 2 years replace the oil filter differential gear oil in the following procedures: 1) place the vehicle on level ground. 2) remove the front under c...

  • Page 40

    0b-11 maintenance and lubrication: 8) install the front under cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 3)”. Final gear oil inspection b827h10206011 inspect final gear oil every 2 000 km (1 200 miles, 6 months) inspect the final gear oil level in the following ...

  • Page 41

    Maintenance and lubrication: 0b-12 3) remove the oil filler plug (2) and oil level plug (3). 4) drain final gear oil by removing the drain plug (4). 5) tighten the oil drain plug (4) to the specified torque. Caution ! Replace the gasket with a new one. Tightening torque final gear oil drain plug (a)...

  • Page 42

    0b-13 maintenance and lubrication: throttle cable play inspection and adjustment b827h10206013 inspect throttle cable play initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter inspect and adjust the throttle cable play “a” as follows. Throttle cable play “a” 3...

  • Page 43

    Maintenance and lubrication: 0b-14 clutch inspection (lt-f400/f) b827h10206031 inspect clutch system every 2 000 km (1200 miles, 6 months) the lt-f400/f is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assemblies it is essential that the ...

  • Page 44

    0b-15 maintenance and lubrication: front brake system inspection b827h10206018 inspect brake system initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter warning ! • the front brake system of this vehicle is filled with a glycol-based brake fluid. Do not use or...

  • Page 45

    Maintenance and lubrication: 0b-16 rear brake pedal / rear brake (parking brake) lever inspection and adjustment b827h10206019 note adjust the rear brake by adjusting the brake pedal first and then adjust the brake lever. Brake pedal free travel 1) inspect the brake pedal free travel “a”. Adjust the...

  • Page 46

    0b-17 maintenance and lubrication: rear brake lining wear limit this vehicle has brake lining wear limit indicator on the 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 tha...

  • Page 47

    Maintenance and lubrication: 0b-18 steering system inspection b827h10206022 inspect steering system initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter steering should be adjusted properly for smooth turning of handlebars and safe running. 1) place the vehicl...

  • Page 48

    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) suspension inspection b827h10206024 inspect suspension every 2 000 km (1 200 miles, 6 months) inspect suspe...

  • Page 49

    Maintenance and lubrication: 0b-20 7 steering knuckle pinch bolt (upper and lower) 50 n ⋅m 5.0 kgf-m, 36.0 lb-ft) 10 tie-rod end nut 29 n ⋅m (2.9 kgf-m, 21.0 lb-ft) 11 tie-rod lock nut 29 n ⋅m (2.9 kgf-m, 21.0 lb-ft) 8 front shock absorber mounting bolt (upper) 55 n ⋅m (5.5 kgf-m, 40.0 lb-ft) 9 fron...

  • Page 50

    0b-21 maintenance and lubrication: compression pressure check b827h10206026 refer to “compression pressure check in section 1d (page 1d-2)”. Oil pressure check b827h10206027 refer to “oil pressure check in section 1e (page 1e- 4)”. Automatic clutch inspection (lt-a400/f) b827h10206029 this vehicle i...

  • Page 51

    Maintenance and lubrication: 0b-22 specifications tightening torque specifications b827h10207002 note 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, ref...

  • 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-14) / ) (page 0b-21) ) (page 0b-13) / ) (page 0b-14) / ) (page 0b-21) 09915–40610 09917–14910 oil filter wrench valve adjuster driver ) (page 0b-8) / )(...

  • Page 53

    Service data: 0c-1 general information service data specifications service data (lt-a400/f) b827h10307001 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit valve diam. In. 30.6 (1.20) — ex. 27.0 (1.06) — valve c...

  • Page 54

    0c-2 service data: conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) drive train unit: mm (in) except ratio piston ring to groove clearance 1st — 0.180 (0.0071) 2nd — 0.150 (0.0059) piston ring groove width 1st 1.01 – 1.03 (0.0398 – 0.0406) — 2nd 1.01 – 1.03 (0.0398 – 0.0406) — oil 2.0...

  • Page 55

    Service data: 0c-3 engine oil temp. Switch + cooling fan thermo-switch carburetor electrical unit: mm (in) item standard/specification limit engine oil temp. Indicator light switch operating temperature off → on approx. 160 °c (320 °f) — on → off approx. 140 °c (284 °f) — cooling fan thermo-switch o...

  • Page 56

    0c-4 service data: wattage unit: w brake + wheel unit: mm (in) tire fuel + oil item specification p-17 others headlight hi 35 x 2 ← lo 35 x 2 ← brake light/taillight 21/5 ← speedometer light 1.7 ← reverse indicator light 3.4 ← neutral indicator light 3.4 ← engine oil temp. Indicator light 3.4 ← high...

  • Page 57

    Service data: 0c-5 service data (lt-f400/f) b827h10307003 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) fuel tank capacity including reserve 16.0 l (4.2/3.5 us/lmp gal) reserve 2.9 l (0.8/0.6 us/lmp gal) engine oil type sae 10 ...

  • Page 58

    0c-6 service data: conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) drive train unit: mm (in) except ratio piston diam. 81.930 – 81.945 (3.2256 – 3.2262) measure at 15 mm (0.6 in) from the skirt end. 81.880 (3.2236) cylinder distortion — 0.05 (0.002) piston ring free end gap 1st r app...

  • Page 59

    Service data: 0c-7 engine oil temp. Switch + cooling fan thermo-switch carburetor electrical unit: mm (in) transmission gear ratio low 3.083 (37/12) — 2nd 1.933 (29/15) — 3rd 1.388 (25/18) — 4th 1.095 (23/21) — top 0.913 (21/13) — reverse 2.833 (34/12) — transmission shift fork to groove clearance 0...

  • Page 60

    0c-8 service data: wattage unit: w brake + wheel unit: mm (in) generator coil resistance 0.3 – 1.5 Ω b – b generator no-load voltage (when the engine is cold) 65 v (ac) and more at 5 000 r/min generator max. Output approx. 225 w at 5 000 r/min regulated voltage 13.5 – 15.0 v at 5 000 r/min ignition ...

  • Page 61

    Service data: 0c-9 tire fuel + oil tightening torque list (lt-a400/f) b827h10307002 engine item standard note cold inflation tire pressure front 32.5 kpa (0.325 kgf/cm 2 , 4.7 psi) load capacity up to 172 kg (380 lbs) rear 30 kpa (0.30 kgf/cm 2 , 4.4 psi) tire size front at25 x 8-12 œœ, tubeless rea...

  • Page 62

    0c-10 service data: differential chassis oil pump drive gear bolt 80 8.0 58.0 exhaust pipe nut 18 1.8 13.0 exhaust pipe mounting bolt 23 2.3 16.5 muffler mounting bolt 23 2.3 16.5 muffler connecting bolt 23 2.3 16.5 engine oil drain plug 23 2.3 16.5 cooling fan thermo-switch 20 2.0 14.5 engine oil t...

  • Page 63

    Service data: 0c-11 tightening torque list (lt-f400/f) b827h10307004 engine brake disc bolt 23 2.3 16.5 brake caliper mounting bolt 26 2.6 19.0 footrest mounting bolt m8 25 2.5 18.0 m10 55 5.5 40.0 rear brake cam lever nut 11 1.1 8.0 rear axle housing mounting bolt (final gear case) 55 5.5 40.0 rear...

  • Page 64

    0c-12 service data: differential chassis muffler mounting bolt 23 2.3 16.5 muffler connecting bolt 23 2.3 16.5 engine oil drain plug 23 2.3 16.5 drive bevel gear nut 100 10.0 72.5 driven bevel gear nut 100 10.0 72.5 engine mounting nut m8 40 4.0 29.0 m10 55 5.5 40.0 engine mounting bracket bolt 28 2...

  • Page 65

    Service data: 0c-13 tightening torque chart for other bolts and nuts not listed in the preceding page, refer to this chart: rear brake cam lever nut 11 1.1 8.0 rear axle housing mounting bolt (final gear case) 55 5.5 40.0 rear axle housing mounting bolt (swingarm) 60 6.0 43.5 rear shock absorber mou...

  • Page 66

    0c-14 service data:.

  • Page 67

    Table of contents 1- i 1 section 1 contents engine precautions .................................................1-1 precautions............................................................. 1-1 precautions for engine.......................................... 1-1 engine general information and diagnos...

  • Page 68

    1-ii table of contents cooling fan components .................................1e-12 cooling fan inspection .....................................1e-12 cooling fan removal and installation ..............1e-13 cooling fan thermo-switch removal and installation.............................................

  • Page 69

    Table of contents 1-iii recoil starter assembly removal and installation........................................................ 1i-13 recoil starter disassembly and assembly ........ 1i-13 recoil starter inspection .................................... 1i-15 specifications..............................

  • Page 70

    1-1 precautions: engine precautions precautions precautions for engine b827h11000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”..

  • Page 71

    Engine general information and diagnosis: 1a-1 engine engine general information and diagnosis diagnostic information and procedures engine symptom diagnosis b827h11104001 condition possible cause correction / reference item engine will not start or is hard to start (compression too low) worn cylind...

  • Page 72

    1a-2 engine general information and diagnosis: 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. Defective cdi unit. Replace. Spark plug gap too wide. A...

  • Page 73

    Emission control devices: 1b-1 engine emission control devices precautions precautions for emission control devices b827h11200001 refer to “general precautions in section 00 (page 00-1)”. General description carburetor system description b827h11201001 lt-a400/f and lt-f400/f are equipped with precis...

  • Page 74

    1b-2 emission control devices: repair instructions crankcase breather (pcv) hose inspection b827h11206001 inspect the pcv hose in the following procedures: 1) remove the right side cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 3)”. 2) inspect the pcv hose (1) for w...

  • Page 75

    Engine mechanical: 1d-1 engine engine mechanical schematic and routing diagram throttle cable routing diagram b827h11402001 “e” “d” 4 5 6 6 “f” “c” “ a ” 12 2 “a” 1 “b” 2 3 up “ b ” 7 11 1 2 “g” 10 9 8 inside “h” i827h1140304-02 1. Clamp : bind the front brake switch lead wire and throttle cable wit...

  • Page 76

    1d-2 engine mechanical: diagnostic information and procedures engine mechanical symptom diagnosis b827h11404001 refer to “engine symptom diagnosis in section 1a (page 1a-1)”. Compression pressure check b827h11404002 the compression pressure reading of a cylinder is a good indicator of its internal c...

  • Page 77

    Engine mechanical: 1d-3 repair instructions engine components removable with the engine in place b827h11406001 engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each ...

  • Page 78

    1d-4 engine mechanical: engine left side movable driven face assembly (lt-a400/f) refer to “v-belt type continuously variable automatic transmission removal and installation in section 5a (page 5a-7)”. Refer to “movable / fixed driven face parts inspection in section 5a (page 5a-16)”. Refer to “v-be...

  • Page 79

    Engine mechanical: 1d-5 air cleaner element removal and installation b827h11406002 removal 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) remove the air cleaner box cover (1). 3) remove the air cleaner element bolt. 4) remove the air cleaner elem...

  • Page 80

    1d-6 engine mechanical: engine assembly removal b827h11406013 before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps: 1) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-7)”...

  • Page 81

    Engine mechanical: 1d-7 10) remove the transfer gearshift arm (7). 11) disconnect the gear position switch lead wire coupler (8), ckp sensor lead wire coupler (9) and generator lead wire coupler (10). 12) disconnect the spark plug cap (11). 13) disconnect the pcv (breather) hose (12). 14) disconnect...

  • Page 82

    1d-8 engine mechanical: 18) remove the muffler and exhaust pipe. 19) remove the front differential mounting bolts and slide the front differential assembly (19) forward. Refer to “front drive (differential) assembly removal and installation (lt-a400f, lt-f400f) in section 3b (page 3b-4)”. 20) remove...

  • Page 83

    Engine mechanical: 1d-9 engine assembly installation b827h11406014 reinstall the engine in the reverse order of removal. Pay attention to the following points: note the engine mounting nuts are self-locking. Once the nut has been removed, it is no longer any use. Be sure to use new nuts, and then ti...

  • Page 84

    1d-10 engine mechanical: • after finishing the engine installation, check the following items: – throttle cable play refer to “throttle cable play inspection and adjustment in section 0b (page 0b-13)”. – rear brake cable play refer to “rear brake pedal / rear brake (parking brake) lever inspection a...

  • Page 85

    Engine mechanical: 1d-11 cylinder head cover 1) remove the valve timing inspection caps (1). 2) remove the cylinder head cover. 3) remove the dowel pins and camshaft end cap (2). Cam shaft 1) flatten the lock washer. 2) remove the cam chain sprocket bolts and lock washer. 3) remove the cam chain ten...

  • Page 86

    1d-12 engine mechanical: cylinder head 1) remove the cylinder head nuts. 2) remove the cylinder head bolts. Note the cylinder head bolts must be loosened diagonally and evenly. 3) remove the cylinder head (1). Cylinder 1) remove the dowel pins and gasket (1). 2) remove the cam chain guide (2). 3) re...

  • Page 87

    Engine mechanical: 1d-13 engine top side assembly b827h11406016 assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: caution ! When turning the crankshaft, pull the cam chain upward, or the chain will be caught between the crankcase and the cam dri...

  • Page 88

    1d-14 engine mechanical: • hold each piston ring with properly position, insert the piston into the cylinder. • tighten the cylinder base nuts temporarily. Caution ! When installing the cylinder and cylinder head, pull the cam chain upward, or the chain will be caught between the crankcase and cam d...

  • Page 89

    Engine mechanical: 1d-15 • tighten the cylinder head nuts to the specified torque. Tightening torque cylinder head nut (8 mm) (initial): 10 n·m (1.0 kgf- m, 7.0 lb-ft) cylinder head nut (8 mm) (final): 25 n·m (2.5 kgf- m, 18.0 lb-ft) • tighten the cylinder base nuts to the specified torque. Tighteni...

  • Page 90

    1d-16 engine mechanical: • install the lock washer so that it is covering the locating pin. • tighten the camshaft sprocket bolts (4). Tightening torque camshaft sprocket bolt (b): 15 n·m (1.5 kgf-m, 11.0 lb-ft) • bend up the washer tongue positively to lock the bolts. • apply engine oil to the cam ...

  • Page 91

    Engine mechanical: 1d-17 • apply bond to the mating surface of the cylinder head cover. : sealant 99000–31140 (suzuki bond no.1207b or equivalent) i827h1140034-01.

  • Page 92

    1d-18 engine mechanical: • lightly tighten the cylinder head cover bolts diagonally, and then tighten them to the specified torque. Tightening torque cylinder head cover bolt: 10 n·m (1.0 kgf-m, 7.0 lb-ft) caution ! • when tightening the cylinder head cover bolts, the piston must be at top dead cent...

  • Page 93

    Engine mechanical: 1d-19 • fit a new gasket (2). Caution ! Use new gasket to prevent oil leakage. • tighten the cam chain tension adjuster bolts (3) to the specified torque. Tightening torque cam chain tension adjuster bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install o-ring, spring and spring holde...

  • Page 94

    1d-20 engine mechanical: spark plug • 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) cylinder head cover disassembly and assembly b827h11406040 disassembly caution ! Be sure to identify each removed part as to it...

  • Page 95

    Engine mechanical: 1d-21 cylinder head cover relate parts inspection b827h11406041 refer to “engine top side disassembly (page 1d-10)”. Refer to “engine top side assembly (page 1d-13)” refer to “cylinder head cover disassembly and assembly (page 1d-20)”. Cylinder head cover distortion 1) remove the ...

  • Page 96

    1d-22 engine mechanical: cylinder head disassembly and assembly b827h11406042 disassembly caution ! Be sure to identify each removed part as to its location, and lay the parts out in groups designated as “exhaust”, “intake”, so that each will be restored to the original location during assembly. 1) ...

  • Page 97

    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. • insta...

  • Page 98

    1d-24 engine mechanical: valve stem runout support the valve with v-blocks as shown, and check its runout with the dial gauge. The valve must be replaced if the runout exceeds the limit. Special tool : 09900–20607 (dial gauge (1/100 mm, 10 mm)) : 09900–20701 (magnetic stand) : 09900–21304 (v-block (...

  • Page 99

    Engine mechanical: 1d-25 valve stem wear if valve stem is worn down to the limit, as measured with a micrometer. Where the clearance is found to be in excess of the limit indicated replace the valve, if the stem is within the limit, then replace the guide. After replacing valve or valve guide, be su...

  • Page 100

    1d-26 engine mechanical: valve seat width 1) visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve. 2) coat the valve seat with a red lead (prussian blue)and set the valve in place. 3) rotate the valve with light pressure. Special tool (a): ...

  • Page 101

    Engine mechanical: 1d-27 4) re-finish the valve guide holes in the cylinder head with the reamer and handle. Special tool : 09916–34580 (valve guide reamer (10.8 mm)) : 09916–34542 (reamer handle) 5) install a ring onto each valve guide. Be sure to use new rings. 6) cool down the new valve guides in...

  • Page 102

    1d-28 engine mechanical: valve seat repair b827h11406027 the valve seats (1) for both the intake and exhaust valves are machined to three different angles. The seat contact surface is cut at 45 °. Caution ! • the valve seat contact area must be inspected after each cut. • do not use lapping compound...

  • Page 103

    Engine mechanical: 1d-29 note to properly measure the oil clearance with plastigauge, all gasket material must be removed from fitting surfaces of cylinder head and cover. Do not apply bond until after the oil clearance has been determined. • tighten the camshaft journal holder bolts evenly and diag...

  • Page 104

    1d-30 engine mechanical: cam chain tension adjuster inspection b827h11406020 the cam chain tension adjuster is maintained at the proper tension automatically. 1) remove the cam chain tension adjuster. Refer to “engine top side disassembly (page 1d-10)”. 2) check that the push rod slides smoothly whe...

  • Page 105

    Engine mechanical: 1d-31 cylinder bore inspect the cylinder wall for any scratches, nicks or other damage.Measure the cylinder bore diameter at six places. Special tool : 09900–20530 (cylinder gauge set) cylinder bore service limit: 82.070 mm (3.2311 in) piston ring removal and installation b827h114...

  • Page 106

    1d-32 engine mechanical: b) install the 2nd ring (3) and 1st ring (4) to piston. Note 1st ring (4) and 2nd ring (3) differ in shape. Note face the stamped mark “c” upward when assembling. 2) position the gaps of the three rings and side rails as shown. Before inserting piston into the cylinder, chec...

  • Page 107

    Engine mechanical: 1d-33 piston ring-to-groove clearance using the thickness gauge, measure the side clearances of the 1st and 2nd piston rings. If any of the clearances exceeds the limit, replace both piston and piston rings. Special tool : 09900–20803 (thickness gauge) : 09900–20205 (micrometer (0...

  • Page 108

    1d-34 engine mechanical: piston pin and pin bore using a small bore gauge, measure the piston pin bore inside diameter, using the micrometer, measure the piston pin outside diameter. If the reading exceeds following limit, replace both piston and piston pin. Special tool : 09900–20602 (dial gauge (1...

  • Page 109

    Engine mechanical: 1d-35 generator remove the generator component parts (1). Refer to “generator removal and installation in section 1j (page 1j-5)”. Starter system remove the starter idle gear no.1, no.2, and starter driven gear. Refer to “starter clutch removal and installation in section 1i (page...

  • Page 110

    1d-36 engine mechanical: automatic transmission remove the automatic transmission component parts (1). Refer to “v-belt type continuously variable automatic transmission removal and installation in section 5a (page 5a-7)”. And “clutch shoe removal and installation in section 5a (page 5a-16)”. Gear p...

  • Page 111

    Engine mechanical: 1d-37 crankcase 1) remove the crankcase bolts. 2) separate the crankcase with the special tool. Note • the crankcase separator plate is parallel with the end face of the crankcase. • the crankshaft must remain in the left crankcase half. Special tool (a): 09920–13120 (crankcase se...

  • Page 112

    1d-38 engine mechanical: balancer 1) remove the balancershaft driven gear (1). 2) remove the key (2). 3) remove the balancershaft with the special tools. Special tool (a): 09930–30104 (rotor remover slide shaft) (b): 09930–30141 (attachment a) crankshaft 1) remove the crankshaft with the special too...

  • Page 113

    Engine mechanical: 1d-39 speedometer gearbox remove the speedometer gearbox (1) and gasket (2). Transfer shift cam stopper remove the bolt, spring and transfer shift cam stopper (1) before removing the generator cover. Generator cover 1) remove the generator cover (1). 2) remove the dowel pins and g...

  • Page 114

    1d-40 engine mechanical: gearshift system 1) remove the gearshift cam plate guide (1). 2) remove the gearshift shaft (2) and gearshift cam plate (3). Cam chain remove the cam chain (1). Oil filter remove the oil filter with the special tool. Special tool (a): 09915–40610 (oil filter wrench) oil pump...

  • Page 115

    Engine mechanical: 1d-41 6) remove the pin (6) and washer (7). 7) remove the oil pump (8). 8) remove the dowel pins. Generator rotor 1) remove the generator rotor bolt with the special tool. Special tool (a): 09930–44541 (rotor holder) 2) install the special tool (attachment) to the crankshaft end. ...

  • Page 116

    1d-42 engine mechanical: 2) remove the crankcase bolts. 3) separator the crankcase with the special tool. Note • the crankcase separator plate is parallel with the end face of the crankcase. • the crankcase must remain in the crankcase half. Special tool (a): 09920–13120 (crankcase separating tool) ...

  • Page 117

    Engine mechanical: 1d-43 3) remove the front output shaft (4) and rear output shaft (5). (lt-f400f) 4) remove the rear output shaft (5). (lt-f400) balancer 1) remove the balancershaft driven gear (1). 2) remove the key (2). 3) remove the balancershaft with the special tools. Special tool (a): 09930–...

  • Page 118

    1d-44 engine mechanical: crankshaft • when installing the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase with the special tools. Special tool (a): 09910–32812 (crankshaft installer) (b): 09940–52861 (front fork oil seal installer) caution ! Never fit the cranksh...

  • Page 119

    Engine mechanical: 1d-45 • install the washers (4), bearing (5) and gearshift shaft (6). • install the washer (7). • install the gearshift forks (8) (9) and transfer output shaft assembly (10). Note each gearshift fork has own embossed letters. • install the transfer input shaft assembly (11). • ins...

  • Page 120

    1d-46 engine mechanical: • apply bond to the mating surface of the left crankcase. • 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. • fit the cramp...

  • Page 121

    Engine mechanical: 1d-47 • install the oil pump driven gear (4) as shown in the figure. • install new snap ring. Caution ! Never reuse the removed snap ring. Special tool : 09900–06107 (snap ring pliers) • install the pin (5). • install the oil pump drive gear (6) and washer (7). • apply thread lock...

  • Page 122

    1d-48 engine mechanical: • apply a bond lightly to the groove of the lead wire grommet. : sealant 99000–31140 (suzuki bond no.1207b or equivalent) automatic transmission • install the automatic transmission component parts (1). Refer to “v-belt type continuously variable automatic transmission remov...

  • Page 123

    Engine mechanical: 1d-49 starter system • install the starter driven gear, starter idle gear no.1 and no.2. Refer to “starter clutch removal and installation in section 1i (page 1i-9)”. Generator • install the generator component parts (1). Refer to “generator removal and installation in section 1j ...

  • Page 124

    1d-50 engine mechanical: starter motor • install the starter motor (1). Refer to “starter motor removal and installation in section 1i (page 1i-3)”. Lt-f400/f crankshaft • when mounting the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase with the special tools. S...

  • Page 125

    Engine mechanical: 1d-51 • install the c-ring (3). Note be sure to fit the pin “a” on the bearings into the groove of the crankcase. • install the driveshaft assembly (4), and countershaft assembly(5). • install the reverse idle gear shaft (6). • install the snap ring (7), washer (8) and spacer (9)....

  • Page 126

    1d-52 engine mechanical: • install the gearshift forks (1), (2), (3), (4), gearshift cam (5) and reverse cam assembly (6). Note • each fork has own embossed letters. • face the letter upward (to the right side). Crankcase • wipe the crankcase mating surfaces (both surfaces) with a cleaning solvent. ...

  • Page 127

    Engine mechanical: 1d-53 • 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. Tightening torque crankcase bolt (m6): 11 n·m (1.1 kgf-m, 8.0 lb-ft) crankc...

  • Page 128

    1d-54 engine mechanical: oil pump • install the dowel pins. • install the oil pump (1). • install the washer (2) and pin (3). • install the oil pump driven gear (4) as shown in the figure. Note install the oil pump driven gear as shown in the figure. • install new snap ring. Caution ! Never reuse th...

  • Page 129

    Engine mechanical: 1d-55 oil filter • 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) cam chain install the cam chain (1). Gearshift • install the gearshift cam plate (1). • instal...

  • Page 130

    1d-56 engine mechanical: gear position switch • install the springs and switch contacts. • install the gear position switch (1). • apply a bond lightly to the groove of the lead wire grommet. : sealant 99000–31140 (suzuki bond no.1207b or equivalent) transfer gearshift system install the transfer re...

  • Page 131

    Engine mechanical: 1d-57 transfer gearshift cam stopper • install the transfer gearshift cam stopper (1) and spring into the bolt (2). • tighten the bolt (2) to the specified torque. Tightening torque transfer gearshift cam stopper bolt (a): 22 n·m ( 2.2 kgf-m, 16.0 lb-ft) speedometer gearbox • appl...

  • Page 132

    1d-58 engine mechanical: conrod and crankshaft inspection b827h11406035 refer to “engine bottom side disassembly (page 1d- 34)”. Conrod small end i.D. Measure the conrod small end inside diameter with the dial calipers. If conrod small end inside diameter exceeds the service limit, replace the conro...

  • Page 133

    Engine mechanical: 1d-59 width between crankshaft webs b827h11406036 measure the width between crankshaft webs “a”. Width between crankshaft webs “a” standard: 59.9 – 60.1 mm (2.36 – 2.37 in) crankshaft oil seal inspection b827h11406037 check the oil seals for damage. If any damage is found, replace...

  • Page 134

    1d-60 engine mechanical: lt-f400/f generator cover bearing removal and installation b827h11406039 removal lt-a400/f left crankcase 1) remove the retainers. 2) remove the oil seal (1) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 3) remove the transfer input shaft bearing an...

  • Page 135

    Engine mechanical: 1d-61 2) remove the other bearings with the special tool. Special tool (c): 09913–70210 (bearing installer set) lt-f400/f left crankcase 1) remove the retainers. 2) remove the balancer shaft bearing with the special tool. Special tool (a): 09921–20240 (bearing remover set) 3) remo...

  • Page 136

    1d-62 engine mechanical: 3) remove other bearings with the special tool. Special tool (a): 09913–70210 (bearing installer set) 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. 3) remove th...

  • Page 137

    Engine mechanical: 1d-63 lt-f400/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. 3) remove the oil seal (1) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 4) remove the s...

  • Page 138

    1d-64 engine mechanical: lt-a400/f left crankcase 1) install the bearings with the special tool. Caution ! Use the suitable size attachment for each bearing. Special tool (a): 09913–70210 (bearing installer set) 2) install the oil seal with the special tool. Special tool (a): 09913–70210 (bearing in...

  • Page 139

    Engine mechanical: 1d-65 lt-f400/f left crankcase 1) install the bearings with the special tool. Caution ! Use the suitable size attachment for each bearing. Special tool (a): 09913–70210 (bearing installer set) 2) apply thread lock to the screws, and tighten them. : thread lock cement 99000–32110 (...

  • Page 140

    1d-66 engine mechanical: • apply grease to bearing, o-ring and oil seal lip. • 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 grea...

  • Page 141

    Engine mechanical: 1d-67 • apply grease to bearing, o-ring and oil seal lip. • 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 grea...

  • Page 142

    1d-68 engine mechanical: camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit cam height in. & ex. 33.130 – 33.170 (1.3043 – 1.3059) 32.830 (1.2925) camshaft journal oil clearance φ 22 0.032 – 0.066 (0.0013 – 0.002...

  • Page 143

    Engine mechanical: 1d-69 tightening torque specifications b827h11407002 note 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...

  • Page 144

    1d-70 engine mechanical: special tool b827h11408002 sealant suzuki bond no.1207b or equivalent p/no.: 99000–31140 ) (page 1d-13) / ) (page 1d-16) / ) (page 1d-17) / ) (page 1d-48) / ) (page 1d-52) / ) (page 1d-56) thread lock cement thread lock cement super 1303 or equivalent p/no.: 99000–32030 ) (p...

  • Page 145

    Engine mechanical: 1d-71 09900–20607 09900–20701 dial gauge (1/100 mm, 10 mm) magnetic stand ) (page 1d-24) / ) (page 1d-24) / ) (page 1d-24) / ) (page 1d-29) / ) (page 1d-58) / ) (page 1d-58) ) (page 1d-24) / ) (page 1d-24) / ) (page 1d-24) / ) (page 1d-29) / ) (page 1d-58) / ) (page 1d-58) 09900–2...

  • Page 146

    1d-72 engine mechanical: 09915–63311 09915–64512 compression gauge attachment compression gauge ) (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 attachment reame...

  • Page 147

    Engine mechanical: 1d-73 09930–31921 09930–40113 rotor remover rotor holder ) (page 1d-41) / ) (page 1d-43) ) (page 1d-36) / ) (page 1d-40) / ) (page 1d-47) / ) (page 1d-54) 09930–44541 09940–52861 rotor holder front fork oil seal installer ) (page 1d-41) / ) (page 1d-53) ) (page 1d-44).

  • Page 148

    1e-1 engine lubrication system: engine engine lubrication system 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 oil sump filter orific...

  • Page 149

    Engine lubrication system: 1e-2 lt-f400/f oil sump fil ter oil jet orifice oil fil ter oil cooler oil pump cylinder camshaft journal (center) st ar ter idle gear shaft primar y driven gear bushing clutch pla tes transfer input shaft bushing/gears countershaft bushing/gears genera t o r cover conrod ...

  • Page 150

    1e-3 engine lubrication system: cylinder head cooling system chart diagram b827h11502002 oil sump filter orifice oil filter oil cooler oil pump cylinder head (ex) cylinder head cooling i827h1150003-01.

  • Page 151

    Engine lubrication system: 1e-4 diagnostic information and procedures engine lubrication symptom diagnosis b827h11504001 oil pressure check b827h11504002 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 152

    1e-5 engine lubrication system: 7) stop the engine and remove the oil pressure gauge and attachment. 8) reinstall the main oil gallery plug (1) and tighten it to the specified torque. Caution ! Use a new gasket to prevent oil leakage. Tightening torque main oil gallery plug (a): 23 n·m (2.3 kgf-m, 1...

  • Page 153

    Engine lubrication system: 1e-6 oil sump filter inspection and cleaning b827h11506004 inspect the oil sump filter in the following procedures: 1) remove the oil sump filter. Refer to “oil sump filter removal and installation (page 1e-5)”. 2) if the oil sump filter is clogged with sediment or rust, c...

  • Page 154

    1e-7 engine lubrication system: 3) remove the oil pump drive gear (1) with holding the oil pump driven gear (2) using the special tool. Special tool (a): 09930–40113 (rotor holder) 4) remove the pin (3). 5) remove the snap ring (4) and oil pump driven gear. Special tool : 09900–06107 (snap ring plie...

  • Page 155

    Engine lubrication system: 1e-8 • install the oil pump drive gear (3) so that its flange side faces side faces the crankcase side. • apply thread lock to the oil pump drive gear bolt. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • tighten the oil pump drive gear bol...

  • Page 156

    1e-9 engine lubrication system: oil cooler and oil hose components b827h11506009 oil cooler / oil cooler hose inspection and cleaning b827h11506010 oil cooler hose inspection inspect the oil cooler hoses in the following procedures: 1) remove the left inner fender. Refer to “exterior parts removal a...

  • Page 157

    Engine lubrication system: 1e-10 oil cooler inspection 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. Refer to “oil cooler / oi...

  • Page 158

    1e-11 engine lubrication system: • pass the oil hoses between the transfer cable and front brake pipe. • apply thread lock to the oil cooler hose bolts (engine side) (1) and tighten them to the specified torque. • clamp the oil hose (inlet) and speedometer cable. : thread lock cement 99000–32130 (th...

  • Page 159

    Engine lubrication system: 1e-12 cooling fan components b827h11506012 cooling fan inspection b827h11506013 inspect the cooling fan in the following procedures: 1) remove the left inner fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 3)”. 2) disconnect the cooling fa...

  • Page 160

    1e-13 engine lubrication system: cooling fan removal and installation b827h11506014 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). 3) remove the cooling fan bracket bol...

  • Page 161

    Engine lubrication system: 1e-14 cooling fan thermo-switch inspection b827h11506016 inspect the cooling fan thermo-switch in the following procedures: 1) remove the cooling fan thermo-switch. Refer to “cooling fan thermo-switch removal and installation (page 1e-13)”. 2) check the thermo-switch closi...

  • Page 162

    1e-15 engine lubrication system: engine oil temperature switch inspection b827h11506018 inspect the engine oil temperature switch in the following procedures: 1) remove the engine oil temperature switch. Refer to “engine oil temperature switch removal and installation (page 1e-14)”. 2) check the swi...

  • Page 163

    Engine lubrication system: 1e-16 oil pressure regulator inspection b827h11506020 refer to “oil pressure regulator removal and installation (page 1e-15)”. 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 press...

  • Page 164

    1e-17 engine lubrication system: tightening torque specifications b827h11507002 note the specified tightening torque is also described in the following. “oil cooler and oil hose components (page 1e-9)” “cooling fan components (page 1e-12)” reference: for the tightening torque of fastener not specifi...

  • Page 165

    Engine lubrication system: 1e-18 09930–40113 rotor holder ) (page 1e-7) / )(page 1e- 8).

  • Page 166

    1g-1 fuel system: engine fuel system 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...

  • Page 167

    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, throu...

  • 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...

  • 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, t...

  • 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), mix...

  • 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). T...

  • 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) k...

  • 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...

  • Page 175

    Fuel system: 1g-10 schematic and routing diagram carburetor hose routing diagram b827h11702001 lh rh [a] lh rh [b] 1 3 2 3 2 3 2 up “a” i827h1170040-02 1. Vacuum hose 3. Air vent hose [a]: intake pipe side 2. Fuel hose “a” clamp end should face downward. [b]: air cleaner side.

  • Page 176

    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 body and carburetor. Tig...

  • Page 177

    Fuel system: 1g-12 repair instructions fuel tank construction b827h11706018 1 2 3 (a) “ a ” 4 3 3 4 i827h1170041-02 1. Fuel tank upper cover “a”: 29 mm (1.14 in) 2. Fuel tank : 4.6 n ⋅m (0.46 kg-f, 3.5 lb-ft) 3. Fuel tank cushion : do not reuse. 4. Frame.

  • Page 178

    1g-13 fuel system: fuel tank removal and installation b827h11706009 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. Refer to “exterior parts removal and installation in section 9d (page...

  • Page 179

    Fuel system: 1g-14 installation install the fuel valve in the reverse order of removal. Pay attention to the following points: warning ! Replace the gasket washers (1) and gasket (2) with new ones to prevent fuel leakage. • tighten the fuel valve bolts to the specified torque. Tightening torque fuel...

  • Page 180

    1g-15 fuel system: fuel level gauge inspection b827h11706007 inspect the fuel level gauge as follows: 1) inspect the float (1) of the fuel gauge assembly moves smoothly. 2) inspect that the needle moves correctly as the float of the fuel gauge assembly moves up and down as shown in the illustration....

  • Page 181

    Fuel system: 1g-16 carburetor components b827h11706027 1 5 7 28 2 3 4 8 9 10 11 6 14 13 15 12 17 18 19 16 24 27 26 23 29 25 21 20 22 fwd fw d 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...

  • Page 182

    1g-17 fuel system: carburetor assembly removal and installation 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 183

    Fuel system: 1g-18 3) remove the carburetor top cap (8). Caution ! Do not use compressed air on the carburetor body before removing the diaphragm; this may damage the diaphragm. 4) remove the spring (9), spring retainer (10), spacer (11), jet needle (12) and diaphragm (13). 5) remove the float chamb...

  • Page 184

    1g-19 fuel system: 9) remove the following parts. • main jet (20) • needle jet holder (21) • needle jet (22) • slow jet (23) • starter jet (24) • pilot screw (25) note before removing the pilot screw (25), its setting must be determined. Slowly turn the pilot screw clockwise and count the number of ...

  • Page 185

    Fuel system: 1g-20 carburetor assembly b827h11706030 reassemble the carburetor in the reverse order of disassembly. Pay attention to the following points: • apply thin coat of the grease to new pilot screw o- ring. Caution ! Replace the o-ring with new one. : grease 99000–25010 (suzuki super grease ...

  • Page 186

    1g-21 fuel system: float height inspection and adjustment b827h11706031 inspect and adjust the float height in the following procedures: 1) remove the carburetor assembly. Refer to “carburetor assembly removal and installation (page 1g-17)”. 2) remove the float chamber body. Refer to “carburetor dis...

  • Page 187

    Fuel system: 1g-22 cleaning warning ! Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. 1) clean all jets with a spray-type carbureto...

  • Page 188

    1g-23 fuel system: fuel tightening torque specifications b827h11707002 note 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-a...

  • Page 189

    Ignition system: 1h-1 engine ignition system schematic and routing diagram ignition system diagram b827h11802001 refer to “wire color symbols in section 0a (page 0a-4)”. Ignition system components location b827h11802002 refer to “electrical components location in section 0a (page 0a-6)”. Diagnostic ...

  • Page 190

    1h-2 ignition system: no spark or poor spark b827h11804002 troubleshooting note check that the transfer is in neutral and the engine stop switch is in the “run” position. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Spark plug quickly becomes fouled with oil o...

  • Page 191

    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 ...

  • Page 192

    1h-4 ignition system: 4) connect the multi-circuit tester with the peak voltage adaptor as follows: caution ! Before using the multi-circuit tester and peak voltage adaptor, refer to the appropriate instruction manual. Note do not disconnect the ignition coil lead wires. Special tool : 09900–25008 (...

  • Page 193

    Ignition system: 1h-5 ignition coil removal and installation b827h11806010 remove 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-13)”. 2) disconnect the spark plug cap. 3) disconnect the lead wires (1) and remove the ignition coil (2). Installation insta...

  • Page 194

    1h-6 ignition system: ckp sensor resistance 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). 3) measure the resistance between the lead wires and ground. If the resistance...

  • Page 195

    Ignition system: 1h-7 3) disconnect the ignition switch coupler (1) (green). Installation install the ignition switch in the reverse order of removal. Pay attention to the following point: • route the wiring harness properly. Refer to “wiring harness routing diagram in section 9a (page 9a-8)”. Speci...

  • Page 196

    1i-1 starting system: engine starting system schematic and routing diagram starting system diagram b827h11902001 refer to “wire color symbols in section 0a (page 0a-4)”. Component location starting system components location b827h11903001 refer to “electrical components location in section 0a (page ...

  • Page 197

    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 starter motor runs but does not crank the engine b827h11904003 the starter motor runs when the transfer is in neutral, but does no...

  • Page 198

    1i-3 starting system: repair instructions starter motor components b827h11906001 starter motor removal and installation b827h11906002 removal 1) turn the ignition switch off and disconnect the battery (–) lead wire. Refer to “battery removal and installation in section 1j (page 1j-13)”. 2) remove th...

  • Page 199

    Starting system: 1i-4 • tighten the starter motor mounting bolts (1) with the engine ground lead wire (2) and starter motor lead wire mounting nut (3) to the specified torque. Refer to “wiring harness routing diagram in section 9a (page 9a-8)”. Tightening torque starter motor mounting bolt (a): 10 n...

  • Page 200

    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. If the measurement is le...

  • Page 201

    Starting system: 1i-6 6) disconnect the starter motor lead wire (4) and battery (+) lead wire (5). 7) remove the starter relay. Installation install the starter relay in the reverse order of removal. Starter relay inspection b827h11906006 inspect the starter relay in the following procedures: 1) rem...

  • Page 202

    1i-7 starting system: 3) remove the neutral relay (1). Installation install the neutral relay in the reverse order of removal. Neutral relay inspection b827h11906008 inspect the neutral relay in the following procedures: 1) remove the neutral relay. Refer to “neutral relay removal and installation (...

  • Page 203

    Starting system: 1i-8 4) connect the neutral switch diode. 5) install the left inner fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 3)”. Ignition / starter control relay removal and installation b827h11906010 removal 1) remove the rear fender. Refer to “exterior pa...

  • Page 204

    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- a400/f) in sec...

  • 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) 7) remove the one way clutch (6) from the guide (7). Installation install the starter clutch in the reverse order of removal. Pay attention to th...

  • Page 206

    1i-11 starting system: starter driven gear bearing removal and installation b827h11906015 removal 1) remove the starter driven gear. Refer to “starter clutch removal and installation (page 1i-9)”. 2) remove the bearing with the special tool. Special tool (a): 09913–70210 (bearing installer set) inst...

  • Page 207

    Starting system: 1i-12 starter idle gear inspect the starter idle gear no.1 (1) and no.2 (2) for wear or damage. If any damage is found, replace it with a new one. Starter button inspection b827h11906017 inspect the starter button in the following procedures: 1) remove the left inner fender. Refer t...

  • Page 208

    1i-13 starting system: recoil starter assembly removal and installation b827h11906019 removal 1) remove the left side cover and left footrest mudguard. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) remove the recoil starter assembly (1). Installation install the re...

  • Page 209

    Starting system: 1i-14 4) disengage the rope (9) from the handle (10). 5) hook the rope to groove “a” of the reel (11). 6) turn the rope on the reel (11) properly. 7) remove the reel (11). 8) remove the spiral spring (12). Assembly assemble the recoil starter in the reverse order of disassembly. Pay...

  • Page 210

    1i-15 starting system: • connect the handle (1) to the rope (2). • install the ratchet related parts. • apply grease to the shaft and ratchet guide. : grease 99000–25010 (suzuki super grease a or equivalent) • tighten the nut to the specified torque. Tightening torque recoil starter center nut (a): ...

  • Page 211

    Starting system: 1i-16 reel inspect the reel for wear or damage. If any defects are found, replace the reel with a new one. Rope inspect the rope for damage. If any defects are found, replace the rope with a new one. Specifications service data (lt-a400/f, lt-f400/f) b827h11907001 unit: mm (in) tigh...

  • Page 212

    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, 200 mm) multi-circuit tester set ) (page 1i-5) ) (pa...

  • Page 213

    Charging system: 1j-1 engine charging system schematic and routing diagram charging system diagram b827h11a02001 component location charging system components location b827h11a03001 refer to “electrical components location in section 0a (page 0a-6)”. Diagnostic information and procedures charging sy...

  • Page 214

    1j-2 charging system: battery runs down quickly b827h11a04002 troubleshooting unstable charging lead wire insulation frayed due to vibration, resulting in intermittent short- circuiting. Repair or replace. Internally short-circuited generator. Replace. Defective regulator/rectifier. Replace. Battery...

  • Page 215

    Charging system: 1j-3 repair instructions battery current leakage inspection b827h11a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 3) disconnect...

  • Page 216

    1j-4 charging system: generator inspection b827h11a06003 generator coil resistance 1) remove the left side cover and left footrest mudguard. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) connect the tachometer to the spark plug high tension cord. 3) disconnect the ...

  • Page 217

    Charging system: 1j-5 generator removal and installation b827h11a06004 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)”. 3) remove the left side cover...

  • Page 218

    1j-6 charging system: 12) remove the generator cover (10). 13) remove the gasket (11) and dowel pins. 14) hold the generator rotor with the special tool and remove the generator rotor nut. Special tool (a): 09930–44541 (rotor holder) 15) install the special tool (attachment) to the crankshaft end. S...

  • Page 219

    Charging system: 1j-7 18) remove the generator stator (15) along with the ckp sensor (16). Installation install the generator in the reverse order of removal. Pay attention to the following points: • tighten the generator stator set bolts and ckp sensor mounting bolts to the specified torque. Note b...

  • Page 220

    1j-8 charging system: • install the dowel pins and new gasket (3). Caution ! Use a new gasket to prevent oil leakage. • install the generator cover and tighten the generator cover bolts. Caution ! Fit the clamp to the bolt “c”. Refer to “wiring harness routing diagram in section 9a (page 9a-8)”. • f...

  • Page 221

    Charging system: 1j-9 • when installing the transfer gearshift arm, align the wide spline teeth of the arm and shaft. • install the gearshift link arm in the following angle. (lt- f400/f). • connect the oil hose. Refer to “oil cooler / oil cooler hose removal and installation in section 1e (page 1e-...

  • Page 222

    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 r...

  • Page 223

    Charging system: 1j-11 battery components b827h11a06006 battery charging b827h11a06007 initial charging filling electrolyte note when filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground. 1) remove the aluminum tape (1) which seals the battery filler ...

  • 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. Note if no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the cont...

  • Page 225

    Charging system: 1j-13 battery recharging caution ! Do not remove the caps on the battery top while recharging. Note when the vehicle is not used for a long period, check the battery every 1 month to prevent the battery discharge. 1) remove the battery from the vehicle. Refer to “battery removal and...

  • Page 226

    1j-14 charging system: specifications service data (lt-a400/f, lt-f400/f) b827h11a07001 battery caution ! Never use anything except the specified battery. Generator tightening torque specifications b827h11a07002 reference: for the tightening torque of fastener not specified in this section, refer to...

  • Page 227

    Charging system: 1j-15 09930–31921 09930–44541 rotor remover rotor holder ) (page 1j-6) ) (page 1j-6) / )(page 1j- 7).

  • Page 228

    1k-1 exhaust system: engine exhaust system 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 ...

  • Page 229

    Exhaust system: 1k-2 muffler / exhaust pipe removal and installation b827h11b06002 removal 1) remove the right inner fender. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) remove the rear fender. Refer to “exterior parts removal and installation in section 9d (page ...

  • Page 230

    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) • install the muffler. • tighten the muffler mou...

  • Page 231

    Exhaust system: 1k-4 specifications tightening torque specifications b827h11b07001 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 tor...

  • Page 232

    1k-5 exhaust system:.

  • Page 233

    Table of contents 2- i 2 section 2 contents suspension precautions .................................................2-1 precautions............................................................. 2-1 precautions for suspension .................................. 2-1 suspension general diagnosis............

  • Page 234

    2-1 precautions: suspension precautions 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...

  • Page 235

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis 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. Defe...

  • Page 236

    2b-1 front suspension: suspension front suspension repair instructions front suspension components b827h12206001 1 2 3 (a) 13 (c) 15 9 10 4 6 7 8 7 5 11 12 12 (e) 17 11 fwd fw d fwd fw d (c) 15 (b) 14 (b) 16 i827h1220045-05 1. Front shock absorber 10. Bushing : 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) 2. Upp...

  • Page 237

    Front suspension: 2b-2 front suspension assembly construction b827h12206002 8. Outer dust seal 17. Tie rod end nut 9. Lower suspension arm : 55 n ⋅m (5.5 kgf-m, 40.0 lb-ft) (a) 1 (g) 7 (b) 2 (c) 3 (j) 10 11 (i) 9 (k) 12 (h) 8 (e) 5 (g) 7 (e) 5 (d) 4 (f) 6 i827h1220001-04 1. Front shock absorber moun...

  • Page 238

    2b-3 front suspension: front suspension inspection b827h12206004 refer to “suspension inspection in section 0b (page 0b-19)”. Front shock absorber inspection b827h12206005 inspect the front shock absorber for damage and oil leakage, and absorber bushing for wear or damage. If any defects are found, ...

  • Page 239

    Front suspension: 2b-4 5) remove the front disc cover (6). 6) remove the cotter pin, tie-rod end nut and washer. 7) disengage the tie-rod end with the special tool. Warning ! When using the tie-rod end remover, keep clear of the tie-rod end because it may come loose with some force and could strike ...

  • Page 240

    2b-5 front suspension: • connect the tie-rod end to the steering knuckle and tighten the tie-rod end nut to the specified torque. Tightening torque tie-rod end nut (b): 29 n·m (2.9 kgf-m, 21.0 lb-ft) • install new cotter pin (1). Caution ! The removed cotter pin (1) must be replaced with a new one. ...

  • Page 241

    Front suspension: 2b-6 • tighten the front hub nut to the specified torque. Tightening torque front hub nut (d): 110 n·m (11.0 kgf-m, 79.5 lb-ft) • install the cotter pin (3). Caution ! The removed cotter pin (3) must be replaced with a new one. Front wheel hub / steering knuckle related parts inspe...

  • Page 242

    2b-7 front suspension: 2) remove the wheel hub bearings with the special tools. Special tool (a): 09923–74511 (bearing remover) (b): 09930–30104 (rotor remover slide shaft) installation install the wheel hub bearings and steering knuckle dust seals in the reverse order of removal. Pay attention to t...

  • Page 243

    Front suspension: 2b-8 • install the steering knuckle dust seals using the special tool. Caution ! Removed oil seal must be replaced with a new one. Special tool (a): 09913–70210 (bearing installer set) front suspension upper / lower arm removal and installation b827h12206010 removal 1) remove the f...

  • Page 244

    2b-9 front suspension: installation 1) apply thread lock to the suspension arm pivot bolts (lower). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) 2) temporarily tighten the suspension arm pivot nuts (lower) (1). 3) install the steering knuckle (2) and suspension uppe...

  • Page 245

    Front suspension: 2b-10 suspension arm inspect the suspension arm for wear or damage. If any damages are found, replace the suspension arm with a new one. Bushing inspect the rubber bushing (suspension arm) for wear or other damage. If any damages are found, replace the bushing with a new one. Refer...

  • Page 246

    2b-11 front suspension: installation 1) install the knuckle end with the special tool. Special tool (a): 09913–70210 (bearing installer set) 2) install the snap ring (1) with the special tool. Caution ! Replace the snap ring (1) with a new one. Special tool : 09900–06107 (snap ring pliers) 3) instal...

  • Page 247

    Front suspension: 2b-12 specifications tightening torque specifications b827h12207001 note the specified tightening torque is also described in the following. “front suspension components (page 2b-1)” “front suspension assembly construction (page 2b-2)” reference: for the tightening torque of fasten...

  • Page 248

    2b-13 front suspension: special tool b827h12208002 09900–06107 09913–50121 snap ring pliers oil seal remover ) (page 2b-10) / ) (page 2b-11) ) (page 2b-6) 09913–70210 09923–74511 bearing installer set bearing remover ) (page 2b-7) / )(page 2b- 8) / )(page 2b-11) ) (page 2b-7) 09930–30104 09942–72410...

  • Page 249

    Rear suspension: 2c-1 suspension rear suspension repair instructions rear suspension components b827h12306001 1 (a) 4 2 3 3 (b) 5 (c) 6 i827h1230011-01 1. Rear shock absorber 5. Rear shock absorber mounting lower nut : 102 n ⋅m (10.2 kgf-m, 74.0 lb-ft) 2. Swingarm 6. Swingarm pivot nut : apply threa...

  • Page 250

    2c-2 rear suspension: rear shock absorber removal and installation b827h12306003 removal 1) place the vehicle on level ground and support the vehicle with a jack. Caution ! Make sure that the vehicle is supported securely. 2) remove the rear shock absorber (1). Installation install the rear shock ab...

  • Page 251

    Rear suspension: 2c-3 6) remove the rear shock absorber lower mounting bolts (2). 7) remove the swingarm (3). Installation install the swingarm in the reverse order of removal. Pay attention to the following points: • apply thread lock to the swingarm pivot bolts. : thread lock cement 99000–32030 (t...

  • Page 252

    2c-4 rear suspension: swingarm bushing removal and installation b827h12306019 refer to “swingarm removal and installation (page 2c- 2)”. Removal remove the swingarm bushings using a hydraulic press and suitable tools. Installation install the swingarm bushings using a hydraulic press and suitable to...

  • Page 253

    Wheels and tires: 2d-1 suspension wheels and tires 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. • using improper tires or tires with imp...

  • Page 254

    2d-2 wheels and tires: repair instructions front and rear wheel components b827h12406001 1 3 5 6 7 8 4 2 (b) (a) (c) (e) (d) (f) i827h1240004-02 1. Front tire 6. Rear tire : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Cotter pin 7. Cotter pin : 12 n ⋅m (1.2 kgf-m, 8.5 lb-ft) 3. Front wheel hub 8. Rear wheel ...

  • Page 255

    Wheels and tires: 2d-3 front / rear wheel removal and installation b827h12406002 note make sure that the vehicle is supported securely. Removal 1) place the vehicle on level ground. 2) support the vehicle with a jack or wooden block. Caution ! Make sure that the vehicle is supported securely. 3) rem...

  • Page 256

    2d-4 wheels and tires: 4) separate the tire from the rim using a set of tire levers and rim protectors. Caution ! When using the tire levers, do not scratch or hit the sealing portion (hump) of the wheel or it may cause air-leakage. 5) after removing the tire, inspect the wheel if necessary. Install...

  • Page 257

    Wheels and tires: 2d-5 note check the “rim line” “b” cast on the tire sidewalls. It must be equidistant from the wheel rim all the way around. If the distance between the rim line and the wheel rim varies, this indicates that the bead is not properly seated. If this is so, deflate the tire completel...

  • Page 258

    2d-6 wheels and tires:.

  • Page 259

    Table of contents 3- i 3 section 3 contents driveline / axle precautions .................................................3-1 precautions............................................................. 3-1 precautions for driveline / axle ............................. 3-1 drive chain / drive train / dr...

  • Page 260

    3-ii table of contents transfer disassembly and assembly (lt- a400/f) .............................................................3c-9 transfer idle gear bearing removal and installation (lt-f400/f).....................................3c-9 transfer gearshift cam components (lt- a400/f) ...............

  • Page 261

    Precautions: 3-1 driveline / axle precautions precautions precautions for driveline / axle b827h13000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train..

  • Page 262

    3a-1 drive chain / drive train / drive shaft: driveline / axle drive chain / drive train / drive shaft diagnostic information and procedures drive shaft symptom diagnosis b827h13104001 repair instructions front drive shaft components (lt-a400f, lt-f400f) b827h13106001 condition possible cause correc...

  • Page 263

    Drive chain / drive train / drive shaft: 3a-2 front drive shaft assembly removal and installation (lt-a400f, lt-f400f) b827h13106002 removal 1) drain the front differential gear oil. Refer to “front differential gear oil inspection (lt-a400f, lt- f400f) in section 0b (page 0b-9)”. 2) remove the stee...

  • Page 264

    3a-3 drive chain / drive train / drive shaft: 2) slide the boot toward the center of the front drive shaft and remove the stopper ring from the outer race. 3) remove the outer race from the front drive shaft. 4) wipe off any grease and remove the snap ring. Special tool (a): 09900–06107 (snap ring p...

  • Page 265

    Drive chain / drive train / drive shaft: 3a-4 3) install the new snap ring to the cage. Caution ! Replace the snap ring with a new one. Special tool (a): 09900–06107 (snap ring pliers) 4) apply grease to the entire surface of the cage and the inside of the outer race. Note the tube of joint grease i...

  • Page 266

    3a-5 drive chain / drive train / drive shaft: 8) install a circlip (2) into the groove of front drive shaft spline. Caution ! The removed circlip must be replaced with a new one. 9) inspect the axle play by using a push-and-pull motion given to the axle shaft and wheel spindle. Front drive shaft ins...

  • Page 267

    Drive chain / drive train / drive shaft: 3a-6 rear axle components b827h13106005 9 10 (a) 8 7 2 3 4 (a) 5 (b) 6 3 1 2 i827h1310025-02 1. Dust seal 6. Rear axle housing (lh) : 55 n ⋅m (5.5 kgf-m, 40 lb-ft) 2. Snap ring 7. Rear axle (rh) : 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) 3. Bearing 8. Rear axle (lh) :...

  • Page 268

    3a-7 drive chain / drive train / drive shaft: rear axle construction b827h13106009 rear axle / axle housing removal and installation b827h13106010 removal 1) remove the final gear case under cover. Refer to “final gear oil replacement in section 0b (page 0b-11)”. 2) remove the rear wheel(-s). Refer ...

  • Page 269

    Drive chain / drive train / drive shaft: 3a-8 5) remove the rear axle housing mounting bolts (2). 6) remove the trailer towing (3). 7) remove the rear axle housing mounting bolt and nuts (4) 8) remove the rear axle housing (5) and rear axle (6). 9) remove the o-ring (7). Installation install the rea...

  • Page 270

    3a-9 drive chain / drive train / drive shaft: • install the trailer towing (1) and tighten the rear axle housing bolts (2) to the specified torque. Tightening torque rear axle housing mounting bolt (final gear case) (a): 55 n·m (5.5 kgf-m, 40.0 lb-ft) • tighten the rear axle housing mounting nuts (3...

  • Page 271

    Drive chain / drive train / drive shaft: 3a-10 rear axle housing disassembly and assembly b827h13106012 disassembly 1) remove the dust seal using the special tool. Special tool (a): 09913–50121 (oil seal remover) 2) remove the snap ring (1). Special tool : 09900–06108 (snap ring pliers) 1) remove th...

  • Page 272

    3a-11 drive chain / drive train / drive shaft: • install the dust seal with special tool. Special tool (a): 09913–70210 (bearing installer set) specifications tightening torque specifications b827h13107001 note the specified tightening torque is also described in the following. “rear axle components...

  • 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

    3b-1 differential: driveline / axle differential diagnostic information and procedures drive train symptom diagnosis b827h13204001 condition possible cause correction / reference item engine noisy (noise seems to come from front/ rear output shaft bevel gear, front drive (differential) bevel gear an...

  • Page 275

    Differential: 3b-2 repair instructions front drive (differential) components (lt-a400f, lt-f400f) b827h13206001 fwd fw d (a) (b) (c) (d) (e) 1 2 3 6 7 8 5 9 4 10 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) ...

  • Page 276

    3b-3 differential: front drive (differential) construction (lt-a400f, lt-f400f) b827h13206002 (a) 2 “a” 1 1 i827h1320001-02 1. Shim : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) : apply thread lock to the thread part. 2. Front drive (differential) case cover bolt : apply grease. : apply bond to mating surface. ...

  • Page 277

    Differential: 3b-4 front drive (differential) gear oil level inspection (lt-a400f, lt-f400f) b827h13206003 refer to “front differential gear oil inspection (lt- a400f, lt-f400f) in section 0b (page 0b-9)”. Front drive (differential) gear oil replacement (lt-a400f, lt-f400f) b827h13206004 refer to “f...

  • Page 278

    3b-5 differential: 6) remove the front drive (differential) mounting bolts. 7) remove the transfer cable bracket bolts and disconnect the transfer cable (2). 8) remove the front drive (differential) assembly from the frame. Installation install the front drive (differential) assembly in the reverse ...

  • Page 279

    Differential: 3b-6 2) remove the front drive (differential) case cover (1). Note use the special tool to remove the cover from housing if necessary. Special tool (a): 09912–34510 (cylinder disassembling tool) 3) remove the front differential gear assembly (2) and shims (3). 4) remove the bearings fr...

  • Page 280

    3b-7 differential: 6) remove the snap ring (4) out of its groove and slide it towards the shifting sleeve. 7) remove the oil universal joint yoke assembly with the special tools. Special tool (c): 09924–21920 (wheel hub remover) (d): 09930–30104 (rotor remover slide shaft) 8) remove the oil seal wit...

  • Page 281

    Differential: 3b-8 14) remove the bearing from the pinion gear with the special tool. Note if there is no abnormal condition, the bearing removal is not necessary. Special tool (e): 09913–70210 (bearing installer set) 15) remove the pinion gear pilot bearing with the special tools. Special tool (f):...

  • Page 282

    3b-9 differential: assembly assemble the front drive (differential) in the reverse order of disassembly. Pay attention to the following points: • install new shifting fork shaft oil seal with the special tool, and then apply grease to the seal lip. Caution ! Replace the removed oil seal with a new o...

  • Page 283

    Differential: 3b-10 • install the pinion gear assembly and fix the bearing with new snap ring (1). Caution ! Replace the snap ring with a new one. • install the shifting sleeve (2) to the pinion gear shaft as shown. • install the bearing into the gear case with the special tool and fix it with the s...

  • Page 284

    3b-11 differential: • install the universal joint and bearings with the special tool. 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) • install the c-rings by tapping them with a cop...

  • Page 285

    Differential: 3b-12 • install new oil seals into the gear case and case 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. • ...

  • Page 286

    3b-13 differential: • tighten the front drive (differential) case cover bolts to the specified torque. Tightening torque front drive (differential) gear case cover bolt (a): 23 n·m (2.3 kgf-m, 16.5 lb-ft) front drive (differential) related parts inspection (lt-a400f, lt-f400f) b827h13206007 refer to...

  • Page 287

    Differential: 3b-14 insert the universal joint to the bearing and check the play by turning the universal joint, as shown. If excessive play is noted, replace the bearing with a new one. Front drive gear case / case cover oil seals inspect the gear case and case cover oil seals for wear or damage. I...

  • Page 288

    3b-15 differential: breather rubber case inspect the breather rubber case (1) for wear or damage. If any defects are found, replace the breather rubber case with a new one. Front drive (differential) gear inspect the front drive (differential) gear for damage. Inspect the front drive (differential) ...

  • Page 289

    Differential: 3b-16 5) remove the dial gauge and turn the front drive (differential) gear 120 °, then measure the backlash. Repeat this procedure once more and compare the difference of the three measurements. The backlash should be re-checked until the backlash is within specification. Check the ta...

  • Page 290

    3b-17 differential: 4) install the front drive (differential) case cover and tighten the bolts to the special torque diagonally. Note • do not apply bond to the mating surface of the gear case. • do not apply thread lock to the case cover bolts. Tightening torque front drive (differential) gear case...

  • Page 291

    Differential: 3b-18 3) install the left and right side shims and front drive (differential) assembly. 4) install the front drive (differential) case cover and tighten the bolts to the specified torque diagonally. Note • do not apply bond to the mating surface of the gear case. • do not apply thread ...

  • Page 292

    3b-19 differential: final gear components b827h13206012 fwd fw d 2 3 5 6 8 9 10 4 (b) (b) (c) (d) (e) (a) 1 7 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 ...

  • Page 293

    Differential: 3b-20 final gear construction b827h13206013 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...

  • Page 294

    3b-21 differential: final gear oil level inspection b827h13206014 refer to “final gear oil inspection in section 0b (page 0b-11)”. Final gear oil replacement b827h13206015 refer to “final gear oil inspection in section 0b (page 0b-11)”. Final gear assembly removal and installation b827h13206016 remo...

  • Page 295

    Differential: 3b-22 7) remove the rear axle housing mounting bolts and trailer towing (4). 8) remove the rear axles together with the axle housings. Installation installation the final gear assembly in the reverse order of removal. Pay attention to the following points: • coat the new o-rings with g...

  • Page 296

    3b-23 differential: • install the final gear case assembly to the frame. • 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 rear axle housing mountin...

  • Page 297

    Differential: 3b-24 5) unlock the bearing lock-nut. 6) remove the bearing lock-nut with the special tool. Special tool (c): 09924–41830 (bearing retainer wrench) 7) remove the final drive gear assembly (3) and shims out of the case. 8) remove the final gear case cover bolts diagonally and evenly. 9)...

  • 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. 13) remove the oil seal out of the case with a suitable tool. Note if...

  • Page 299

    Differential: 3b-26 assembly assemble the final drive in the reverse order of disassembly. Pay attention to the following points: caution ! The removed oil seals, o-rings and bearings must be replaced with new ones. • install the bearings into the final gear case and case cover with the special tool...

  • Page 300

    3b-27 differential: • coat a new o-ring with silicone grease and apply bond to the mating surface of the cover. : grease 99000–25100 (suzuki silicone grease or equivalent) : sealant 99000–31140 (suzuki bond no.1207b or equivalent) note after the backlash and tooth contact have been checked or adjust...

  • Page 301

    Differential: 3b-28 • apply gear oil to the oil seal lip. • install new oil seal by tapping it with a plastic mallet. • apply silicone grease to the o-ring. : grease 99000–25100 (suzuki silicone grease or equivalent) • insert the final gear coupling (5) into the final gear case. • hold the final gea...

  • Page 302

    3b-29 differential: final drive / final driven gear oil seal inspect the oil seals for damage or wear. If any defect are found, replace the oil seal with a new one. Final drive / driven gear bering inspect the bearings for abnormal noise and smooth rotation. Replace the bearing if there is anything ...

  • Page 303

    Differential: 3b-30 breather rubber case inspect the breather rubber case (1) for wear or damage. If any defects are found, replace the breather rubber case with a new one. Final gear backlash inspection and shim adjustment b827h13206019 refer to “final gear assembly removal and installation (page 3...

  • Page 304

    3b-31 differential: right side shim selection 1) put a few pieces of solder (1) (o.D.: 1.2 – 1.5 mm (0.05 – 0.06 in) x l: 6 mm (0.24 in)) on the back side of final driven gear, as shown in the figure. Note do not install the right side shim(-s) at this time. 2) install the final gear case cover and ...

  • 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, ...

  • Page 306

    3b-33 differential: transfer cable inspection and adjustment (lt- a400f, lt-f400f) b827h13206021 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. 1) remove the speedometer cover ...

  • Page 307

    Differential: 3b-34 specifications service data (lt-a400/f, lt-f400/f) b827h13207001 drive train unit: mm (in) tightening torque specifications b827h13207002 note the specified tightening torque is also described in the following. “front drive (differential) components (lt-a400f, lt-f400f) (page 3b-...

  • Page 308

    3b-35 differential: special tools and equipment recommended service material b827h13208001 note required service material is also described in the following. “front drive (differential) components (lt-a400f, lt-f400f) (page 3b-2)” “front drive (differential) construction (lt-a400f, lt-f400f) (page 3...

  • Page 309

    Differential: 3b-36 09913–70210 09921–20210 bearing installer set bearing remover ) (page 3b-8) / )(page 3b- 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 3b-26) ) (pag...

  • Page 310

    3c-1 transfer: driveline / axle transfer diagnostic information and procedures transfer symptom diagnosis (lt-a400/f) b827h13304001 transfer symptom diagnosis (lt-f400/f) b827h13304002 condition possible cause correction / reference item engine is noisy (noise seems to come from the transfer) worn o...

  • Page 311

    Transfer: 3c-2 repair instructions transfer components (lt-a400/f) b827h13306001 1 2 3 4 5 6 7 8 9 10 11 20 12 13 14 15 16 17 18 19 23 22 21 34 33 32 31 30 29 27 26 25 24 35 36 28 fwd fw d i827h1330001-02 1. Washer 14. Washer 27. Bearing 2. Reverse idle gear 15. Lock washer 28. High driven gear 3. B...

  • Page 312

    3c-3 transfer: transfer components (lt-f400/f) b827h13306017 1 3 5 6 7 8 9 10 4 2 11 12 13 14 16 fwd fw d 15 i827h1330002-03 1. Washer 7. Transfer selecting dog 13. Transfer idle gear 2. Transfer low gear 8. Washer 14. Washer 3. Bushing 9. Transfer high gear 15. Transfer output shaft 4. Bearing 10. ...

  • Page 313

    Transfer: 3c-4 transfer removal and installation (lt-a400/f) 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)”. 3) separate...

  • Page 314

    3c-5 transfer: 12) remove the washer (11) and drive bevel gear (12). 13) remove the shim (13). 14) remove the transfer output shaft (14) with a plastic mallet. Caution ! • do not disassemble the transfer output shaft. • the transfer driven gear and transfer output shaft is available only as an assem...

  • Page 315

    Transfer: 3c-6 • hold the transfer driven gear with the special tool and tighten the drive bevel gear nut to the specified torque. Caution ! The removed drive bevel gear nut must be replaced with a new one. Special tool (a): 09920–53740 (clutch sleeve hub holder) tightening torque drive bevel gear n...

  • Page 316

    3c-7 transfer: transfer removal and installation (lt-f400/f) 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. 3) remove the shaft and transfer gear shift fork (...

  • Page 317

    Transfer: 3c-8 installation install the transfer in the reverse order of removal. Pay attention to the following points: caution ! Apply engine oil to each gear and shaft. • assemble the transfer gearshift shaft. Refer to “transfer gearshift cam components (lt-f400/f) (page 3c-11)”. • install the tr...

  • Page 318

    3c-9 transfer: transfer disassembly and assembly (lt-a400/ f) b827h13306004 caution ! Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original position. Disassembly disassemble the transfer countershaft and reverse id...

  • Page 319

    Transfer: 3c-10 transfer gearshift cam components (lt-a400/f) b827h13306005 1 3 5 6 7 8 9 11 10 20 22 12 13 14 15 16 17 18 19 4 2 23 21 (a) fwd fw d 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. ...

  • Page 320

    3c-11 transfer: transfer gearshift cam components (lt-f400/f) b827h13306019 1 2 3 5 6 7 8 9 10 4 11 12 13 14 15 16 17 18 19 fwd fw d 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 1...

  • Page 321

    Transfer: 3c-12 gearshift system construction (lt-a400/f) b827h13306006 gearshift system construction (lt-f400/f) b827h13306020 2 1 i827h1330029-01 1. Transfer gearshift shaft no. 1 2. Transfer counter shaft 1 2 i827h1330030-01 1. Transfer gearshift shaft no. 1 2. Reverse gearshift cam shaft.

  • Page 322

    3c-13 transfer: transfer gearshift cam disassembly and assembly (lt-a400/f) b827h13306007 refer to “transfer removal and installation (lt-a400/f) (page 3c-4)”. Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstal...

  • Page 323

    Transfer: 3c-14 transfer gearshift cam disassembly and assembly (lt-f400/f) b827h13306021 refer to “transfer removal and installation (lt-f400/f) (page 3c-7)”. Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstal...

  • Page 324

    3c-15 transfer: transfer related parts inspection (lt-a400/f) b827h13306010 refer to “transfer removal and installation (lt-a400/f) (page 3c-4)” and “transfer disassembly and assembly (lt-a400/f) (page 3c-9)”. Gearshift fork to groove clearance note the clearance for each gearshift fork plays an imp...

  • Page 325

    Transfer: 3c-16 gearshift fork groove width measure the gearshift fork groove width using the vernier calipers. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) gearshift fork groove width standard (transfer): 5.5 – 5.6 mm (0.217 – 0.220 in) gearshift fork thickness measure the gea...

  • Page 326

    3c-17 transfer: installation install the gear position switch in the reverse order of removal. Pay attention to the following points: • apply bond lightly to the gear position switch lead wire grommet (1). : sealant 99000–31140 (suzuki bond no.1207b or equivalent) • route the gear position switch le...

  • Page 327

    Transfer: 3c-18 6) remove the spring (11) and gearshift cam stopper (12). Installation install the gearshift shaft and gearshift cam plate in the reverse order of removal. Pay attention to the following points: • apply a small quantity of thread lock to the thread of gearshift cam stopper bolt. : th...

  • Page 328

    3c-19 transfer: • install the gearshift shaft assembly by aligning the punch mark of shift gear with the match mark of gearshift cam stopper plate. • install the generator cover. Refer to “generator removal and installation in section 1j (page 1j-5)”. • pour engine oil. Refer to “engine oil and filt...

  • Page 329

    Transfer: 3c-20 transfer range lever components (lt-a400/f) b827h13306024 transfer range lever components (lt-f400/f) b827h13306025 transfer range lever removal and installation b827h13306026 removal 1) keep the vehicle on a level ground. 2) remove the front fender. Refer to “exterior parts removal ...

  • Page 330

    3c-21 transfer: • align the wide spline teeth of the arm and shaft. • inspect the shift rod length and adjust it if necessary. Refer to “shift rod length adjustment (page 3c-21)”. Transfer range lever disassembly and assembly b827h13306027 disassembly 1) removed the transfer range lever assembly. Re...

  • Page 331

    Transfer: 3c-22 2) disconnect the reverse switch coupler (1). 3) inspect the reverse switch for continuity with the taster. If any abnormality is found, replace the reverse switch with a new one. Refer to “transfer range lever removal and installation (page 3c- 20)”. Special tool : 09900–25008 (mult...

  • Page 332

    3c-23 transfer: tightening torque specifications b827h13307003 note the specified tightening torque is also described in the following. “transfer gearshift cam components (lt-a400/f) (page 3c-10)” “transfer range lever components (lt-a400/f) (page 3c-20)” “transfer range lever components (lt-f400/f)...

  • Page 333

    Propeller shafts: 3d-1 driveline / axle propeller shafts repair instructions front output shaft components b827h13406001 lt-a400/f fwd fw d 5 1 3 4 2 6 (a) (a) (a) i827h1340001-05 1. Front output shaft (lt-a400f) 4. Shim(-s) : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear output shaft 5. Driven bevel ge...

  • Page 334

    3d-2 propeller shafts: lt-f400/f fwd fw d 1 2 3 6 4 (a) (a) (a) 5 i827h1340003-02 1. Front output shaft (lt-f400f) 4. Shim(-s) : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear output shaft 5. Driven bevel gear : apply grease. 3. Drive bevel gear 6. Shim(-s) : do not reuse..

  • Page 335

    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...

  • Page 336

    3d-4 propeller shafts: • insert c-ring (1). • check that the output shaft(-s) rotates smoothly. • 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) b...

  • Page 337

    Propeller shafts: 3d-5 4) remove the c-rings (3) from the universal joint (4). 5) remove the bearings by tapping them with the special tool and hammer. Special tool (a): 09913–70210 (bearing installer set) 6) remove the universal joint. 7) using a chisel, unlock the nut. 8) with the rear output shaf...

  • Page 338

    3d-6 propeller shafts: • apply grease to the lip “b” of the oil seal. • install the oil seal to the joint yoke. : grease 99000–25010 (suzuki super grease a or equivalent) caution ! Replace the removed oil seal with a new one. Note the lip “b” of the oil seal should be positioned joint yoke side. • w...

  • Page 339

    Propeller shafts: 3d-7 • after reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. • install the bearing (4), driven bevel gear (5), washer and nut. Note the wider side “c” of the bearing shoul...

  • Page 340

    3d-8 propeller shafts: 3) remove the washer, bearing (1) and driven bevel gear (2). 4) remove the c-rings (3) from the universal joint (4). 5) remove the bearings by tapping them with the special tool and hammer. Special tool (a): 09913–70210 (bearing installer set) 6) remove the universal joint. 7)...

  • Page 341

    Propeller shafts: 3d-9 • apply grease to the lip “b” of the oil seal. • install the oil seal to the joint yoke. : grease 99000–25010 (suzuki super grease a or equivalent) caution ! Replace the removed oil seal with a new one. Note the lip “b” of the oil seal should be positioned joint yoke side. • w...

  • Page 342

    3d-10 propeller shafts: • after reassembling the universal joint, check the joint movement smoothly. If a large resistance is felt to movement, tap the bearing with a plastic mallet lightly. • install the driven bevel gear (4), bearing (5), washer and nut. Note the wider side “c” of the bearing shou...

  • Page 343

    Propeller shafts: 3d-11 assembly assemble the front drive shaft in the reverse order of removal. Pay attention to the following points: • install the spacer using a suitable size tool and hydraulic press. Note the bearing knock-pin “a” should be positioned inside. • apply grease to the lip “b” of th...

  • Page 344

    3d-12 propeller shafts: driven bevel gear inspect the driven bevel gear for wear or damage. If any defects are found, replace the driven bevel gear with a new one. Rear output shaft oil seal visually inspect the oil seal for damage, with particular attention given to the lip. Replace the oil seal th...

  • Page 345

    Propeller shafts: 3d-13 insert the universal joint to the bearing and check the play by turning the universal joint, as shown. If excessive play is noted, replace the bearing with a new one. Front output shaft related parts inspection (lt- a400f, lt-f400f) b827h13406020 refer to “front output shaft ...

  • Page 346

    3d-14 propeller shafts: 6) remove the washer (1) and drive bevel gear (2). 7) remove the shim (3). 8) remove the transfer output shaft (4) with a plastic mallet. Caution ! • do not disassemble the transfer output shaft. • the transfer driven gear and transfer output shaft is available only as an ass...

  • Page 347

    Propeller shafts: 3d-15 • after the backlash and tooth contact have been checked or adjusted, stake the nut with a center punch. Drive bevel gear removal and installation (lt- f400/f) b827h13406022 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d ...

  • Page 348

    3d-16 propeller shafts: • install the shim (2), drive bevel gear (3) and washer (4). • hold the output shaft with the special tool. Special tool (a): 09930–73190 (output shaft holder) • tighten the drive bevel gear nut to the specified torque. Caution ! The removed drive bevel gear nut must be repla...

  • Page 349

    Propeller shafts: 3d-17 2) set the dial gauge on the drive bevel gear. Special tool (b): 09900–20607 (dial gauge (1/100 mm, 10 mm)) (c): 09900–20701 (magnetic stand) 3) measure the backlash by turning the drive bevel gear shaft in each direction, reading the total backlash with the dial gauge. If th...

  • 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 b...

  • Page 351

    Propeller shafts: 3d-19 list of shims (for drive bevel gear) final assembly 1) after adjusting the gear backlash and tooth contact correctly, remove the rear output shaft and drive bevel gear. 2) clean off any machinist’s dye or paste from the gear teeth, and lubricate the teeth with engine oil. 3) ...

  • Page 352

    3d-20 propeller shafts: driven and drive bevel gear shim adjustment information b827h13406023 lt-a400/f (a) 1 2 (b) (c) i827h1340082-01 1. Driven bevel gear shim : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Drive bevel gear shim : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) : do ...

  • Page 353

    Propeller shafts: 3d-21 lt-f400/f (a) 1 2 (b) (c) i827h1340083-01 1. Driven bevel gear shim : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Drive bevel gear shim : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) : do not reuse.

  • Page 354

    3d-22 propeller shafts: specifications service data (lt-a400/f, lt-f400/f) b827h13407001 drive train unit: mm (in) tightening torque specifications b827h13407002 note the specified tightening torque is also described in the following. “front output shaft components (page 3d-1)” “driven and drive bev...

  • 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-14) ) (page 3d-16) 09930–73190 output shaft hol...

  • Page 356

    3d-24 propeller shafts:.

  • Page 357

    Table of contents 4- i 4 section 4 contents brake precautions .................................................4-1 precautions............................................................. 4-1 precautions for brake system .............................. 4-1 brake fluid information .......................

  • Page 358

    4-ii table of contents parking / rear brake lever inspection and adjustment ........................................................4d-1 parking / rear brake lever removal and installation.........................................................4d-1 parking / rear brake cable removal and installatio...

  • Page 359

    Precautions: 4-1 brake precautions 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 differe...

  • Page 360

    4a-1 brake control system and diagnosis: brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b827h14102001 “c” 2 7 1 (a) “d” 7 7 “e” “c” (b) “a” “ a ” “b” 2 11 3 4 6 5 “c” 8 (b) “f” 5 (c) (a) 9 (c) 6 (a) 9 “c” 8 4 “c” 10 “g” i827h1410035-04 1. Fron...

  • Page 361

    Brake control system and diagnosis: 4a-2 brake cable routing diagram b827h14102002 “e” “d” 4 5 6 6 “f” “c” “ a ” 12 2 “a” 1 “b” 2 3 up “ b ” 7 11 1 2 “g” 10 9 8 inside “h” i827h1410036-06 1. Clamp : bind the front brake switch lead wire and throttle cable with the clamp. 12. Clamp : bind the starter...

  • Page 362

    4a-3 brake control system and diagnosis: diagnostic information and procedures brake symptom diagnosis b827h14104001 repair instructions brake pedal adjustment b827h14106001 refer to “rear brake pedal / rear brake (parking brake) lever inspection and adjustment in section 0b (page 0b-16)”. Front bra...

  • Page 363

    Brake control system and diagnosis: 4a-4 2) inspect the switch for continuity with a tester. If any abnormality is found, replace the front brake light switch with a new one. Refer to “front brake master cylinder / brake lever disassembly and assembly (page 4a-10)”. Special tool : 09900–25008 (multi...

  • Page 364

    4a-5 brake control system and diagnosis: parking / rear brake light switch inspection b827h14106005 inspect the parking/rear brake light switch in the following procedures: 1) remove the left inner fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 3)”. 2) disconnect t...

  • Page 365

    Brake control system and diagnosis: 4a-6 4) loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. 5) close the air bleeder valve, pump and squeeze the le...

  • Page 366

    4a-7 brake control system and diagnosis: 6) close the air bleeder valve (1) and disconnect the clear hose. Tightening torque front brake air bleeder valve (a): 6 n·m (0.6 kgf- m, 4.5 lb-ft) 7) fill the reservoir with brake fluid. 8) reinstall the diaphragm and reservoir cap. Front brake hose removal...

  • Page 367

    Brake control system and diagnosis: 4a-8 front brake master cylinder components b827h14106013 front brake master cylinder assembly removal and installation b827h14106014 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-6)”. 2) remove the throttle case assembly. Refer to “hand...

  • 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. 5) remove the brake hose union bolt (2) and disconnect the brake hose. 6) remove the master cylinder assembly (3). Installation install the front br...

  • Page 369

    Brake control system and diagnosis: 4a-10 front brake master cylinder / brake lever disassembly and assembly b827h14106015 refer to “front brake master cylinder assembly removal and installation (page 4a-8)”. Disassembly 1) remove the reservoir cap (1) and diaphragm (2). 2) remove the brake lever (3...

  • Page 370

    4a-11 brake control system and diagnosis: • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • apply grease to the brake lever pivot bolt. • apply grease to the contact point between piston and brake lever. : grease 99000–25100 (suzuki ...

  • Page 371

    Brake control system and diagnosis: 4a-12 rear brake pedal construction b827h14106017 rear brake pedal removal and installation b827h14106018 removal 1) remove the right footrest mudguard. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) remove the cotter pin (1), was...

  • Page 372

    4a-13 brake control system and diagnosis: 4) remove the nut (6), washer (7), o-rings (8) and bolt (9). 5) remove the rear brake pedal (10). Installation install the rear brake pedal in the reverse order of removal. Pay attention to the following points: • apply grease to the o-rings and brake pedal ...

  • Page 373

    Brake control system and diagnosis: 4a-14 tightening torque specifications b827h14107002 note the specified tightening torque is also described in the following. “front brake hose routing diagram (page 4a-1)” “front brake master cylinder components (page 4a-8)” “rear brake pedal construction (page 4...

  • Page 374

    4b-1 front brakes: brake front brakes 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 an...

  • Page 375

    Front brakes: 4b-2 front brake pad inspection b827h14206002 refer to “front brake system inspection in section 0b (page 0b-15)”. Front brake pad replacement b827h14206003 1) remove the front wheel assembly. Refer to “front / rear wheel removal and installation in section 2d (page 2d-3)”. 2) loosen t...

  • Page 376

    4b-3 front brakes: 9) apply a small quantity of thread lock to the front brakes caliper mounting bolts (2). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) 10) tighten the brake caliper mounting bolts (2) to the specified torque. Tightening torque brake caliper mountin...

  • Page 377

    Front brakes: 4b-4 installation install the brake caliper in the reverse order of removal. Pay attention to the following points: • apply a small quantity of thread lock to the front brake caliper mounting bolts (1). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • ti...

  • Page 378

    4b-5 front brakes: 5) place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air. Caution ! Do not use high pressure air to prevent brake caliper piston damage. 6) remove the dust seal (6) and piston seal (7). Assembly assemble the cal...

  • Page 379

    Front brakes: 4b-6 • install the piston seal as shown in the figure. • apply thread lock to the caliper holder slide pin (3). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • tighten the caliper holder slide pin nut (4) and caliper holder pin (5) to the specified torq...

  • Page 380

    4b-7 front brakes: brake pad mounting pin inspect the brake pad mounting pins for wear or other damage. If any defects are found, replace the mounting pins with new ones. Brake pad spring inspect the brake pad spring for damage or excessive bend. If any defects are found, replace the spring with a n...

  • Page 381

    Front brakes: 4b-8 front brake disc inspection b827h14206008 brake disc thickness 1) dismount the front brake caliper. Refer to “front brake caliper removal and installation (page 4b- 3)”. 2) check the brake disc for damage or cracks and measure the thickness using the micrometer. Replace the brake ...

  • Page 382

    4b-9 front brakes: tightening torque specifications b827h14207002 note 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)...

  • Page 383

    Rear brakes: 4c-1 brake rear brakes 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 insid...

  • Page 384

    4c-2 rear brakes: repair instructions rear brake components b827h14306001 fw d fw d 2 2 2 2 (b) (c) 9 1 2 3 5 6 7 8 4 (a) “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 s...

  • Page 385

    Rear brakes: 4c-3 rear brake construction b827h14306007 rear brake shoe inspection b827h14306002 refer to “rear brake pedal / rear brake (parking brake) lever inspection and adjustment in section 0b (page 0b-16)” and “rear brake related parts inspection (page 4c-8)”. Rear brake disassembly and assem...

  • Page 386

    4c-4 rear brakes: 4) disconnect the brake cables by removing the adjuster nuts (3). 5) disconnect the breather hose (4). 6) loosen the drum cover bolts. 7) remove the drum cover (5) with rear hub (6) by using the slotted screwdriver. 8) remove the rear hub (6) and dust seal (7) from the drum cover (...

  • Page 387

    Rear brakes: 4c-5 12) remove the brake anchor panel (10). Note do not turn the brake anchor panel around the rear axle housing to prevent the pipe from getting damage. 13) remove the o-ring (11). 14) remove the o-ring (12). 15) loosen the brake cam lever bolt and nut (13). 16) remove the brake cam l...

  • Page 388

    4c-6 rear brakes: • install the brake camshaft (1) and washer (2). • install the spring (3) with the spring end hooked to the hole on the brake panel. • install the brake cam lever (4) to the brake camshaft (1). • align the punched mark “a” on the brake cam lever with the slit “b” on the brake camsh...

  • Page 389

    Rear brakes: 4c-7 • apply grease to the anchor pin and brake camshaft sliding surface slightly. Warning ! Be careful not to apply too much grease to the brake camshaft and pin. If grease gets on the lining, brake slippage will result. : grease 99000–25010 (suzuki super grease a or equivalent) • inst...

  • Page 390

    4c-8 rear brakes: • assemble the drum cover (11) and rear hub (13). • install the drum cover and tighten the bolts. Note when installing the drum cover, make sure that the o-ring must be fitted into the groove on the brake panel securely. • connect the breather hose (14) and brake cables (15). • tig...

  • Page 391

    Rear brakes: 4c-9 brake shoe inspect the brake shoes for wear or damage. If they are worn or damaged, replace the shoes with new ones. Caution ! Replace the brake shoes as a set, otherwise braking performance will be adversely affected. Dust seal inspect the dust seal wear or damage. If it is worn o...

  • Page 392

    4c-10 rear brakes: special tools and equipment recommended service material b827h14308001 note required service material is also described in the following. “rear brake components (page 4c-2)” “rear brake construction (page 4c-3)” material suzuki recommended product or specification note grease suzu...

  • Page 393

    Parking brake: 4d-1 brake parking 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 parking / rear brake light switch i...

  • Page 394

    4d-2 parking brake: parking / rear brake lever removal and installation b827h14406004 removal 1) disconnect the brake cable (1) from the brake lever. Note • align the slit of lock-nut (2) with the slit of adjuster (3). • loosen the adjuster nut, if necessary. Refer to “rear brake pedal / rear brake ...

  • Page 395

    Parking brake: 4d-3 parking / rear brake cable removal and installation b827h14406002 removal 1) remove the seat and side cover. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) remove the parking/rear brake cable as shown in the brake cable routing diagram. Refer to ...

  • Page 396

    4d-4 parking brake:.

  • Page 397

    Table of contents 5- i 5 section 5 contents transmission / transaxle precautions .................................................5-1 precautions............................................................. 5-1 precautions for transmission / transaxle............. 5-1 automatic transmission............

  • Page 398

    5-ii table of contents specifications.....................................................5c-10 service data (lt-f400/f) .................................5c-10 tightening torque specifications......................5c-10 special tools and equipment ...........................5c-11 recommended service...

  • Page 399

    Precautions: 5-1 transmission / transaxle precautions precautions precautions for transmission / transaxle b827h15000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 400

    5a-1 automatic transmission: transmission / transaxle automatic transmission 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 be...

  • Page 401

    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. Output drive gear.

  • Page 403

    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 ...

  • Page 404

    5a-5 automatic transmission: repair instructions automatic transmission components b827h15106001 (b) (a) (c) (d) 1 3 5 6 7 8 9 11 10 24 26 25 27 28 20 23 22 22 21 12 13 14 15 16 17 18 19 4 2 i827h1510004-03 1. Clutch shoe assembly 13. Spacer 25. Movable driven face 2. One way clutch 14. Movable driv...

  • Page 405

    Automatic transmission: 5a-6 v-belt cooling duct construction b827h15106002 v-belt cooling duct removal and installation (lt-a400/f) b827h15106003 removal 1) remove the right inner fender. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) remove the cooling fan. Refer ...

  • Page 406

    5a-7 automatic transmission: 6) remove the front fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 3)”. 7) remove the induction box assembly (5). Installation 1) install the v-belt cooling ducts as shown in the v-belt cooling duct construction. Refer to “v-belt coolin...

  • Page 407

    Automatic transmission: 5a-8 fixed drive face remove the fixed drive face (1). Installation install the automatic transmission component parts. Pay attention to the following points: fixed drive face • install the fixed drive face (1). Caution ! Degrease the fixed drive face (1). Use nonflammable cl...

  • Page 408

    5a-9 automatic transmission: movable drive face • install the movable drive face assembly (1). Caution ! Degrease the movable drive face assembly (1). Use nonflammable cleaning solvent to wipe off oily or greasy matter and make its surfaces completely dry. • tighten the movable drive face nut to the...

  • Page 409

    Automatic transmission: 5a-10 movable drive face disassembly and assembly b827h15106006 refer to “automatic transmission components (page 5a-5)” and “v-belt type continuously variable automatic transmission removal and installation (page 5a-7)”. Disassembly 1) remove the spacer (1). 2) remove the da...

  • Page 410

    5a-11 automatic transmission: 4) assemble the dampers (3) to the movable drive plate (4). 5) assemble the movable plate (4) to the movable drive face (2). 6) install the spacer (5). Note when installing the spacer, press down the movable drive face plate so as not to cause the rollers to come out of...

  • Page 411

    Automatic transmission: 5a-12 3) remove the movable driven face ring nut (2). 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. 4) loosen the special tool handle slowly and remove the special too...

  • Page 412

    5a-13 automatic transmission: 9) remove the oil seals (9) and (10) from the movable driven face. Note if there are no abnormal conditions, the oil seal removal is not necessary. Assembly assemble the movable driven face in the reverse order of disassembly. Pay attention to the following points: • in...

  • Page 413

    Automatic transmission: 5a-14 • install the pins and rollers. • install the spring seat (4) with aligning the hole “a” with the hole “b”. • install the spring (5) and spring plate (6) with hooking the spring ends with the holes “c” and “d”. • compress the spring with the special tool. Special tool (...

  • Page 414

    5a-15 automatic transmission: drive v-belt inspection b827h15106008 inspect that the drive belt is free from any greasy substance. Inspect the contact surface of the drive belt for cracks or damage and measure the width of the drive belt with the vernier calipers. If any defects are found or measure...

  • Page 415

    Automatic transmission: 5a-16 movable / fixed driven face parts inspection b827h15106010 movable / fixed driven face inspect the driven face for any abnormal conditions, such as stepped wear or discoloration caused by burning. If any defects are found, replace them with new ones. Movable driven pin ...

  • Page 416

    5a-17 automatic transmission: 6) remove the gasket (5) and dowel pins. 7) remove the one way clutch (6). 8) remove the clutch shoe nut with the special tool. Caution ! The clutch shoe nut has left-hand threads. Special tool (a): 09930–40113 (rotor holder) 9) remove the clutch shoe (7). Installation ...

  • Page 417

    Automatic transmission: 5a-18 • install the dowel pins and new gasket (3). Caution ! Use new gasket to prevent oil leakage. • install the drive v-belt inner cover. Caution ! Fit the gasket washer to the bolt “b” • install the drive/driven face assemblies and v-belt outlet cover. Refer to “v-belt typ...

  • Page 418

    5a-19 automatic transmission: installation installation is in the reverse order of removal. Pay attention to the following points: • install the bearing with the special tool. Special tool (a): 09913–70210 (bearing installer set) caution ! The removed bearing must be replaced with a new one. • insta...

  • Page 419

    Automatic transmission: 5a-20 3) remove the retainers (3). 4) remove the bearing with the special tool. Special tool (a): 09913–70210 (bearing installer set) note if there is no abnormal noise, the bearing removal is not necessary. 5) remove the oil seal with the special tool. Special tool (a): 0991...

  • Page 420

    5a-21 automatic transmission: • fit the bearing retainers. • apply a small quantity of thread lock to the bearing retainer screws, and tighten them securely. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • apply grease to the o-ring and oil seal lip. • install the co...

  • Page 421

    Automatic transmission: 5a-22 clutch wheel inspect the clutch wheel for any abnormal surface damage. Measure the inside diameter of the clutch wheel. If the measurement exceeds the service limit, replace the clutch wheel with a new one. Clutch wheel i.D. Service limit: 140.5 mm (5.53 in) v-belt inne...

  • Page 422

    5a-23 automatic transmission: drive train unit: mm (in) except ratio transmission unit: mm (in) tightening torque specifications b827h15107002 note the specified tightening torque is also described in the following. “automatic transmission components (page 5a-5)” reference: for the tightening torque...

  • Page 423

    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-13) / ) (page 5a-19) / ) (page 5a-19) / ) (page...

  • Page 424

    5b-1 manual transmission: transmission / transaxle manual transmission diagnostic information and procedures manual transmission symptom diagnosis (lt-f400/f) b827h15204001 condition possible cause correction / reference item engine is noisy (noise seems to come from the transmission). Gear worn or ...

  • Page 425

    Manual transmission: 5b-2 repair instructions transmission components (lt-f400/f) b827h15206001 1 2 3 4 8 7 6 5 9 10 11 12 13 15 14 fwd fw d 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. Coun...

  • Page 426

    5b-3 manual transmission: transmission removal and installation (lt- f400/f) b827h15206002 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-1...

  • Page 427

    Manual transmission: 5b-4 • install the reverse idle gear shaft (5). • install the snap ring (6), washer (7) and spacer (8). Special tool : 09900–06107 (snap ring pliers) • install the reverse idle gear (9) and washer (10). Transmission construction b827h15206004 8 7 6 5 i827h1520007-01 9 10 i827h15...

  • Page 428

    5b-5 manual transmission: countershaft gear / driveshaft gear disassembly and assembly (lt-f400/f) b827h15206005 refer to “transmission removal and installation (lt- f400/f) (page 5b-3)”. Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective groups ...

  • Page 429

    Manual transmission: 5b-6 • fit the special tool and install the 2nd drive gear using a hydraulic press. Special tool (a): 09913–70210 (bearing installer set) • when installing the bushings, align the shaft hole with the bushing hole. Transmission reverse gearshift cam disassembly and assembly (lt-f...

  • Page 430

    5b-7 manual transmission: transmission related parts inspection (lt- f400/f) b827h15206007 refer to “transmission removal and installation (lt- f400/f) (page 5b-3)” and “countershaft gear / driveshaft gear disassembly and assembly (lt-f400/f) (page 5b-5)”. Gearshift fork to groove clearance note the...

  • Page 431

    Manual transmission: 5b-8 5) remove the gear position switch (2). 6) remove the switch contacts and springs. Installation install the gear position switch in the reverse order of removal. Pay attention to the following points: • apply a bond lightly to the gear position switch lead wire grommet (1)....

  • Page 432

    5b-9 manual transmission: installation install the gearshift lever assembly in the reverse order of removal. Pay attention to the following points: • apply grease to the o-rings and pedal pivot. Caution ! Replace the o-rings with new ones. : grease 99000–25010 (suzuki super grease a or equivalent) •...

  • Page 433

    Manual transmission: 5b-10 gearshift shaft / gearshift cam plate components (lt-f400/f) b827h15206019 (a) 4 (b) 5 1 3 2 6 7 8 9 (c) 11 10 fwd fw d 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 dri...

  • Page 434

    5b-11 manual transmission: gearshift shaft / gearshift cam plate removal 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)”. 3) remove the gearshift cam plate guide (1)...

  • Page 435

    Manual transmission: 5b-12 • apply a small quantity of thread lock to the gearshift shaft stopper (2) and tighten it to the specified torque. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) tightening torque gearshift shaft stopper (b): 19 n·m (1.9 kgf-m, 13.5 lb-ft) •...

  • Page 436

    5b-13 manual transmission: gearshift shaft oil seal removal and installation (lt-a400/f) b827h15206022 removal • remove the generator cover. Refer to “generator removal and installation in section 1j (page 1j-5)”. • remove the gearshift shaft oil seal (1). Installation install the oil seal in the re...

  • Page 437

    Manual transmission: 5b-14 tightening torque specifications b827h15207002 note 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 sectio...

  • Page 438

    5c-1 clutch: transmission / transaxle clutch 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 engi...

  • Page 439

    Clutch: 5c-2 repair instructions clutch components (lt-f400/f) b827h15306014 1 2 (a) 4 3 5 6 6 6 7 7 6 6 6 8 9 7 7 7 10 11 12 13 (b) fwd fw d 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. Clu...

  • Page 440

    5c-3 clutch: clutch removal and installation (lt-f400/f) b827h15306016 remove 1) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-7)”. 2) remove the right footrest mudguard. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 3) remove th...

  • Page 441

    Clutch: 5c-4 9) unlock the clutch sleeve hub nut. 10) remove the clutch sleeve hub nut using the special tool. Special tool (a): 09920–53730 (clutch sleeve hub holder) 11) remove the clutch shoe assembly (7) and primary driven gear assembly (8). 12) remove the thrust washer (9), thrust washer (10) a...

  • Page 442

    5c-5 clutch: • install the collar (3) onto the primary driven gear assembly. • install the clutch sleeve hub assembly into the primary driven gear assembly. • install the primary driven gear assembly together with the clutch wheel. • install the washer and clutch sleeve hub nut. Note the convex side...

  • Page 443

    Clutch: 5c-6 • install the clutch springs and clutch release plate. • tighten the clutch spring bolts diagonally. • install the dowel pins and new gasket (4). Caution ! Use new gasket to prevent oil leakage. • install the clutch cover. • loosen the lock nuts (1) and (2). • rotate the adjusting screw...

  • Page 444

    5c-7 clutch: measure the claw width of drive plates with a vernier calipers. Replace the drive plates found to have worn down to the limit. Special tool (a): 09900–20102 (vernier calipers (1/20 mm, 200 mm)) clutch drive plate claw width service limit: 13.05 mm (0.514 in) measure each driven plate fo...

  • Page 445

    Clutch: 5c-8 clutch wheel inspect the clutch wheel for any abnormal surface damage. Measure the inside diameter of the clutch wheel. If the measurement exceeds the service limit, replace the clutch wheel with a new one. Clutch wheel i.D. Service limit: 140.5 mm (5.53 in) one-way clutch 1) install th...

  • Page 446

    5c-9 clutch: 2) remove the snap ring (1) with the special tool. Special tool : 09900–06108 (snap ring pliers) note if there is no abnormal noise, the bearing removal is not necessary. 3) remove the bearing with the special tool. Special tool (a): 09921–20240 (bearing remover set) assembly assembly i...

  • Page 447

    Clutch: 5c-10 clutch release roller inspection (lt-f400/f) b827h15306020 refer to “clutch cover disassembly and assembly (lt- f400/f) (page 5c-8)”. Rotate the rollers by hand to inspect for an abnormal noise and a smooth rotation. Replace the clutch release roller assembly if there is anything unusu...

  • Page 448

    5c-11 clutch: special tools and equipment recommended service material b827h15308001 note required service material is also described in the following. “clutch components (lt-f400/f) (page 5c-2)” special tool b827h15308002 material suzuki recommended product or specification note grease suzuki super...

  • Page 449

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions for steering ....................................... 6-1 steering general diagnosis.............

  • Page 450

    6-1 precautions: steering precautions precautions precautions for steering b827h16000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 451

    Steering general diagnosis: 6a-1 steering steering general diagnosis 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. Insuffici...

  • Page 452

    6b-1 steering / handlebar: steering steering / handlebar repair instructions steering / handlebars components b827h16206001 1 2 2 3 5 5 6 7 8 9 11 10 12 12 13 4 4 “a” “a” (a) (b) (d) (d) (d) (c) i827h1620049-02 1. Handlebars 6. Steering shaft 11. Dust seal : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Handle...

  • Page 453

    Steering / handlebar: 6b-2 steering assembly construction b827h16206008 (c) 8 1 7 (a) 3 7 (a) 4 6 9 (a) 4 (a) 1 2 (b) 5 i827h1620001-03 1. Steering shaft 6. O-ring : 49 n ⋅m (4.9 kgf-m, 35.5 lb-ft) 2. Tie-rod 7. Cotter pin : 26 n ⋅m (2.6 kgf-m, 19.0 lb-ft) 3. Tie-rod end nut 8. Handlebar clamp bolt ...

  • Page 454

    6b-3 steering / handlebar: handlebars removal and installation b827h16206003 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). Caution ! Do not...

  • Page 455

    Steering / handlebar: 6b-4 installation install the handlebars in the reverse order of removal. Pay attention to the following points: • insert the rear brake lever holder (1) and starter lever (2) onto the handlebars. • apply handle grip bond “a” onto the left handlebar before installing the left g...

  • Page 456

    6b-5 steering / handlebar: • apply grease to the parking brake cable end. : grease 99000–25010 (suzuki super grease a or equivalent) • insert the projection “f” of the transfer lever into the hole of the handlebars. (lt-a400f, lt-f400f) lt-a400f, lt-f400f • install the right grip as the same manner ...

  • Page 457

    Steering / handlebar: 6b-6 tie-rod 1) remove cotter pins and tie-rod end nuts and washers. 2) disconnect each tie-rod end using the special tool. Special tool (a): 09942–72410 (tie rod end remover) 3) loosen the lock-nut (1) and (2). Caution ! The lock-nut (1) have left-hand threads. 4) remove the t...

  • Page 458

    6b-7 steering / handlebar: 5) remove the steering shaft holders (1) and dust seals (2). 6) remove the dust seal (3), washer (4) and o-ring (5). 7) remove the steering shaft (6). 8) remove the dust seal (7) from the steering shaft (6). 9) remove the steering shaft bushing (8) using the special tools ...

  • Page 459

    Steering / handlebar: 6b-8 • apply grease to the steering shaft bushing (1). : grease 99000–25010 (suzuki super grease a or equivalent) • apply grease to the steering shaft and dust seal (2). : grease 99000–25010 (suzuki super grease a or equivalent) • install the dust seal (2) to the steering shaft...

  • Page 460

    6b-9 steering / handlebar: • tighten the steering shaft lower nut to the specified torque. Tightening torque steering shaft lower nut (b): 49 n·m (4.9 kgf-m, 35.5 lb-ft) • install a new cotter pin. Caution ! Replace the cotter pin with a new one. Tie-rod • temporarily install the lock-nut (1), (2) a...

  • Page 461

    Steering / handlebar: 6b-10 • check the steering moves smoothly. • check the wiring harness routing, cable routing and brake hose routing. Refer to “wiring harness routing diagram in section 9a (page 9a-8)”, “brake cable routing diagram in section 4a (page 4a-2)”and “front brake hose routing diagram...

  • Page 462

    6b-11 steering / handlebar: steering shaft holder inspect the steering shaft holders for wear or damage. If any defects are found, replace the steering shaft holders with new ones. Steering shaft bushing inspect the steering shaft bushing for wear or damage. If any defects are found, replace the ste...

  • Page 463

    Steering / handlebar: 6b-12 special tools and equipment recommended service material b827h16208001 note required service material is also described in the following. “steering / handlebars components (page 6b-1)” “steering assembly construction (page 6b-2)” special tool b827h16208002 material suzuki...

  • Page 464

    6b-13 steering / handlebar:.

  • Page 465

    Table of contents 9- i 9 section 9 contents body and accessories precautions .................................................9-1 precautions............................................................. 9-1 precautions for electrical system ......................... 9-1 component location .............

  • Page 466

    9-1 precautions: body and accessories precautions 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 b827h19...

  • Page 467

    Wiring systems: 9a-1 body and accessories wiring systems schematic and routing diagram wiring diagram b827h19102001 refer to “wire color symbols in section 0a (page 0a-4)”..

  • Page 468

    9a-2 wiring systems: lt-a400 (p-28, 33), lt-a400f (p-24) hi run on off on off on light off off push lo on off on off push on off on off rear brake switch (l) headlight(r) headlight(l) power source speedometer indica t o r light ill nu re oi nu re oi : neutral indica t or light : reverse indica t or ...

  • Page 469

    Wiring systems: 9a-3 lt-a400f (p-17) reversing light rela y buzzer (option) reversing light hi run on off set secede on off on light off off push lo on off on off push on off on off rear brake switch (l) headlight(r) headlight(l) power source speedometer indica t o r light ill nu hi re oi nu hi : hi...

  • Page 470

    9a-4 wiring systems: lt-a400f (p-28, 33) hi run on off on light off off push lo on off on off push on off on off rear brake switch (l) off headlight(r) headlight(l) power source speedometer indica t o r light ill nu re oi nu re oi : neutral indica t or light : reverse indica t or light : oil temp . ...

  • Page 471

    Wiring systems: 9a-5 lt-f400 (p-24, 28, 33), lt-f400f (p-24) hi run on off on off on light off off push lo on off on off push on off on off push free headlight(r) headlight(l) power source speedometer pilot light ill nu re oi nu re oi : neutral indica t or light : reverse indica t or light : oil tem...

  • Page 472

    9a-6 wiring systems: lt-f400/f (p-17) hi run on off set secede on off on light off off push lo on off on off push on off on off rear brake switch (l) push free headlight(r) headlight(l) power source speedometer indica t or light ill nu hi re oi nu hi : hi beam light re oi : neutral indica t or light...

  • Page 473

    Wiring systems: 9a-7 lt-f400f (p-28, 33) hi run on off on off on light off off push lo on off on off push on off on off rear brake switch (l) free push headlight(r) headlight(l) power source speedometer indica t o r light ill nu re oi nu re oi : neutral indica t or light : reverse indica t or light ...

  • Page 474

    9a-8 wiring systems: wiring harness routing diagram b827h19102002 2 1 “a” “b” 10 4 3 5 “d” “c” 8 9 7 22 21 20 19 10 8 9 13 14 17 18 “g” 15 16 12 “ a ” 11 6 “e” “f” i827h1910901-06 1. Clamp : bind the handlebar switch lead wire, parking/rear brake light switch lead wire and horn button lead wire (p-1...

  • Page 475

    Wiring systems: 9a-9 9. Engine ground lead wire “b”: pass the front brake light switch lead wire behind the speedometer cable. 10. Rear brake light switch lead wire “c”: pass the starter cable between frame and harness guide, and horn lead wire inside of frame. 11. Horn (p-17,24) “d”: pass the indic...

  • Page 476

    9a-10 wiring systems: specifications service data (lt-a400/f, lt-f400/f) b827h19107001 electrical unit: mm tightening torque specifications b827h19107002 note the specified tightening torque is also described in the following. “wiring harness routing diagram (page 9a-8)” reference: for the tightenin...

  • Page 477

    Lighting systems: 9b-1 body and accessories lighting systems repair instructions headlight construction b827h19206001 1. Headlight housing 2. Grommet 3. Yellow tape (lh) white tape (rh) 2 3 1 i827h1920001-02.

  • Page 478

    9b-2 lighting systems: front side reflector construction b827h19206015 2 1 (a) (b) i827h1920003-01 1. Front side reflector (p-28 only) : 1.8 n ⋅m (0.18 kgf-m, 1.5 lb-ft) 2. Bracket stopper : 3.3 n ⋅m (0.33 kgf-m, 2.5 lb-ft).

  • Page 479

    Lighting systems: 9b-3 headlight components b827h19206002 headlight removal and installation b827h19206003 removal 1) disconnect the headlight coupler (1). 2) remove the headlight with the housing (2). 1 1 i827h1920004-01 1. Headlight bulb (12 v 35/35 w x2) 1 i827h1920005-01 2 i827h1920006-03.

  • Page 480

    9b-4 lighting systems: 3) remove the headlight (3) from the housing. Installation install the headlight in the reverse order of removal. Pay attention to the following point: • after installing, be sure to inspect the headlight beam. Refer to “headlight beam adjustment (page 9b-4)”. Headlight bulb r...

  • Page 481

    Lighting systems: 9b-5 rear combination light components b827h19206009 rear combination light removal and installation b827h19206010 removal 1) remove the rear combination light coupler (1). 2) remove the rear combination light assembly (2). 1 i827h1920002-01 1. Brake light / taillight bulb (12 v 21...

  • Page 482

    9b-6 lighting systems: installation install the rear combination light in the reverse order of removal. Rear combination light bulb replacement b827h19206011 caution ! • if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature...

  • Page 483

    Lighting systems: 9b-7 dimmer switch inspection b827h19206014 inspect the dimmer switch in the following procedures: 1) turn the ignition switch off. 2) remove the left inner fender. Refer to “exterior parts removal and installation in section 9d (page 9d- 3)”. 3) disconnect the handlebar switch cou...

  • Page 484

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn repair instructions speedometer components b827h19306001 1 2 3 4 5 i827h1930001-01 1. Speedometer 3. Speedometer light bulb (12v 1.7 w) 5. Indicator light bulb (12v 3.4 w) 2. Damper 4. Speedometer ...

  • Page 485

    Combination meter / fuel meter / horn: 9c-2 speedometer removal and installation b827h19306002 removal 1) remove the indicator light lenses (1). 2) remove the speedometer cover bolts and ignition switch ring nut (2). 3) disconnect the indicator light sockets (3). 4) disconnect the speedometer cable ...

  • Page 486

    9c-3 combination meter / fuel meter / horn: installation install the speedometer in the reverse order of removal. Pay attention to the following points: • rout the speedometer cable properly. Refer to “throttle cable routing diagram in section 1d (page 1d-1)”. • install the indicator lights in the p...

  • Page 487

    Combination meter / fuel meter / horn: 9c-4 horn inspection (for p-17, 24) b827h19306014 note if the horn sound condition is normal, it is not necessary to inspect the horn button continuity. Horn button inspection 1) disconnect the horn connectors as shown in the wiring harness routing diagram. Ref...

  • Page 488

    9d-1 exterior parts: body and accessories exterior parts repair instructions rear fender heat shield construction b827h19406002 1 2 “a” “ a ” i827h1940003-02 1. Rear fender heat shield “a”: do not cover the hole with the heat shield 2. Rear fender “a”: 0 mm (0 in).

  • Page 489

    Exterior parts: 9d-2 fastener removal and installation b827h19406004 type a removal 1) depress the head of fastener center piece (1). 2) pull out the fastener (2). Installation 1) let the center piece stick out toward the head so that the pawls “a” closes. 2) insert the fastener into the installatio...

  • Page 490

    9d-3 exterior parts: exterior parts removal and installation b827h19406005 seat removal unlock and remove the seat. Installation insert the seat hooks into the retainers and push down the seat firmly. Side cover removal 1) remove the seat. 2) remove the side cover (1) (lh/rh). Installation installat...

  • Page 491

    Exterior parts: 9d-4 inner fender removal remove the inner fender (1) (lh/rh) by removing the following screw and fasteners. Installation installation is in the reverse order of removal. Front under cover removal remove the front under cover (1). Installation installation is in the reverse order of ...

  • Page 492

    9d-5 exterior parts: engine under cover removal remove the engine under cover (1). Installation installation is in the reverse order of removal. Front fender removal 1) remove the front carrier. Refer to “front carrier removal and installation in section 9e (page 9e-4)”. 2) remove the inner fenders....

  • 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. 3) remove the side covers. 4) remove the footrest mudguards. 5) remove the battery (2). Refer to “battery remo...

  • Page 494

    9e-1 body structure: body and accessories body structure repair instructions body frame construction b827h19506001 footrest construction b827h19506002 2 3 1 fwd fw d (a) (b) i827h1950001-03 1. Frame 3. Battery plate : 28 n ⋅m (2.8 kgf-m, 20.0 lb-ft) 2. Engine mounting upper bracket : 28 n ⋅m (2.8 kg...

  • Page 495

    Body structure: 9e-2 footrest removal and installation b827h19506003 removal 1) remove the footrest mudguard. Refer to “exterior parts removal and installation in section 9d (page 9d-3)”. 2) remove the gearshift link arm (1) from the engine. (lt-f400/f lh). 3) remove the footrest (2). 4) remove the ...

  • Page 496

    9e-3 body structure: carrier construction b827h19506004 1. Front carrier : 28 n ⋅m (2.8 kgf-m, 20.0 lb-ft) : apply thread lock to the thread part. 2. Rear carrier : 28 n ⋅m (2.8 kgf-m, 20.0 lb-ft) 2 1 fwd fw d (a) (b) i827h1950005-04.

  • Page 497

    Body structure: 9e-4 front carrier removal and installation b827h19506005 removal • remove the front carrier (1) by removing the bolts (2). Installation install the front carrier in the reverse order of removal. Pay attention to the following point: • tighten the front carrier mounting bolts to the ...

  • Page 498

    9e-5 body structure: front grip bar construction b827h19506007 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)”. 2) remove the front grip bar (1) by removing the bolts. 1 (a) (b...

  • Page 499

    Body structure: 9e-6 installation install the front grip bar in the reverse order of removal. Pay attention to the following point: • tighten the front grip bar mounting bolts to the specified torque. Tightening torque front grip bar mounting bolt (a): 28 n·m (2.8 kgf- m, 20.0 lb-ft) trailer towing ...

  • Page 500

    9e-7 body structure: specifications tightening torque specifications b827h19507001 note the specified tightening torque is also described in the following. “body frame construction (page 9e-1)” “footrest construction (page 9e-1)” “carrier construction (page 9e-3)” “front grip bar construction (page ...

  • Page 501

    Prepared by december, 2007 part no. 99500-43070-01e printed in japan 504.

  • Page 502

    Printed in japan k8 9 9 5 0 0 - 4 3 0 7 0 - 0 1 e k8.