1. DL manuals
  2. Suzuki
  3. Offroad Vehicle
  4. LT-F400
  5. Owner's Manual

Suzuki LT-F400 Owner's Manual

Other manuals for LT-F400: Service Manual

Summary of LT-F400

  • Page 1

    Top 1st cover 4th cover top 1st cover 4th cover lt-f400/f owner’s manual 99011-27h61-03a lt-f400/f part no. 99011-27h61-03a april, 2008 en tk 6 mm 6 mm no.2845 lt-f400/f 99011-27h61-03a 2/1 no.2845 lt-f400/f 99011-27h61-03a 2/1 dic184(tdp006) dic157 this owner’s manual contains important safety info...

  • Page 2

    Top 3rd cover 2nd cover 6 mm no.2845 lt-f400/f 99011-27h61-03a 2/1 black california proposition 65 warning warning engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the state of california to cause cancer and birth defects or other reproduc...

  • Page 3

    Important warning /caution /note please read this manual and fol- low its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay spe- cial attention to the messages highlighted by these signal words: note: indicates spe...

  • Page 4

    Foreword • this owner’s manual contains important safety and mainte- nance information. Read it carefully before you ride your new atv. Failure to follow the warnings contained in this manual can result in injury or death. • do not allow anyone under age 16 to ride this atv. • in the usa, anyone who...

  • Page 5

    • the proper care and mainte- nance that your atv requires is outline in this manual. By fol- lowing these instructions explicitly you will ensure a long trouble-free operating life for your atv. This atv also con- forms to the u.S. Environmen- tal protection agency (epa) and california air resource...

  • Page 6

    • always avoid operating an atv on paved surfaces, including sidewalks, paths, parking lots, drive ways, and streets. • never operate an atv on any public street, road or highway, even a dirt or gravel one. • never operate an atv without wearing an approved motorcy- cle helmet that fits properly. Yo...

  • Page 7

    • always follow proper proce- dures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the vehicle ...

  • Page 8

    • never exceed the stated load capacity for an atv. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. For more information about atv safety, owners in the usa ca...

  • Page 9

    Table of contents 1 2 3 4 5 6 7 8 9 10 fuel and oil recommendations controls, equipment and adjustments riding your atv accessory use and vehicle loading inspection and maintenance troubleshooting preparation for winter riding transporting cleaning procedure and storage procedure consumer informatio...

  • Page 10

    Www.Quad-forum.Sk.

  • Page 11

    1-1 1 fuel and oil recommendations fuel .................................................................................................................... 1-2 engine oil ......................................................................................................... 1-3 front differential...

  • Page 12

    1-2 fuel and oil recommendations fuel your vehicle requires regular unleaded gasoline, with a mini- mum pump octane rating of 87 ((r+m)/2 method). In some areas, the only fuels that are available are oxygenated fuels. Oxygenated fuels which meet the minimum octane requirement and the requirements de...

  • Page 13

    1-3 note: • to help minimize air pollution, suzuki recommends that you use oxygenated fuels. • be sure that any oxygenated fuel you use has octane rat- ings of at least 87 pump octane ((r+m)/2 method). • if you are not satisfied with the driveability or fuel economy of your atv when you are using an...

  • Page 14

    1-4 jaso t903 the jaso t903 standard is an index to select engine oils for 4- stroke motorcycle and atv engines. Motorcycle and atv engines lubricate clutch and transmission gears with engine oil. Jaso t903 specifies perfor- mance requirements for motorcy- cle and atv clutches and transmissions. The...

  • Page 15

    2-1 2 controls, equipment and adjustments location of parts ....................................................................................... 2-2 key ...................................................................................................................... 2-5 ignition switch ........

  • Page 16

    2-2 controls, equipment and adjustments location of parts 1 rear brake lever 2 left handlebar switches 3 choke lever 4 speedometer and indicator lights 5 selection lever (lt-f400f) 6 front brake fluid reservoir 7 front brake lever 8 range lever 9 fuel tank cap 0 fuel gauge a ignition switch b thrott...

  • Page 17

    2-3 c fuel valve d box e seat lock f recoil starter g gearshift lever h footrests www.Quad-forum.Sk.

  • Page 18

    2-4 i rear brake pedal www.Quad-forum.Sk.

  • Page 19

    2-5 key two keys come with this vehicle. Keep the spare key in a safe place. An identifying number is stamped on the keys. Use this number when making a replace- ment key. Please write down your key num- ber in the box provided for your future reference. Warning indicates a potential hazard that cou...

  • Page 20

    2-6 ignition switch the ignition switch has three posi- tions. “off” position all electrical circuits are cut off. The engine will not start. The key can be removed. “on” position the ignition circuit is on and the engine can be started. The key cannot be removed in this posi- tion. “ (lights)” posi...

  • Page 21

    2-7 speedometer and indicator lights speedometer 1 the speedometer shows approxi- mate vehicle speed. Odometer 2 the odometer shows the total dis- tance that the vehicle has been ridden. Trip meter 3 the trip meter is a resettable odometer. It can be used to show the distance traveled on short trips...

  • Page 22

    2-8 range lever select a range position according to how you intend to use the vehi- cle. L (low range): carrying heavy loads or trailer towing. Compared to high range, this position provides lower speed and greater torque to the wheels. H (high range): normal riding with light loads. R (reverse): s...

  • Page 23

    2-9 selection lever (lt-f400f) the selection lever is used for changing the manner in which engine power is supplied to the wheels. Select 2wd or 4wd according to surface conditions. 2wd: engine power is supplied only to the rear wheels. Use this position for normal riding on dry, hard surfaces. 4wd...

  • Page 24

    2-10 gearshift lever this vehicle has a 5-speed trans- mission which operates as shown in the illustration. The shift lever is attached to a ratchet type mecha- nism in the transmission. Each time you select a gear, the gear- shift lever will return to its normal position ready to select the next ge...

  • Page 25

    2-11 dimmer switch 3 use the dimmer switch to select the high or low headlight beam when the ignition switch is in the “ (lights)” position. When you move the dimmer switch to the “ ” position, the high beam will light and the high beam indicator light will come on. When you move the dimmer switch t...

  • Page 26

    2-12 engine stop switch 4 “ ” position the ignition circuit is off and the engine cannot start or run. “ ” position the ignition circuit is on and the engine can run. Electric starter button “ ” 5 use this button to turn the starter motor. Before starting the engine, turn the ignition switch to the ...

  • Page 27

    2-13 choke lever “ ” the carburetor of this vehicle has a choke system to provide easy starting when the engine is cold. The choke system works by mov- ing the choke lever to the engage position. The choke system works best when the throttle is in the closed position. When the engine is warm, you do...

  • Page 28

    2-14 throttle limiter use the throttle limiter to restrict maximum engine power by limit- ing throttle lever travel. Adjust this limiter according to the rider’s skill and experience. To adjust the throttle limiter: 1. Loosen the lock nut 1 . 2. Turn the throttle limiter screw 2 clockwise to restric...

  • Page 29

    2-15 fuel valve this vehicle is equipped with an automatic type, diaphragm style fuel valve. There are three posi- tions: “on,” “res” and “pri.” “on” position the normal position for the fuel valve lever is in the “on” position. In this position, no fuel will flow from the fuel valve to the carbure-...

  • Page 30

    2-16 recoil starter this vehicle has a recoil starter which can start the vehicle’s engine if the electric starter does not work. To use the recoil starter, grip the starter rope handle located on the engine magneto cover. Pull the rope gently until you feel the starter engage. Pull the rope forcefu...

  • Page 31

    2-17 fuel gauge “ ” the fuel gauge shows the approx- imate amount of gasoline remain- ing in the fuel tank. The symbol mark in the fuel gauge shows as follows. Position 1 –fuel valve must be turned to res position soon. Position 2 –fuel tank has half amount of gasoline. Position 3 –fuel tank has ful...

  • Page 32

    2-18 seat lock to remove the seat, move the seat lock lever upward. Raise the rear end of the seat and slide it backward. To lock the seat, slide the seat hook into the seat hook retainer and push down firmly. Flag bracket a bracket is provided so you can mount a flag on your lt-f400/f. Warning impr...

  • Page 33

    2-19 box small and light articles such as the tool kit, owner’s manual, rain gear or a wind breaker can be placed in the box. Note: • the box can get very hot since the heated engine is under the box. Do not keep any flamma- ble items, low heat-resistant items, foods or drink in the box. • do not ke...

  • Page 34

    Www.Quad-forum.Sk.

  • Page 35

    3-1 3 riding your atv what you should know before riding ................................................ 3-2 inspection before riding .......................................................................... 3-4 what to wear ............................................................................

  • Page 36

    3-2 riding your atv what you should know before riding before you ride, you should read all of the following information carefully. If you are properly pre- pared, you will have a safer and more enjoyable ride. Warning indicates a potential hazard that could result in injury or death. Warning operat...

  • Page 37

    3-3 before you begin riding, you should find a good place to prac- tice the skills you need to ride safely. Find a flat, open area with enough space to practice new skills. Make sure that it is legal to ride in the area you have selected. Review local laws to make sure you are not trespassing. Check...

  • Page 38

    3-4 inspection before riding warning failure to inspect the atv before operating it can be haz- ardous. Failure to perform proper maintenance can also be hazardous. Failure to inspect and maintain your atv increases the chances of an accident or equipment damage. Always inspect your atv each time yo...

  • Page 39

    3-5 check the condition of the atv to help make sure that you do not have mechanical problems, or you might get stranded somewhere when you ride. Before riding the atv, be sure to check the follow- ing items. Be sure your lt-f400/f is in good condition for the per- sonal safety of the rider and pro-...

  • Page 40

    3-6 what to wear a helmet is the most important piece of gear you should wear. A helmet can help prevent a serious head injury. Choose a helmet that fits snugly. Ask your dealer for help in selecting a good quality helmet that fits properly. You should wear eye protection when you ride. If a rock or...

  • Page 41

    3-7 break-in the first month is the most impor- tant in the life of your vehicle. Proper operation during this break-in period will help assure maximum life and performance from your new vehicle. The follow- ing guidelines explain proper break-in procedures. Maximum throttle opening recommendation d...

  • Page 42

    3-8 starting the engine before attempting to start the engine, make sure to follow these steps: 1. Set the parking brake. 2. Shift the transmission to neu- tral. 3. Turn the key to the “on” posi- tion. 4. Set the engine stop switch to the “ ” position. 5. Set the fuel valve to the “on” position. Thi...

  • Page 43

    3-9 if the ambient temperature is at or above 5°c (40°f): 1. Move the choke lever to the engage position halfway. 2. Push the electric starter button or use the recoil starter as described above to start the engine. 3. When the engine is sufficiently warmed up, move the choke lever to the “off” posi...

  • Page 44

    3-10 starting off and shifting warning carrying a passenger on this atv can be hazardous. Carrying a passenger can greatly reduce your ability to balance and steer this atv. If you carry a passenger, you can lose control, and both you and the passenger can be severely injured. Never carry a passenge...

  • Page 45

    3-11 warning operating this atv on public streets, roads or highways can be hazardous. You can collide with another vehicle if you ride on public roads. • never operate this atv on any public street, road or highway, even a dirt or gravel one. • in many states it is illegal to operate atvs on public...

  • Page 46

    3-12 warning removing your hands from the handlebars or feet from the footrests during operation can be hazardous. If you remove even one hand or foot from the atv, you can reduce your ability to control the atv. This could cause you to lose your balance and fall off the atv. If you remove a foot fr...

  • Page 47

    3-13 after making sure that the engine is warm, apply the rear brake and then release the parking brake. To release the parking brake, simply squeeze the rear brake lever until the parking brake lock releases. While holding the rear brake, engage first gear by lifting up on the gearshift lever. To s...

  • Page 48

    3-14 the table below shows the approximate speed range for each gear with the range lever set to high range. Shifting up schedule shifting down schedule gear position km/h miles/h 1st → 2nd 12 7 2nd → 3rd 20 12 3rd → 4th 30 19 4th → 5th 40 25 gear position km/h miles/h 5th → 4th 30 19 4th → 3rd 20 1...

  • Page 49

    3-15 braking to stop the lt-f400/f, first release the throttle lever. Next, apply the front and rear brakes evenly and at the same time. As vehicle speed decreases, shift down through the gears. Warning braking while turning the atv can be hazardous. Use of the brake when turning could cause the atv...

  • Page 50

    3-16 turning to turn the lt-f400/f, the rider must use the proper technique. Because this vehicle has a solid rear axle, both rear wheels always turn at the same speed. This means that if the rear wheels are getting equal traction, the vehicle will tend to move straight ahead. This is because the re...

  • Page 51

    3-17 skidding or sliding you may experience skidding or sliding when you are not braking. You may be able to overcome it by using the techniques listed below. If your front wheel skids: gain front wheel traction by reducing the throttle opening and leaning your body weight slightly forward. If your ...

  • Page 52

    3-18 operation on hills climbing a hill warning operating this atv on exces- sively steep hills can be haz- ardous. The atv can overturn more easily on extremely steep hills than on level surfaces or small hills. Never operate the atv on hills too steep for the atv or for your abilities. Practice on...

  • Page 53

    3-19 to climb a hill with the lt-f400/f, follow the directions below. 1. Speed up and maintain a steady speed before reaching the bottom of the hill. Shift down to increase approach speed, if necessary. Remem- ber that you must ride at a steady speed all the way to the top of the hill. 2. Shift body...

  • Page 54

    3-20 you may start to climb a hill and may be unable to make it to the top. If this happens, use the cor- rect procedure described below to turn around to get back down the hill. If you still have forward movement and enough space to turn around safely, follow these instructions. 1. Turn around on t...

  • Page 55

    3-21 descending a hill warning going down a hill improperly can be hazardous. Going down a hill improperly can cause loss of control or cause the atv to overturn. Always follow the proper pro- cedures for going down hills as described in this section. Ok warning braking on hills can be hazard- ous. ...

  • Page 56

    3-22 to ride down a hill with the lt- f400/f, follow the instructions below. 1. Check the terrain carefully for any obstacles before you start down the hill. 2. Point the lt-f400/f straight downhill. 3. Transfer body weight to the rear by sliding back on the seat. 4. Shift the transmission into a lo...

  • Page 57

    3-23 riding over obstacles if you come to an obstacle that you cannot avoid, you may be able to cross over it using the fol- lowing procedure. 1. With the obstacle straight in front of you, approach at walk- ing speed. 2. Rise up slightly on the foot- rests. 3. Pull up on the handlebars and apply a ...

  • Page 58

    3-24 riding through water you can ride the lt-f400/f through shallow water. Make sure it is not more than 30 cm (12 in) deep and is not moving fast. Choose a good place to cross before you ride through any water. Look for a spot where the banks are gently sloped on both sides and the bottom of the s...

  • Page 59

    3-25 riding in cold weather pre-ride inspection check that the throttle and all control levers move freely. Make sure that the footrests shift lever, and rear brake pedal are free of ice or snow. With the transmission in neutral, move the atv forward and back- ward to check that the wheels roll free...

  • Page 60

    3-26 any water that enters the brakes while you ride may freeze after you park your atv. The frozen water can prevent the wheels from turning or the brakes from working. After riding through water, mud, snow, or slush it is important to dry the brakes before parking the atv. To dry the brakes, apply...

  • Page 61

    3-27 we strongly recommend that if you do any cold-weather riding, you familiarize yourself with the symptoms, treatment, and pre- vention of hypothermia. Informa- tion is available at libraries and through government agencies. Plan your winter rides with safety and comfort in mind. Dress for the wo...

  • Page 62

    3-28 practice riding your atv in an open snow- or ice-covered area, at slow speeds, before heading out on snow- or ice-covered trails. Learn how your atv responds to steering and braking on the type of terrain you will encounter on your ride. Your eyes may be sensitive to sunlight when you ride over...

  • Page 63

    3-29 riding in reverse to engage reverse gear, follow these directions. 1. Stop the vehicle and shift into neutral. 2. Apply the front and rear brakes and move the range lever to the reverse position. 3. Look to make sure there is nothing in your way behind you. 4. Slowly release the brakes and appl...

  • Page 64

    Www.Quad-forum.Sk.

  • Page 65

    4-1 4 accessory use and vehicle loading atv winch lead wires ................................................................................. 4-4 www.Quad-forum.Sk.

  • Page 66

    4-2 accessory use and vehicle loading there are many types of accesso- ries for sale. However, suzuki can not have direct control over the quality or suitability of non-suzuki accessories. Suzuki can not test each accessory that is available. If you add the wrong accessories or misuse the vehicle wi...

  • Page 67

    4-3 suzuki dealers offer a variety of genuine suzuki accessories for your atv. Please contact your suzuki dealer for details. Accessory use and vehicle load- ing guidelines. 1. The combined weight of the rider, gear, trailer tongue weight and any accessories or cargo must never exceed the vehicle’s ...

  • Page 68

    4-4 atv winch lead wires lt-f400f has lead wires in the wiring harness that can be used to attach a suzuki genuine acces- sory atv winch, rated line pull: 1360 kg (3000 lbs). The part num- ber of the suzuki atv winch for this vehicle is 99000-990yw-016. Consult your suzuki dealer for details about a...

  • Page 69

    5 5-1 inspection and maintenance maintenance schedule .............................................................................. 5-2 notice ................................................................................................................ 5-3 tool .....................................

  • Page 70

    5-2 inspection and maintenance maintenance schedule perform maintenance according to odometer reading or time interval, whichever comes first. I= inspect and clean, adjust, lubricate or replace, as necessary, c= clean, t= tighten, r= replace, l= lubricate warning indicates a potential hazard that co...

  • Page 71

    5-3 notice it is very important to inspect and maintain your lt-f400/f regularly. Follow the guidelines in the chart. The intervals between periodic services in miles (kilometers) and months are shown. At the end of each interval, be sure to perform the maintenance listed. Maintenance, replace- ment...

  • Page 72

    5-4 caution if you use your atv under severe conditions, it will need maintenance more often than shown in the chart. Operating your atv under severe conditions causes more wear on your atv. Severe con- ditions include operating under frequent full throttle, or in dusty, wet, sandy, or muddy areas. ...

  • Page 73

    5-5 tool a tool kit is provided with your atv. It is located under the seat. Battery the battery is located under the seat. This battery is a sealed type battery and requires no mainte- nance. Have your dealer check the battery’s state of charge peri- odically. To remove the battery, loosen the bolt...

  • Page 74

    5-6 warning hydrogen gas produced by bat- teries can be hazardous. Batteries produce flammable hydrogen gas which can explode if exposed to flames or sparks. Keep flames and sparks away from the battery. Never smoke when working near the battery. Caution exceeding the maximum charging rate for the a...

  • Page 75

    5-7 spark plug spark plug removal 1. Remove the seat by referring to the seat lock section. 2. Remove the left side frame cover. 3. Disconnect the spark plug cap. 4. Remove the spark plug with a spark plug wrench. Your lt-f400/f comes equipped with an ngk cr7e or denso u22esr-n. To determine if the ...

  • Page 76

    5-8 note: if the above-named plugs are not available, consult your suzuki dealer. To install a spark plug, turn it in as far as possible with your fingers, then tighten it with a wrench. To maintain a hot, strong spark, keep the plug free from carbon. Adjust the gap to 0.7 – 0.8 mm (0.028 – 0.031 in...

  • Page 77

    5-9 idle speed adjustment to adjust the idle speed properly, you need a tachometer. If you do not have one, ask your suzuki dealer to perform this adjustment. To adjust the idle speed: 1. Start the engine and warm it up. 2. Turn the throttle stop screw 1 in or out so that the engine idles at 1400 – ...

  • Page 78

    5-10 choke cable adjustment to adjust the choke cable play: 1. Remove the boot. 2. Loosen the lock nut 1 . 3. Turn the adjuster 2 in or out to obtain the proper amount of outer cable free play 0.5 – 1.0 mm (0.02 – 0.04 in). Measure choke cable free play by pull- ing on the outer cable. 4. After adju...

  • Page 79

    5-11 engine oil long engine life depends much on the selection of a quality oil and the periodic changing of the oil. Daily oil level checks and peri- odic changes are two of the most important maintenance items to be performed. Engine oil level check follow the procedure below to inspect the engine...

  • Page 80

    5-12 engine oil and filter change change the engine oil and oil filter at the scheduled times. The engine should always be warm when the oil is changed so the oil will drain easily. The procedure is as follows: 1. Park the vehicle on level ground. 2. Remove the oil filler cap 1 . 3. Remove the drain...

  • Page 81

    5-13 4. Remove the screw and fasten- ers. Remove the left inner cover 3 . Available from suzuki dealer oil filter wrench (part no. 09915-40610) 5. Turn the oil filter 4 counter- clockwise with a suzuki “cap type” oil filter wrench or a “strap type” filter wrench of the proper size. Www.Quad-forum.Sk.

  • Page 82

    5-14 6. Wipe off the mounting surface 5 on the engine where the new filter will be seated with a clean rag. 7. Smear a little engine oil around the rubber gasket 6 of the new oil filter. 8. Screw the new filter by hand until the filter gasket contacts the mounting surface (a small resistance will be...

  • Page 83

    5-15 9. Mark the top dead center posi- tion on the “cap type” filter wrench or on the oil filter. Use an oil filter wrench to tighten the filter 2 turns or to specified torque. Oil filter tightening torque: 20 n·m (2.0 kgf-m, 14.5 lb-ft) 10.Reinstall the drain plug and tighten it securely. Pour abou...

  • Page 84

    5-16 air cleaner the air cleaner element must be kept clean to provide good engine power and gas mileage. If you use your vehicle under normal, low- stress conditions, you should ser- vice the air cleaner at the intervals specified. If you ride in dusty, wet, or muddy conditions, you will need to in...

  • Page 85

    5-17 removing the element 1. Remove the seat. 2. Remove the fastener. Unhook the hooks and take off the air cleaner case cover 1 . 3. Remove the screw 2 , then remove the element assembly 3 . 4. Pull out the foam element from the element frame. Www.Quad-forum.Sk.

  • Page 86

    5-18 washing the element wash the element as follows: 1. Fill a wash pan larger than the element with a non-flammable cleaning solvent a . Dip the element in the solvent and wash it. 2. Squeeze the element by pressing it between the palms of both hands to remove excess solvent. Do not twist or wring...

  • Page 87

    5-19 air cleaner drain tube periodically check the drain tube shown by the arrow to see if any gasoline or oil has accumulated. If you notice any gasoline or oil, remove the drain tube cap, drain the gasoline or oil into a suitable container, and replace the cap. Warning oil and solvent can be hazar...

  • Page 88

    5-20 gear oil change inspect and change the gear oil according to the maintenance schedule. When changing the gear oil, use sae90 hypoid gear oil which is rated gl-5 under the api classification system. If you operate the lt-f400f where the ambient temperature is normally below 0°c (32°f), use sae 8...

  • Page 89

    5-21 tires the lt-f400/f is equipped with low pressure tubeless tires of the size and type listed below: warning new and used oil can be haz- ardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used gear oil has been found to cause skin cancer in laboratory...

  • Page 90

    5-22 tire tread condition tire pressure a low pressure gauge is provided in the tool kit, so you can measure the air pressure in your lt-f400/ f’s tires. Check the air pressure in all tires before each use of the vehicle. Improper air pressure can affect handling, steering response, traction, tire l...

  • Page 91

    5-23 tire replacement your atv has low-pressure tube- less tires. Air is sealed by the con- tact surfaces of the inner wheel rim and the tire bead. If either the inner wheel rim or tire bead is damaged, air may leak. Be extremely careful not to damage these sections when replacing tires. It is very ...

  • Page 92

    5-24 brakes the atv is equipped with front disk and rear drum brakes. Warning failure to properly inspect and maintain your atv’s brake sys- tems can be hazardous. Improper maintenance of the brakes increases your chances of having an accident. Be sure to inspect the brakes before each use of the ve...

  • Page 93

    5-25 front brake brake fluid be sure to check the brake fluid level in the front brake fluid reser- voir. Inspect for brake pad wear and leaks. Warning brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. If swallowed, do not induce vomiting. Immediatel...

  • Page 94

    5-26 front brake pads inspect the front brake pads as follows. 1. Inspect the brake pads to see if they are worn down to the grooved wear limit line. 2. If you find that the pads are worn to the grooved wear limit line, bring the vehicle to your authorized suzuki dealer to have the brake pads replac...

  • Page 95

    5-27 warning riding this atv after brake sys- tem repair or brake pad replacement without pumping the brake lever can be hazard- ous. If you do not pump the brake lever before starting, you can not get enough braking perfor- mance and may result in an accident. Pump the brake lever several times unt...

  • Page 96

    5-28 rear brake adjust the rear brake by adjusting the brake pedal first and then adjust the brake lever. Brake pedal adjust the brake pedal as follows: 20 – 30 mm (0.8 – 1.2 in) turn the adjuster 1 clockwise or counterclockwise so that there is 20 – 30 mm (0.8 – 1.2 in) of free travel. Warning misa...

  • Page 97

    5-29 brake lever (parking brake) the rear brake lever play as mea- sured at the lever holder should be 3 – 5 mm (0.1 – 0.2 in) when the lever is lightly pulled in toward the grip. This adjustment is nec- essary for proper operation of the rear brake lever and the parking brake. 3 – 5 mm (0.1 – 0.2 i...

  • Page 98

    5-30 rear brake lining wear limit this vehicle has brake lining wear limit indicator on the rear brake. To check wear of the brake lining, perform the following. 1. Check that the brake system is properly adjusted. 2. While fully applying the brake, check to see that the extension line of the index ...

  • Page 99

    5-31 front and rear wheel removal 1. Park the vehicle on level ground and set the parking brake. 2. Loosen the wheel nuts 1 on the wheel to be removed. 3. Lift up the front or rear end of the vehicle by placing a jack or block under the final gear case. 4. Remove the wheel nuts. 5. Remove the wheel....

  • Page 100

    5-32 spark arrester the muffler has a spark arrester which must be periodically cleaned to maintain good effi- ciency. At the intervals shown in the maintenance chart, clean the spark arrester as follows. 1. Remove the bolt 1 and pull out the spark arrester 2 . 2. Use a brush to remove carbon deposi...

  • Page 101

    5-33 drive shaft boots (lt-f400f) check the drive shaft rubber boots for damage and grease leak. Ask you suzuki dealer if replacement is necessary. Light bulb replacement the wattage rating of each bulb is shown in the following chart. When replacing a burned-out bulb, always use the same watt- age ...

  • Page 102

    5-34 headlight to replace the headlight bulb, use the following procedure: 1. Remove the rubber cap 1 . 2. Remove the socket cover 2 . 3. Disconnect the socket 3 . 4. Unhook the bulb holder spring 4 and pull out the bulb 5 . 5. To replace the headlight bulb, reverse the above sequence. Caution touch...

  • Page 103

    5-35 brake/taillight replace the brake/taillight bulb as follow: 1. Turn the socket counterclock- wise and pull it off. 2. Push the bulb in and turn it to the left. Remove the bulb. 3. To install a new bulb, push the bulb in firmly and turn it to the right while pushing in. Fuse the main fuse is loc...

  • Page 104

    5-36 fuse list • 30a main fuse protects the all electrical circuits. • 10a head-hi fuse protects the headlight high beam and high beam indicator light. • 10a head-lo fuse protects the headlight low beam. • 10a tail fuse protects the tail- light and speedometer light. • 10a ignition fuse protects the...

  • Page 105

    5-37 general lubrication proper lubrication is important for safe, smooth operation and long life of your vehicle. Be sure that all lubrication is performed during periodic maintenance on the vehi- cle. Shorten intervals when you use your atv in severe condi- tions. Your authorized suzuki dealer sho...

  • Page 106

    5-38 trailer towing you may use your lt-f400/f to tow a light trailer but always observe the requirements and recommendation in this section. Trailer towing equipment use a trailer and trailer towing equipment that are compatible. Use only a no.1 trailer hitch ball (48 mm (1-7/8 in) in diameter). Ne...

  • Page 107

    5-39 the weight of your loaded trailer (gross trailer weight) should never exceed 180 kg (400 lbs) when towing on uneven surfaces. When towing at low speed along a straight level path, you may tow up to the vehicle towing limit of 450 kg (992 lbs). Spread the cargo in your trailer so that the tongue...

  • Page 108

    Www.Quad-forum.Sk.

  • Page 109

    6-1 6 troubleshooting fuel system check ...................................................................................... 6-2 ignition system check ................................................................................ 6-3 www.Quad-forum.Sk.

  • Page 110

    6-2 troubleshooting this troubleshooting guide is pro- vided to help you find the cause of some common complaints. Complaint: engine is hard to start or does not start at all. Something is probably wrong with the fuel system or ignition system. Fuel system check 1. Make sure there is adequate fuel i...

  • Page 111

    6-3 c. Tighten the drain screw. D. Push the electric starter button for a few seconds to turn the engine. E. Loosen the drain screw and check that the carburetor is filled back up with fuel. F. If fuel is reaching the carbu- retor, the ignition system should be checked next. Ignition system check 1....

  • Page 112

    Www.Quad-forum.Sk.

  • Page 113

    7-1 7 preparation for winter riding engine oil change ........................................................................................ 7-2 www.Quad-forum.Sk.

  • Page 114

    7-2 preparation for winter riding use of some engine oils in cold weather may make the engine hard to start. It may also cause clutch drag and stiff transmission operation. Select the right oil for cold weather according to the chart in the fuel and oil rec- ommendations section. Engine oil change d...

  • Page 115

    8-1 8 transporting transporting ................................................................................................. 8-2 www.Quad-forum.Sk.

  • Page 116

    8-2 transporting transporting it is best to transport the lt-f400/ f in the normal position. It may also be transported on its back wheels, but this is not as stable as the normal position. Before transporting the lt-f400/f, drain the fuel from the carburetor as follows: 1. Turn the fuel valve to th...

  • Page 117

    8-3 warning draining fuel from the carbure- tor can be hazardous. Fuel can catch on fire if you do not handle it properly. When draining the carburetor, always shut the engine off. Do not smoke, and never drain or refuel in an area where there are open flames or sparks. Do not spill the fuel or you ...

  • Page 118

    Www.Quad-forum.Sk.

  • Page 119

    9-1 9 cleaning procedure and storage procedure preparation for cleaning ....................................................................... 9-2 washing your atv ........................................................................................ 9-3 inspection after cleaning ...................

  • Page 120

    9-2 cleaning procedure and storage procedure a thorough cleaning of your atv is a necessary part of mainte- nance and will help keep your atv looking and performing its best. Proper cleaning can also extend the life of your atv. It is important to clean and inspect your atv after every ride if it is...

  • Page 121

    9-3 washing your atv with some care, your atv can be washed in a similar manner to washing an automobile. Note: avoid spraying or allowing water to flow over the following places: • ignition switch • spark plug • fuel tank cap • carburetor • brake master cylinder • snorkel air intake for air filter ...

  • Page 122

    9-4 inspection after cleaning remove the rags or wrapping from the exhaust pipe. Check the drain tubes on the bottom of the air filter box and drain any water that has collected in them. For extended life of your atv, lubri- cate it according to the “gen- eral lubrication” section. Follow the proced...

  • Page 123

    9-5 engine remove the spark plug and pour one tablespoon of motor oil into the spark plug hole. Reinstall the spark plug and crank the engine a few times to spread the oil in the cylinder. Battery • remove the battery from the vehicle. • clean the outside of the bat- tery with mild soap and remove c...

  • Page 124

    Www.Quad-forum.Sk.

  • Page 125

    10 10-1 consumer information emission control warranty ................................................................. 10-2 serial number location .......................................................................... 10-2 location of labels .......................................................

  • Page 126

    10-2 consumer information emission control warranty warranties the warranties for your atv are explained in a separate warranty policy booklet given to you at the time of sale. Please read this booklet carefully so you can understand your rights and responsibilities. The following warranties are pro...

  • Page 127

    10-3 location of labels read and follow all of the warn- ings labeled on your atv. Make sure you understand all of the labels. Keep the labels on the atv. Do not remove them for any reason. If a label comes off or becomes difficult to read, you can get a replacement by contacting your suzuki dealer....

  • Page 128

    10-4 3 warning under under operating this atv if you are under the age of 16 increases your chance of severe injury or death. Never operate this atv if you are under age 16 . Improper atv use can result in severe injury or death a l w a y s u s e a n a p p r o v e d h e l m e t a n d p r o t e c t i...

  • Page 129

    10-5 4 5 7 8 9 6 warning loss of control can result in severe injury or death. Tire size : front at25 × 8 – 12 rear at25 × 10 – 12 improper tire pressure or overloading can cause loss of control. Always maintain proper tire pressure as shown below. Never exceed the maximum weight capacity of 380 lbs...

  • Page 130

    Specifications dimensions and curb mass overall length ..................................................2060 mm (81.1 in) overall width....................................................1145 mm (45.1 in) overall height ..................................................1220 mm (48.0 in) wheelbase ....

  • Page 131

    Chassis front suspension .............................................Independent, double wishbone, coil spring, oil damped rear suspension .............................................Swingarm type, coil spring, oil damped front wheel travel ............................................170 mm (6.7 i...

  • Page 132

    Index a air cleaner ..................... 5-16 air cleaner drain tube.................................... 5-19 atv winch lead wires.................................... 4-4 b battery............................... 5-5 box...................................... 2-19 brakes.................................

  • Page 133

    K key ........................................ 2-5 l left handlebar.............. 2-10 light bulb replacement .................. 5-33 location of labels ...... 10-3 location of parts .......... 2-2 m maintenance during storage.............................. 9-5 maintenance schedule......................

  • Page 134

    T throttle cable adjustment ....................... 5-9 throttle limiter ........... 2-14 tires................................... 5-21 tool...................................... 5-5 trailer towing .............. 5-38 transporting................... 8-2 turning ............................. 3-16 w w...

  • Page 135

    Warning indicates a potential hazard that could result in injury or death. Www.Quad-forum.Sk.

  • Page 136

    Www.Quad-forum.Sk.

  • Page 137

    Www.Quad-forum.Sk.

  • Page 138

    Www.Quad-forum.Sk.

  • Page 139

    Top 3rd cover 2nd cover 6 mm no.2845 lt-f400/f 99011-27h61-03a 2/1 black california proposition 65 warning warning engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the state of california to cause cancer and birth defects or other reproduc...

  • Page 140: Lt-F400/f

    Top 1st cover 4th cover top 1st cover 4th cover lt-f400/f owner’s manual 99011-27h61-03a lt-f400/f part no. 99011-27h61-03a april, 2008 en tk 6 mm 6 mm no.2845 lt-f400/f 99011-27h61-03a 2/1 no.2845 lt-f400/f 99011-27h61-03a 2/1 dic184(tdp006) dic157 this owner’s manual contains important safety info...