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SUZUKI LT-A400F, LT-F400F KingQuad Service Manual – PDF DOWNLOAD
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Description
SUZUKI LT-A400F, LT-F400F KingQuad Service Manual – PDF DOWNLOAD
FILE DETAILS:
SUZUKI LT-A400F, LT-F400F KingQuad Service Manual – PDF DOWNLOAD
Language : English
Pages : 518
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
SUZUKI LT-A400F, LT-F400F KingQuad Service Manual – PDF DOWNLOAD
- This manual contains an introductory description on the SUZUKI LT-A400/F, LT-F400/F and procedures for its inspection/service and overhaul of its main components.
- Other information considered as generally known is not included.
- Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
- This manual will help you know the vehicle better so that you can assure your customers of fast and reliable service.
TABLE OF CONTENTS:
SUZUKI LT-A400F, LT-F400F KingQuad Service Manual – PDF DOWNLOAD
FOREWORD๏ฟฝ................................................................................................. 1
TABLE OF CONTENTS๏ฟฝ........................................................................................ 3
00 PRECAUTIONS๏ฟฝ........................................................................................... 7
PRECAUTIONS๏ฟฝ.......................................................................................... 8
PRECAUTIONS๏ฟฝ...................................................................................... 8
WARNING / CAUTION / NOTE๏ฟฝ..................................................................... 8
GENERAL PRECAUTIONS๏ฟฝ.......................................................................... 8
PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE๏ฟฝ................................................... 9
0 GENERAL INFORMATION๏ฟฝ.................................................................................... 15
GENERAL INFORMATION๏ฟฝ.................................................................................. 16
GENERAL DESCRIPTION๏ฟฝ.............................................................................. 16
SYMBOLS๏ฟฝ...................................................................................... 16
ABBREVIATIONS๏ฟฝ................................................................................ 16
SAE-TO-FORMER SUZUKI TERM๏ฟฝ.................................................................... 17
VEHICLE SIDE VIEW๏ฟฝ............................................................................ 17
VEHICLE IDENTIFICATION NUMBER๏ฟฝ................................................................ 18
FUEL AND OIL RECOMMENDATION๏ฟฝ.................................................................. 18
BREAK-IN PROCEDURES๏ฟฝ.......................................................................... 19
COUNTRY AND AREA CODES๏ฟฝ....................................................................... 19
WIRE COLOR SYMBOLS๏ฟฝ........................................................................... 19
WARNING, CAUTION AND INFORMATION LABELS LOCATION๏ฟฝ............................................. 20
COMPONENT LOCATION๏ฟฝ............................................................................... 21
ELECTRICAL COMPONENTS LOCATION๏ฟฝ............................................................... 21
SPECIFICATIONS๏ฟฝ................................................................................... 25
SPECIFICATIONS๏ฟฝ............................................................................... 25
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ...................................................................... 29
SPECIAL TOOL๏ฟฝ................................................................................. 29
MAINTENANCE AND LUBRICATION๏ฟฝ.......................................................................... 32
PRECAUTIONS๏ฟฝ...................................................................................... 32
PRECAUTIONS FOR MAINTENANCE๏ฟฝ.................................................................. 32
GENERAL DESCRIPTION๏ฟฝ.............................................................................. 32
RECOMMENDED FLUIDS AND LUBRICANTS๏ฟฝ............................................................ 32
SCHEDULED MAINTENANCE๏ฟฝ............................................................................ 32
PERIODIC MAINTENANCE SCHEDULE CHART๏ฟฝ.......................................................... 32
LUBRICATION POINTS๏ฟฝ........................................................................... 33
REPAIR INSTRUCTIONS๏ฟฝ.............................................................................. 34
AIR CLEANER ELEMENT INSPECTION AND CLEANING๏ฟฝ.................................................. 34
EXHAUST PIPE BOLT AND MUFFLER BOLT INSPECTION๏ฟฝ................................................ 35
VALVE CLEARANCE INSPECTION AND ADJUSTMENT๏ฟฝ.................................................... 35
SPARK PLUG REPLACEMENT๏ฟฝ....................................................................... 36
SPARK PLUG INSPECTION AND CLEANING๏ฟฝ........................................................... 37
SPARK ARRESTER CLEANING๏ฟฝ...................................................................... 38
FUEL LINE INSPECTION๏ฟฝ......................................................................... 38
ENGINE OIL AND FILTER REPLACEMENT๏ฟฝ............................................................ 38
FRONT DIFFERENTIAL GEAR OIL INSPECTION (LT-A400F, LT-F400F)๏ฟฝ.................................. 40
FRONT DIFFERENTIAL GEAR OIL REPLACEMENT (LT- A400F, LT-F400F)๏ฟฝ................................ 41
FINAL GEAR OIL INSPECTION๏ฟฝ.................................................................... 42
FINAL GEAR OIL REPLACEMENT๏ฟฝ................................................................... 42
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT๏ฟฝ................................................ 44
ENGINE IDLE SPEED ADJUSTMENT๏ฟฝ................................................................. 44
DRIVE V-BELT INSPECTION (LT-A400/F)๏ฟฝ.......................................................... 44
CLUTCH INSPECTION (LT-F400/F)๏ฟฝ................................................................ 45
DRIVE SHAFT BOOTS INSPECTION (LT-A400F, LT- F400F)๏ฟฝ........................................... 45
FRONT BRAKE SYSTEM INSPECTION๏ฟฝ................................................................ 46
REAR BRAKE PEDAL / REAR BRAKE (PARKING BRAKE) LEVER INSPECTION AND ADJUSTMENT๏ฟฝ................ 47
TIRE INSPECTION๏ฟฝ.............................................................................. 48
STEERING SYSTEM INSPECTION๏ฟฝ................................................................... 49
TOE-IN ADJUSTMENT๏ฟฝ............................................................................ 49
SUSPENSION INSPECTION๏ฟฝ........................................................................ 50
CHASSIS BOLT AND NUT INSPECTION๏ฟฝ.............................................................. 50
COMPRESSION PRESSURE CHECK๏ฟฝ................................................................... 52
OIL PRESSURE CHECK๏ฟฝ........................................................................... 52
AUTOMATIC CLUTCH INSPECTION (LT-A400/F)๏ฟฝ...................................................... 52
SPECIFICATIONS๏ฟฝ................................................................................... 53
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ............................................................. 53
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ...................................................................... 53
RECOMMENDED SERVICE MATERIAL๏ฟฝ................................................................. 53
SPECIAL TOOL๏ฟฝ................................................................................. 53
SERVICE DATA๏ฟฝ......................................................................................... 55
SPECIFICATIONS๏ฟฝ................................................................................... 55
SERVICE DATA (LT-A400/F)๏ฟฝ..................................................................... 55
SERVICE DATA (LT-F400/F)๏ฟฝ..................................................................... 59
TIGHTENING TORQUE LIST (LT-A400/F)๏ฟฝ........................................................... 63
TIGHTENING TORQUE LIST (LT-F400/F)๏ฟฝ........................................................... 65
01 ENGINE๏ฟฝ................................................................................................ 69
PRECAUTIONS๏ฟฝ.......................................................................................... 72
PRECAUTIONS๏ฟฝ...................................................................................... 72
PRECAUTIONS FOR ENGINE๏ฟฝ....................................................................... 72
ENGINE GENERAL INFORMATION AND DIAGNOSIS๏ฟฝ............................................................. 73
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................ 73
ENGINE SYMPTOM DIAGNOSIS๏ฟฝ..................................................................... 73
EMISSION CONTROL DEVICES๏ฟฝ............................................................................. 75
PRECAUTIONS๏ฟฝ...................................................................................... 75
PRECAUTIONS FOR EMISSION CONTROL DEVICES๏ฟฝ..................................................... 75
GENERAL DESCRIPTION๏ฟฝ.............................................................................. 75
CARBURETOR SYSTEM DESCRIPTION๏ฟฝ................................................................ 75
REPAIR INSTRUCTIONS๏ฟฝ.............................................................................. 76
CRANKCASE BREATHER (PCV) HOSE INSPECTION๏ฟฝ..................................................... 76
CRANKCASE BREATHER (PCV) HOSE REMOVAL AND INSTALLATION๏ฟฝ....................................... 76
ENGINE MECHANICAL๏ฟฝ.................................................................................... 77
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ.................................................................... 77
THROTTLE CABLE ROUTING DIAGRAM๏ฟฝ............................................................... 77
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................ 78
ENGINE MECHANICAL SYMPTOM DIAGNOSIS๏ฟฝ.......................................................... 78
COMPRESSION PRESSURE CHECK๏ฟฝ................................................................... 78
REPAIR INSTRUCTIONS๏ฟฝ.............................................................................. 79
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE๏ฟฝ......................................... 79
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION๏ฟฝ................................................. 81
AIR CLEANER ELEMENT INSPECTION AND CLEANING๏ฟฝ.................................................. 81
AIR CLEANER BOX REMOVAL AND INSTALLATION๏ฟฝ..................................................... 81
ENGINE ASSEMBLY REMOVAL๏ฟฝ...................................................................... 82
ENGINE ASSEMBLY INSTALLATION๏ฟฝ................................................................. 85
ENGINE TOP SIDE DISASSEMBLY๏ฟฝ.................................................................. 86
ENGINE TOP SIDE ASSEMBLY๏ฟฝ..................................................................... 89
CYLINDER HEAD COVER DISASSEMBLY AND ASSEMBLY๏ฟฝ................................................. 96
CYLINDER HEAD COVER RELATE PARTS INSPECTION๏ฟฝ.................................................. 97
CYLINDER HEAD DISASSEMBLY AND ASSEMBLY๏ฟฝ....................................................... 98
CYLINDER HEAD RELATED PARTS INSPECTION๏ฟฝ....................................................... 99
VALVE GUIDE REPLACEMENT๏ฟฝ......................................................................102
VALVE SEAT REPAIR๏ฟฝ............................................................................104
CAMSHAFT INSPECTION๏ฟฝ..........................................................................104
CAM CHAIN TENSION ADJUSTER INSPECTION๏ฟฝ........................................................106
CAM CHAIN TENSIONER INSPECTION๏ฟฝ...............................................................106
CAM CHAIN GUIDE INSPECTION๏ฟฝ...................................................................106
CYLINDER INSPECTION๏ฟฝ..........................................................................106
PISTON RING REMOVAL AND INSTALLATION๏ฟฝ.........................................................107
PISTON AND PISTON RING INSPECTION๏ฟฝ............................................................108
ENGINE BOTTOM SIDE DISASSEMBLY๏ฟฝ...............................................................110
ENGINE BOTTOM SIDE ASSEMBLY๏ฟฝ..................................................................119
CONROD AND CRANKSHAFT INSPECTION๏ฟฝ.............................................................134
WIDTH BETWEEN CRANKSHAFT WEBS๏ฟฝ................................................................135
CRANKSHAFT OIL SEAL INSPECTION๏ฟฝ...............................................................135
BEARING INSPECTION๏ฟฝ...........................................................................135
BEARING REMOVAL AND INSTALLATION๏ฟฝ.............................................................136
SPECIFICATIONS๏ฟฝ...................................................................................143
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................143
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................145
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................145
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................145
SPECIAL TOOL๏ฟฝ.................................................................................146
ENGINE LUBRICATION SYSTEM๏ฟฝ............................................................................150
PRECAUTIONS๏ฟฝ......................................................................................150
PRECAUTIONS FOR ENGINE OIL๏ฟฝ...................................................................150
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................150
ENGINE LUBRICATION SYSTEM CHART DIAGRAM๏ฟฝ......................................................150
CYLINDER HEAD COOLING SYSTEM CHART DIAGRAM๏ฟฝ...................................................152
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................153
ENGINE LUBRICATION SYMPTOM DIAGNOSIS๏ฟฝ.........................................................153
OIL PRESSURE CHECK๏ฟฝ...........................................................................153
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................154
ENGINE OIL AND FILTER REPLACEMENT๏ฟฝ............................................................154
ENGINE OIL LEVEL INSPECTION๏ฟฝ..................................................................154
OIL SUMP FILTER REMOVAL AND INSTALLATION๏ฟฝ.....................................................154
OIL SUMP FILTER INSPECTION AND CLEANING๏ฟฝ......................................................155
OIL JET REMOVAL AND INSTALLATION (LT-F400/F)๏ฟฝ.................................................155
OIL JET INSPECTION (LT-F400/F)๏ฟฝ...............................................................155
OIL PUMP DRIVE GEAR / OIL PUMP REMOVAL AND INSTALLATION๏ฟฝ......................................155
OIL PUMP INSPECTION๏ฟฝ..........................................................................157
OIL COOLER AND OIL HOSE COMPONENTS๏ฟฝ...........................................................158
OIL COOLER / OIL COOLER HOSE INSPECTION AND CLEANING๏ฟฝ.........................................158
OIL COOLER / OIL COOLER HOSE REMOVAL AND INSTALLATION๏ฟฝ........................................159
OIL COOLER CLEANING๏ฟฝ..........................................................................160
COOLING FAN COMPONENTS๏ฟฝ.......................................................................161
COOLING FAN INSPECTION๏ฟฝ.......................................................................161
COOLING FAN REMOVAL AND INSTALLATION๏ฟฝ.........................................................162
COOLING FAN THERMO-SWITCH REMOVAL AND INSTALLATION๏ฟฝ...........................................162
COOLING FAN THERMO-SWITCH INSPECTION๏ฟฝ.........................................................163
ENGINE OIL TEMPERATURE SWITCH REMOVAL AND INSTALLATION๏ฟฝ.......................................163
ENGINE OIL TEMPERATURE SWITCH INSPECTION๏ฟฝ.....................................................164
OIL PRESSURE REGULATOR REMOVAL AND INSTALLATION๏ฟฝ..............................................164
OIL PRESSURE REGULATOR INSPECTION๏ฟฝ............................................................165
SPECIFICATIONS๏ฟฝ...................................................................................165
SERVICE DATA (LT-A400/F)๏ฟฝ.....................................................................165
SERVICE DATA (LT-F400/F)๏ฟฝ.....................................................................165
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................166
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................166
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................166
SPECIAL TOOL๏ฟฝ.................................................................................166
FUEL SYSTEM๏ฟฝ..........................................................................................168
PRECAUTIONS๏ฟฝ......................................................................................168
PRECAUTIONS FOR FUEL SYSTEM๏ฟฝ..................................................................168
GENERAL DESCRIPTION๏ฟฝ..............................................................................168
I.D. NO. LOCATION๏ฟฝ............................................................................168
FUEL SYSTEM DESCRIPTION๏ฟฝ......................................................................169
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................177
CARBURETOR HOSE ROUTING DIAGRAM๏ฟฝ..............................................................177
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................178
CARBURETOR SYMPTOM DIAGNOSIS๏ฟฝ.................................................................178
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................179
FUEL TANK CONSTRUCTION๏ฟฝ.......................................................................179
FUEL TANK REMOVAL AND INSTALLATION๏ฟฝ...........................................................180
FUEL VALVE REMOVAL AND INSTALLATION๏ฟฝ..........................................................180
FUEL FILTER INSPECTION AND CLEANING๏ฟฝ..........................................................181
FUEL LEVEL GAUGE REMOVAL AND INSTALLATION๏ฟฝ....................................................181
FUEL LEVEL GAUGE INSPECTION๏ฟฝ..................................................................182
THROTTLE CABLE REMOVAL AND INSTALLATION๏ฟฝ......................................................182
THROTTLE CABLE INSPECTION๏ฟฝ....................................................................182
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT๏ฟฝ................................................182
STARTER CABLE REMOVAL AND INSTALLATION๏ฟฝ.......................................................182
STARTER CABLE INSPECTION๏ฟฝ.....................................................................182
STARTER CABLE PLAY INSPECTION AND ADJUSTMENT๏ฟฝ.................................................182
CARBURETOR COMPONENTS๏ฟฝ........................................................................183
CARBURETOR ASSEMBLY REMOVAL AND INSTALLATION๏ฟฝ.................................................184
CARBURETOR DISASSEMBLY๏ฟฝ.......................................................................184
CARBURETOR ASSEMBLY๏ฟฝ..........................................................................187
FLOAT HEIGHT INSPECTION AND ADJUSTMENT๏ฟฝ.......................................................188
CARBURETOR INSPECTION AND CLEANING๏ฟฝ...........................................................188
ENGINE IDLE SPEED INSPECTION๏ฟฝ.................................................................189
FUEL LINE INSPECTION๏ฟฝ.........................................................................189
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION๏ฟฝ.................................................189
AIR CLEANER ELEMENT INSPECTION AND CLEANING๏ฟฝ..................................................189
SPECIFICATIONS๏ฟฝ...................................................................................189
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................189
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................190
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................190
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................190
SPECIAL TOOL๏ฟฝ.................................................................................190
IGNITION SYSTEM๏ฟฝ......................................................................................191
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................191
IGNITION SYSTEM DIAGRAM๏ฟฝ......................................................................191
IGNITION SYSTEM COMPONENTS LOCATION๏ฟฝ..........................................................191
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................191
IGNITION SYSTEM SYMPTOM DIAGNOSIS๏ฟฝ............................................................191
NO SPARK OR POOR SPARK๏ฟฝ.......................................................................192
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................193
SPARK PLUG REMOVAL AND INSTALLATION๏ฟฝ..........................................................193
SPARK PLUG INSPECTION AND CLEANING๏ฟฝ...........................................................193
IGNITION COIL AND PLUG CAP INSPECTION๏ฟฝ........................................................193
IGNITION COIL REMOVAL AND INSTALLATION๏ฟฝ.......................................................195
CKP SENSOR INSPECTION๏ฟฝ........................................................................195
CKP SENSOR REMOVAL AND INSTALLATION๏ฟฝ..........................................................196
ENGINE STOP SWITCH INSPECTION๏ฟฝ................................................................196
IGNITION SWITCH INSPECTION๏ฟฝ...................................................................196
IGNITION SWITCH REMOVAL AND INSTALLATION๏ฟฝ.....................................................196
SPECIFICATIONS๏ฟฝ...................................................................................197
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................197
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................197
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................197
SPECIAL TOOL๏ฟฝ.................................................................................197
STARTING SYSTEM๏ฟฝ......................................................................................198
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................198
STARTING SYSTEM DIAGRAM๏ฟฝ......................................................................198
COMPONENT LOCATION๏ฟฝ...............................................................................198
STARTING SYSTEM COMPONENTS LOCATION๏ฟฝ..........................................................198
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................198
STARTING SYSTEM SYMPTOM DIAGNOSIS๏ฟฝ............................................................198
STARTER MOTOR WILL NOT RUN๏ฟฝ...................................................................199
STARTER MOTOR RUNS BUT DOES NOT CRANK THE ENGINE๏ฟฝ.............................................199
ENGINE DOES NOT TURN THOUGH THE STARTER MOTOR RUNS๏ฟฝ...........................................199
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................200
STARTER MOTOR COMPONENTS๏ฟฝ.....................................................................200
STARTER MOTOR REMOVAL AND INSTALLATION๏ฟฝ.......................................................200
STARTER MOTOR DISASSEMBLY AND ASSEMBLY๏ฟฝ.......................................................201
STARTER MOTOR INSPECTION๏ฟฝ.....................................................................201
STARTER RELAY REMOVAL AND INSTALLATION๏ฟฝ.......................................................202
STARTER RELAY INSPECTION๏ฟฝ.....................................................................203
NEUTRAL RELAY REMOVAL AND INSTALLATION๏ฟฝ.......................................................203
NEUTRAL RELAY INSPECTION๏ฟฝ.....................................................................204
NEUTRAL SWITCH DIODE INSPECTION๏ฟฝ..............................................................204
IGNITION / STARTER CONTROL RELAY REMOVAL AND INSTALLATION๏ฟฝ....................................205
IGNITION / STARTER CONTROL RELAY INSPECTION๏ฟฝ..................................................205
PARKING BRAKE SWITCH INSPECTION๏ฟฝ..............................................................205
GEAR POSITION SWITCH INSPECTION๏ฟฝ..............................................................205
STARTER CLUTCH REMOVAL AND INSTALLATION๏ฟฝ......................................................206
STARTER DRIVEN GEAR BEARING REMOVAL AND INSTALLATION๏ฟฝ.........................................208
STARTER RELATED PARTS INSPECTION๏ฟฝ.............................................................208
STARTER BUTTON INSPECTION๏ฟฝ....................................................................209
RECOIL STARTER COMPONENTS๏ฟฝ....................................................................209
RECOIL STARTER ASSEMBLY REMOVAL AND INSTALLATION๏ฟฝ.............................................210
RECOIL STARTER DISASSEMBLY AND ASSEMBLY๏ฟฝ......................................................210
RECOIL STARTER INSPECTION๏ฟฝ....................................................................212
SPECIFICATIONS๏ฟฝ...................................................................................213
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................213
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................213
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................213
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................213
SPECIAL TOOL๏ฟฝ.................................................................................214
CHARGING SYSTEM๏ฟฝ......................................................................................215
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................215
CHARGING SYSTEM DIAGRAM๏ฟฝ......................................................................215
COMPONENT LOCATION๏ฟฝ...............................................................................215
CHARGING SYSTEM COMPONENTS LOCATION๏ฟฝ..........................................................215
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................215
CHARGING SYSTEM SYMPTOM DIAGNOSIS๏ฟฝ............................................................215
BATTERY RUNS DOWN QUICKLY๏ฟฝ....................................................................216
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................217
BATTERY CURRENT LEAKAGE INSPECTION๏ฟฝ...........................................................217
REGULATED VOLTAGE INSPECTION๏ฟฝ.................................................................217
GENERATOR INSPECTION๏ฟฝ.........................................................................218
GENERATOR REMOVAL AND INSTALLATION๏ฟฝ...........................................................219
REGULATOR / RECTIFIER INSPECTION๏ฟฝ.............................................................224
BATTERY COMPONENTS๏ฟฝ...........................................................................225
BATTERY CHARGING๏ฟฝ.............................................................................225
BATTERY REMOVAL AND INSTALLATION๏ฟฝ.............................................................227
BATTERY VISUAL INSPECTION๏ฟฝ....................................................................227
SPECIFICATIONS๏ฟฝ...................................................................................228
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................228
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................228
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................228
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................228
SPECIAL TOOL๏ฟฝ.................................................................................228
EXHAUST SYSTEM๏ฟฝ.......................................................................................230
PRECAUTIONS๏ฟฝ......................................................................................230
PRECAUTIONS FOR EXHAUST SYSTEM๏ฟฝ...............................................................230
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................230
EXHAUST SYSTEM COMPONENTS๏ฟฝ....................................................................230
MUFFLER / EXHAUST PIPE REMOVAL AND INSTALLATION๏ฟฝ..............................................231
EXHAUST SYSTEM INSPECTION๏ฟฝ....................................................................232
SPARK ARRESTER INSPECTION๏ฟฝ....................................................................232
SPECIFICATIONS๏ฟฝ...................................................................................233
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................233
02 SUSPENSION๏ฟฝ............................................................................................235
PRECAUTIONS๏ฟฝ..........................................................................................236
PRECAUTIONS๏ฟฝ......................................................................................236
PRECAUTIONS FOR SUSPENSION๏ฟฝ...................................................................236
SUSPENSION GENERAL DIAGNOSIS๏ฟฝ.........................................................................237
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................237
SUSPENSION AND WHEEL SYMPTOM DIAGNOSIS๏ฟฝ.......................................................237
FRONT SUSPENSION๏ฟฝ.....................................................................................238
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................238
FRONT SUSPENSION COMPONENTS๏ฟฝ..................................................................238
FRONT SUSPENSION ASSEMBLY CONSTRUCTION๏ฟฝ.......................................................239
FRONT SUSPENSION INSPECTION๏ฟฝ..................................................................240
FRONT SHOCK ABSORBER INSPECTION๏ฟฝ..............................................................240
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATION๏ฟฝ................................................240
FRONT WHEEL HUB / STEERING KNUCKLE REMOVAL AND INSTALLATION๏ฟฝ..................................240
FRONT WHEEL HUB / STEERING KNUCKLE RELATED PARTS INSPECTION๏ฟฝ..................................243
STEERING KNUCKLE DUST SEAL / FRONT WHEEL HUB BEARING REMOVAL AND INSTALLATION๏ฟฝ................243
FRONT SUSPENSION UPPER / LOWER ARM REMOVAL AND INSTALLATION๏ฟฝ..................................245
FRONT SUSPENSION ARM RELATED PARTS INSPECTION๏ฟฝ................................................246
STEERING KNUCKLE END REMOVAL AND INSTALLATION๏ฟฝ................................................247
FRONT SUSPENSION UPPER / LOWER ARM BUSHING REMOVAL AND INSTALLATION๏ฟฝ..........................248
SPECIFICATIONS๏ฟฝ...................................................................................249
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................249
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................249
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................249
SPECIAL TOOL๏ฟฝ.................................................................................250
REAR SUSPENSION๏ฟฝ......................................................................................251
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................251
REAR SUSPENSION COMPONENTS๏ฟฝ...................................................................251
REAR SHOCK ABSORBER REMOVAL AND INSTALLATION๏ฟฝ.................................................252
REAR SUSPENSION INSPECTION๏ฟฝ...................................................................252
REAR SHOCK ABSORBER INSPECTION๏ฟฝ...............................................................252
SWINGARM REMOVAL AND INSTALLATION๏ฟฝ............................................................252
SWINGARM INSPECTION๏ฟฝ..........................................................................253
SWINGARM BUSHING REMOVAL AND INSTALLATION๏ฟฝ....................................................254
SPECIFICATIONS๏ฟฝ...................................................................................254
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................254
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................254
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................254
WHEELS AND TIRES๏ฟฝ.....................................................................................255
PRECAUTIONS๏ฟฝ......................................................................................255
PRECAUTIONS FOR WHEEL AND TIRE๏ฟฝ...............................................................255
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................256
FRONT AND REAR WHEEL COMPONENTS๏ฟฝ..............................................................256
FRONT / REAR WHEEL REMOVAL AND INSTALLATION๏ฟฝ..................................................257
TIRE REMOVAL AND INSTALLATION๏ฟฝ................................................................257
SPECIFICATIONS๏ฟฝ...................................................................................259
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................259
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................259
03 DRIVELINE / AXLE๏ฟฝ......................................................................................261
PRECAUTIONS๏ฟฝ..........................................................................................263
PRECAUTIONS๏ฟฝ......................................................................................263
PRECAUTIONS FOR DRIVELINE / AXLE๏ฟฝ.............................................................263
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT๏ฟฝ..............................................................264
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................264
DRIVE SHAFT SYMPTOM DIAGNOSIS๏ฟฝ................................................................264
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................264
FRONT DRIVE SHAFT COMPONENTS (LT-A400F, LT-F400F)๏ฟฝ............................................264
FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION (LT-A400F, LT-F400F)๏ฟฝ.....................265
FRONT DRIVE SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400F, LT-F400F)๏ฟฝ..............................265
FRONT DRIVE SHAFT INSPECTION (LT-A400F, LT- F400F)๏ฟฝ...........................................268
REAR AXLE COMPONENTS๏ฟฝ.........................................................................269
REAR AXLE CONSTRUCTION๏ฟฝ.......................................................................270
REAR AXLE / AXLE HOUSING REMOVAL AND INSTALLATION๏ฟฝ............................................270
REAR AXLE / AXLE HOUSING INSPECTION๏ฟฝ..........................................................272
REAR AXLE HOUSING DISASSEMBLY AND ASSEMBLY๏ฟฝ...................................................273
SPECIFICATIONS๏ฟฝ...................................................................................274
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................274
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................274
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................274
SPECIAL TOOL๏ฟฝ.................................................................................274
DIFFERENTIAL๏ฟฝ.........................................................................................276
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................276
DRIVE TRAIN SYMPTOM DIAGNOSIS๏ฟฝ................................................................276
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................277
FRONT DRIVE (DIFFERENTIAL) COMPONENTS (LT-A400F, LT-F400F)๏ฟฝ...................................277
FRONT DRIVE (DIFFERENTIAL) CONSTRUCTION (LT-A400F, LT-F400F)๏ฟฝ.................................278
FRONT DRIVE (DIFFERENTIAL) GEAR OIL LEVEL INSPECTION (LT-A400F, LT-F400F)๏ฟฝ....................279
FRONT DRIVE (DIFFERENTIAL) GEAR OIL REPLACEMENT (LT-A400F, LT-F400F)๏ฟฝ.........................279
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY REMOVAL AND INSTALLATION (LT-A400F, LT-F400F)๏ฟฝ............279
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY DISASSEMBLY AND ASSEMBLY (LT-A400F, LT- F400F)๏ฟฝ...........280
FRONT DRIVE (DIFFERENTIAL) RELATED PARTS INSPECTION (LT-A400F, LT-F400F)๏ฟฝ.....................288
UNIVERSAL JOINT BEARING / PINION GEAR PILOT BEARING INSPECTION๏ฟฝ...............................289
FRONT DRIVE (DIFFERENTIAL) GEAR SHIM INSPECTION AND SELECTION (LT-A400F, LT-F400F)๏ฟฝ...........290
FINAL GEAR COMPONENTS๏ฟฝ........................................................................294
FINAL GEAR CONSTRUCTION๏ฟฝ......................................................................295
FINAL GEAR OIL LEVEL INSPECTION๏ฟฝ..............................................................296
FINAL GEAR OIL REPLACEMENT๏ฟฝ...................................................................296
FINAL GEAR ASSEMBLY REMOVAL AND INSTALLATION๏ฟฝ.................................................296
FINAL GEAR ASSEMBLY DISASSEMBLY AND ASSEMBLY๏ฟฝ.................................................298
FINAL GEAR RELATED PARTS INSPECTION๏ฟฝ..........................................................303
FINAL GEAR BACKLASH INSPECTION AND SHIM ADJUSTMENT๏ฟฝ...........................................305
TRANSFER CABLE INSPECTION AND ADJUSTMENT (LT- A400F, LT-F400F)๏ฟฝ...............................308
TRANSFER CABLE REMOVAL AND INSTALLATION (LT- A400F, LT-F400F)๏ฟฝ................................308
SPECIFICATIONS๏ฟฝ...................................................................................309
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................309
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................309
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................310
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................310
SPECIAL TOOL๏ฟฝ.................................................................................310
TRANSFER๏ฟฝ.............................................................................................312
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................312
TRANSFER SYMPTOM DIAGNOSIS (LT-A400/F)๏ฟฝ.......................................................312
TRANSFER SYMPTOM DIAGNOSIS (LT-F400/F)๏ฟฝ.......................................................312
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................313
TRANSFER COMPONENTS (LT-A400/F)๏ฟฝ..............................................................313
TRANSFER COMPONENTS (LT-F400/F)๏ฟฝ..............................................................314
TRANSFER REMOVAL AND INSTALLATION (LT-A400/F)๏ฟฝ................................................315
TRANSFER REMOVAL AND INSTALLATION (LT-F400/F)๏ฟฝ................................................318
TRANSFER CONSTRUCTION (LT-A400/F)๏ฟฝ............................................................319
TRANSFER DISASSEMBLY AND ASSEMBLY (LT-A400/ F)๏ฟฝ...............................................320
TRANSFER IDLE GEAR BEARING REMOVAL AND INSTALLATION (LT-F400/F)๏ฟฝ..............................320
TRANSFER GEARSHIFT CAM COMPONENTS (LT-A400/F)๏ฟฝ................................................321
TRANSFER GEARSHIFT CAM COMPONENTS (LT-F400/F)๏ฟฝ................................................322
GEARSHIFT SYSTEM CONSTRUCTION (LT-A400/F)๏ฟฝ....................................................323
GEARSHIFT SYSTEM CONSTRUCTION (LT-F400/F)๏ฟฝ....................................................323
TRANSFER GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-A400/F)๏ฟฝ..................................324
TRANSFER GEARSHIFT SHAFT NO.1 BEARING INSPECTION (LT-A400/F)๏ฟฝ.................................324
TRANSFER GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-F400/F)๏ฟฝ..................................325
TRANSFER RELATED PARTS INSPECTION (LT-A400/F)๏ฟฝ................................................326
TRANSFER RELATED PARTS INSPECTION (LT-F400/F)๏ฟฝ................................................326
GEAR POSITION (GP) SWITCH INSPECTION๏ฟฝ.........................................................327
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-A400/F)๏ฟฝ...............................327
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-F400/F)๏ฟฝ...............................328
TRANSFER GEARSHIFT SHAFT NO. 2 / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION (LT-A400/F)๏ฟฝ....328
GEARSHIFT LINKAGE INSPECTION (LT-A400/F)๏ฟฝ.....................................................330
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION (LT-A400/F)๏ฟฝ................................330
TRANSFER RANGE LEVER COMPONENTS (LT-A400/F)๏ฟฝ..................................................331
TRANSFER RANGE LEVER COMPONENTS (LT-F400/F)๏ฟฝ..................................................331
TRANSFER RANGE LEVER REMOVAL AND INSTALLATION๏ฟฝ................................................331
TRANSFER RANGE LEVER DISASSEMBLY AND ASSEMBLY๏ฟฝ................................................332
SHIFT ROD LENGTH ADJUSTMENT๏ฟฝ..................................................................332
REVERSE SWITCH INSPECTION (LT-F400/F)๏ฟฝ........................................................332
SPECIFICATIONS๏ฟฝ...................................................................................333
SERVICE DATA (LT-A400/F)๏ฟฝ.....................................................................333
SERVICE DATA (LT-F400/F)๏ฟฝ.....................................................................333
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................334
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................334
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................334
SPECIAL TOOL๏ฟฝ.................................................................................334
PROPELLER SHAFTS๏ฟฝ.....................................................................................335
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................335
FRONT OUTPUT SHAFT COMPONENTS๏ฟฝ................................................................335
OUTPUT SHAFT REMOVAL AND INSTALLATION๏ฟฝ........................................................337
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400/F)๏ฟฝ.......................................338
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-F400/F)๏ฟฝ.......................................341
FRONT OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400F, LT-F400F)๏ฟฝ.............................344
REAR OUTPUT SHAFT RELATED PARTS INSPECTION๏ฟฝ...................................................345
FRONT OUTPUT SHAFT RELATED PARTS INSPECTION (LT- A400F, LT-F400F)๏ฟฝ............................347
DRIVE BEVEL GEAR REMOVAL AND INSTALLATION (LT- A400/F)๏ฟฝ.......................................347
DRIVE BEVEL GEAR REMOVAL AND INSTALLATION (LT- F400/F)๏ฟฝ.......................................349
DRIVEN AND DRIVE BEVEL GEAR SHIM INSPECTION AND ADJUSTMENT๏ฟฝ...................................350
DRIVEN AND DRIVE BEVEL GEAR SHIM ADJUSTMENT INFORMATION๏ฟฝ......................................354
SPECIFICATIONS๏ฟฝ...................................................................................356
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................356
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................356
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................356
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................356
SPECIAL TOOL๏ฟฝ.................................................................................356
04 BRAKE๏ฟฝ.................................................................................................359
PRECAUTIONS๏ฟฝ..........................................................................................361
PRECAUTIONS๏ฟฝ......................................................................................361
PRECAUTIONS FOR BRAKE SYSTEM๏ฟฝ.................................................................361
BRAKE FLUID INFORMATION๏ฟฝ......................................................................361
BRAKE CONTROL SYSTEM AND DIAGNOSIS๏ฟฝ...................................................................362
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................362
FRONT BRAKE HOSE ROUTING DIAGRAM๏ฟฝ.............................................................362
BRAKE CABLE ROUTING DIAGRAM๏ฟฝ..................................................................363
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................364
BRAKE SYMPTOM DIAGNOSIS๏ฟฝ......................................................................364
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................364
BRAKE PEDAL ADJUSTMENT๏ฟฝ.......................................................................364
FRONT BRAKE LIGHT SWITCH INSPECTION๏ฟฝ..........................................................364
REAR BRAKE LIGHT SWITCH INSPECTION๏ฟฝ...........................................................365
REAR BRAKE LIGHT SWITCH INSPECTION AND ADJUSTMENT๏ฟฝ............................................365
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION๏ฟฝ.................................................366
PARKING BRAKE SWITCH INSPECTION๏ฟฝ..............................................................366
BRAKE FLUID LEVEL CHECK๏ฟฝ......................................................................366
FRONT BRAKE HOSE INSPECTION๏ฟฝ..................................................................366
AIR BLEEDING FROM FRONT BRAKE FLUID CIRCUIT๏ฟฝ..................................................366
BRAKE FLUID REPLACEMENT๏ฟฝ......................................................................367
FRONT BRAKE HOSE REMOVAL AND INSTALLATION๏ฟฝ....................................................368
REAR BRAKE CABLE REMOVAL AND INSTALLATION๏ฟฝ....................................................368
FRONT BRAKE MASTER CYLINDER COMPONENTS๏ฟฝ.......................................................369
FRONT BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION๏ฟฝ................................369
FRONT BRAKE MASTER CYLINDER / BRAKE LEVER DISASSEMBLY AND ASSEMBLY๏ฟฝ...........................371
FRONT BRAKE MASTER CYLINDER PARTS INSPECTION๏ฟฝ.................................................372
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATION๏ฟฝ..........................................372
REAR BRAKE PEDAL CONSTRUCTION๏ฟฝ................................................................373
REAR BRAKE PEDAL REMOVAL AND INSTALLATION๏ฟฝ....................................................373
SPECIFICATIONS๏ฟฝ...................................................................................374
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................374
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................375
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................375
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................375
SPECIAL TOOL๏ฟฝ.................................................................................375
FRONT BRAKES๏ฟฝ.........................................................................................376
PRECAUTIONS๏ฟฝ......................................................................................376
PRECAUTIONS FOR FRONT BRAKES๏ฟฝ.................................................................376
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................376
FRONT BRAKE COMPONENTS๏ฟฝ.......................................................................376
FRONT BRAKE PAD INSPECTION๏ฟฝ...................................................................377
FRONT BRAKE PAD REPLACEMENT๏ฟฝ..................................................................377
FRONT BRAKE CALIPER REMOVAL AND INSTALLATION๏ฟฝ.................................................378
FRONT BRAKE CALIPER DISASSEMBLY AND ASSEMBLY๏ฟฝ.................................................379
FRONT BRAKE CALIPER PARTS INSPECTION๏ฟฝ.........................................................381
FRONT BRAKE DISC REMOVAL AND INSTALLATION๏ฟฝ....................................................382
FRONT BRAKE DISC INSPECTION๏ฟฝ..................................................................383
SPECIFICATIONS๏ฟฝ...................................................................................383
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................383
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................384
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................384
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................384
SPECIAL TOOL๏ฟฝ.................................................................................384
REAR BRAKES๏ฟฝ..........................................................................................385
PRECAUTIONS๏ฟฝ......................................................................................385
PRECAUTIONS FOR REAR BRAKE๏ฟฝ...................................................................385
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................385
REAR BRAKE BREATHER HOSE ROUTING DIAGRAM๏ฟฝ.....................................................385
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................386
REAR BRAKE COMPONENTS๏ฟฝ........................................................................386
REAR BRAKE CONSTRUCTION๏ฟฝ......................................................................387
REAR BRAKE SHOE INSPECTION๏ฟฝ...................................................................387
REAR BRAKE DISASSEMBLY AND ASSEMBLY๏ฟฝ..........................................................387
REAR BRAKE RELATED PARTS INSPECTION๏ฟฝ..........................................................392
SPECIFICATIONS๏ฟฝ...................................................................................393
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................393
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................393
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................394
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................394
PARKING BRAKE๏ฟฝ........................................................................................395
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................395
PARKING / REAR BRAKE CABLE ROUTING DIAGRAM๏ฟฝ...................................................395
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................395
PARKING / REAR BRAKE LEVER COMPONENTS๏ฟฝ........................................................395
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION๏ฟฝ.................................................395
PARKING BRAKE SWITCH INSPECTION๏ฟฝ..............................................................395
IGNITION / STARTER CONTROL RELAY (PARKING BRAKE RELAY) INSPECTION๏ฟฝ............................395
PARKING / REAR BRAKE LEVER INSPECTION AND ADJUSTMENT๏ฟฝ.........................................395
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATION๏ฟฝ..........................................396
PARKING / REAR BRAKE CABLE REMOVAL AND INSTALLATION๏ฟฝ..........................................397
SPECIFICATIONS๏ฟฝ...................................................................................397
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................397
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................397
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................397
05 TRANSMISSION / TRANSAXLE๏ฟฝ..............................................................................399
PRECAUTIONS๏ฟฝ..........................................................................................401
PRECAUTIONS๏ฟฝ......................................................................................401
PRECAUTIONS FOR TRANSMISSION / TRANSAXLE๏ฟฝ.....................................................401
AUTOMATIC TRANSMISSION๏ฟฝ...............................................................................402
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................402
DRIVE TRAIN OPERATION (LT-A400/F)๏ฟฝ............................................................402
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................405
AUTOMATIC TRANSMISSION SYMPTOM DIAGNOSIS๏ฟฝ.....................................................405
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................406
AUTOMATIC TRANSMISSION COMPONENTS๏ฟฝ............................................................406
V-BELT COOLING DUCT CONSTRUCTION๏ฟฝ.............................................................407
V-BELT COOLING DUCT REMOVAL AND INSTALLATION (LT-A400/F)๏ฟฝ.....................................407
CLUTCH ENGAGEMENT AND LOCK-UP SPEED INSPECTION๏ฟฝ...............................................408
V-BELT TYPE CONTINUOUSLY VARIABLE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION๏ฟฝ............408
MOVABLE DRIVE FACE DISASSEMBLY AND ASSEMBLY๏ฟฝ..................................................411
MOVABLE DRIVEN FACE DISASSEMBLY AND ASSEMBLY๏ฟฝ.................................................412
DRIVE V-BELT INSPECTION๏ฟฝ......................................................................416
MOVABLE / FIXED DRIVE FACE PARTS INSPECTION๏ฟฝ..................................................416
MOVABLE / FIXED DRIVEN FACE PARTS INSPECTION๏ฟฝ.................................................417
CLUTCH SHOE REMOVAL AND INSTALLATION๏ฟฝ.........................................................417
V-BELT OUTER COVER BEARING REMOVAL AND INSTALLATION๏ฟฝ..........................................419
V-BELT INNER COVER DISASSEMBLY AND ASSEMBLY๏ฟฝ..................................................420
CLUTCH RELATED PARTS INSPECTION๏ฟฝ..............................................................422
SPECIFICATIONS๏ฟฝ...................................................................................423
SERVICE DATA (LT-A400/F)๏ฟฝ.....................................................................423
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................424
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................424
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................424
SPECIAL TOOL๏ฟฝ.................................................................................425
MANUAL TRANSMISSION๏ฟฝ..................................................................................426
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................426
MANUAL TRANSMISSION SYMPTOM DIAGNOSIS (LT-F400/F)๏ฟฝ............................................426
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................427
TRANSMISSION COMPONENTS (LT-F400/F)๏ฟฝ..........................................................427
TRANSMISSION REMOVAL AND INSTALLATION (LT- F400/F)๏ฟฝ...........................................428
TRANSMISSION CONSTRUCTION๏ฟฝ....................................................................429
COUNTERSHAFT GEAR / DRIVESHAFT GEAR DISASSEMBLY AND ASSEMBLY (LT-F400/F)๏ฟฝ.....................430
TRANSMISSION REVERSE GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-F400/F)๏ฟฝ......................431
TRANSMISSION RELATED PARTS INSPECTION (LT- F400/F)๏ฟฝ...........................................432
GEAR POSITION (GP) SWITCH INSPECTION (LT-F400/ F)๏ฟฝ............................................432
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-F400/F)๏ฟฝ...............................432
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-A400/F)๏ฟฝ...............................433
GEARSHIFT LEVER REMOVAL AND INSTALLATION (LT- F400/F)๏ฟฝ........................................433
GEARSHIFT LEVER HEIGHT INSPECTION AND ADJUSTMENT (LT-F400/F)๏ฟฝ.................................434
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE COMPONENTS (LT-F400/F)๏ฟฝ.................................435
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION (LT-F400/F)๏ฟฝ...................436
GEARSHIFT LINKAGE INSPECTION (LT-F400/F)๏ฟฝ.....................................................437
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION (LT-A400/F)๏ฟฝ................................438
SPECIFICATIONS๏ฟฝ...................................................................................438
SERVICE DATA (LT-F400/F)๏ฟฝ.....................................................................438
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................439
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................439
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................439
SPECIAL TOOL๏ฟฝ.................................................................................439
CLUTCH๏ฟฝ...............................................................................................440
PRECAUTIONS๏ฟฝ......................................................................................440
PRECAUTIONS FOR CLUTCH SYSTEM๏ฟฝ................................................................440
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................440
CLUTCH SYSTEM SYMPTOM DIAGNOSIS๏ฟฝ..............................................................440
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................441
CLUTCH COMPONENTS (LT-F400/F)๏ฟฝ................................................................441
CLUTCH REMOVAL AND INSTALLATION (LT-F400/F)๏ฟฝ..................................................442
CLUTCH RELATED PARTS INSPECTION (LT-F400/F)๏ฟฝ..................................................445
CLUTCH COVER DISASSEMBLY AND ASSEMBLY (LT- F400/F)๏ฟฝ...........................................447
CLUTCH RELEASE ROLLER INSPECTION (LT-F400/F)๏ฟฝ.................................................449
SPECIFICATIONS๏ฟฝ...................................................................................449
SERVICE DATA (LT-F400/F)๏ฟฝ.....................................................................449
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................449
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................450
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................450
SPECIAL TOOL๏ฟฝ.................................................................................450
06 STEERING๏ฟฝ..............................................................................................451
PRECAUTIONS๏ฟฝ..........................................................................................452
PRECAUTIONS๏ฟฝ......................................................................................452
PRECAUTIONS FOR STEERING๏ฟฝ.....................................................................452
STEERING GENERAL DIAGNOSIS๏ฟฝ...........................................................................453
DIAGNOSTIC INFORMATION AND PROCEDURES๏ฟฝ............................................................453
STEERING SYMPTOM DIAGNOSIS๏ฟฝ...................................................................453
STEERING / HANDLEBAR๏ฟฝ.................................................................................454
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................454
STEERING / HANDLEBARS COMPONENTS๏ฟฝ.............................................................454
STEERING ASSEMBLY CONSTRUCTION๏ฟฝ...............................................................455
HANDLEBARS REMOVAL AND INSTALLATION๏ฟฝ..........................................................456
HANDLEBARS INSPECTION๏ฟฝ........................................................................458
STEERING SHAFT / TIE-ROD REMOVAL AND INSTALLATION๏ฟฝ............................................458
STEERING PARTS INSPECTION๏ฟฝ....................................................................463
SPECIFICATIONS๏ฟฝ...................................................................................464
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................464
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................464
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................465
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................465
SPECIAL TOOL๏ฟฝ.................................................................................465
09 BODY AND ACCESSORIES๏ฟฝ..................................................................................467
PRECAUTIONS๏ฟฝ..........................................................................................468
PRECAUTIONS๏ฟฝ......................................................................................468
PRECAUTIONS FOR ELECTRICAL SYSTEM๏ฟฝ............................................................468
COMPONENT LOCATION๏ฟฝ...............................................................................468
ELECTRICAL COMPONENTS LOCATION๏ฟฝ...............................................................468
WIRING SYSTEMS๏ฟฝ.......................................................................................469
SCHEMATIC AND ROUTING DIAGRAM๏ฟฝ....................................................................469
WIRING DIAGRAM๏ฟฝ...............................................................................469
WIRING HARNESS ROUTING DIAGRAM๏ฟฝ...............................................................476
SPECIFICATIONS๏ฟฝ...................................................................................478
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................478
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................478
LIGHTING SYSTEMS๏ฟฝ.....................................................................................479
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................479
HEADLIGHT CONSTRUCTION๏ฟฝ.......................................................................479
FRONT SIDE REFLECTOR CONSTRUCTION๏ฟฝ............................................................480
HEADLIGHT COMPONENTS๏ฟฝ.........................................................................481
HEADLIGHT REMOVAL AND INSTALLATION๏ฟฝ...........................................................481
HEADLIGHT BULB REPLACEMENT๏ฟฝ...................................................................482
HEADLIGHT BEAM ADJUSTMENT๏ฟฝ....................................................................482
REAR COMBINATION LIGHT COMPONENTS๏ฟฝ............................................................483
REAR COMBINATION LIGHT REMOVAL AND INSTALLATION๏ฟฝ..............................................483
REAR COMBINATION LIGHT BULB REPLACEMENT๏ฟฝ......................................................484
REVERSING LIGHT BULB REPLACEMENT (FOR P-17)๏ฟฝ..................................................484
REVERSING LIGHT RELAY INSPECTION (FOR P-17)๏ฟฝ..................................................484
DIMMER SWITCH INSPECTION๏ฟฝ.....................................................................485
SPECIFICATIONS๏ฟฝ...................................................................................485
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................485
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................485
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................485
SPECIAL TOOL๏ฟฝ.................................................................................485
COMBINATION METER / FUEL METER / HORN๏ฟฝ................................................................486
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................486
SPEEDOMETER COMPONENTS๏ฟฝ.......................................................................486
SPEEDOMETER REMOVAL AND INSTALLATION๏ฟฝ.........................................................487
SPEEDOMETER DISASSEMBLY AND ASSEMBLY๏ฟฝ.........................................................488
SPEEDOMETER LIGHT BULB / INDICATOR LIGHT BULB REPLACEMENT๏ฟฝ....................................488
IGNITION SWITCH INSPECTION๏ฟฝ...................................................................488
IGNITION SWITCH REMOVAL AND INSTALLATION๏ฟฝ.....................................................488
HORN INSPECTION (FOR P-17, 24)๏ฟฝ...............................................................489
HORN REMOVAL AND INSTALLATION (FOR P-17, 24)๏ฟฝ.................................................489
SPECIFICATIONS๏ฟฝ...................................................................................489
SERVICE DATA (LT-A400/F, LT-F400/F)๏ฟฝ..........................................................489
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................489
SPECIAL TOOL๏ฟฝ.................................................................................489
EXTERIOR PARTS๏ฟฝ.......................................................................................490
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................490
REAR FENDER HEAT SHIELD CONSTRUCTION๏ฟฝ.........................................................490
FASTENER REMOVAL AND INSTALLATION๏ฟฝ............................................................491
EXTERIOR PARTS REMOVAL AND INSTALLATION๏ฟฝ......................................................492
BODY STRUCTURE๏ฟฝ.......................................................................................496
REPAIR INSTRUCTIONS๏ฟฝ..............................................................................496
BODY FRAME CONSTRUCTION๏ฟฝ......................................................................496
FOOTREST CONSTRUCTION๏ฟฝ........................................................................496
FOOTREST REMOVAL AND INSTALLATION๏ฟฝ............................................................497
CARRIER CONSTRUCTION๏ฟฝ.........................................................................498
FRONT CARRIER REMOVAL AND INSTALLATION๏ฟฝ.......................................................499
REAR CARRIER REMOVAL AND INSTALLATION๏ฟฝ........................................................499
FRONT GRIP BAR CONSTRUCTION๏ฟฝ..................................................................500
FRONT GRIP BAR REMOVAL AND INSTALLATION๏ฟฝ......................................................500
TRAILER TOWING REMOVAL AND INSTRUCTION๏ฟฝ.......................................................501
SPECIFICATIONS๏ฟฝ...................................................................................502
TIGHTENING TORQUE SPECIFICATIONS๏ฟฝ.............................................................502
SPECIAL TOOLS AND EQUIPMENT๏ฟฝ......................................................................502
RECOMMENDED SERVICE MATERIAL๏ฟฝ.................................................................502
10 LT-A400F / LT-F400F K9 ('09 MODELS)๏ฟฝ...................................................................503
SPECIFICATIONS (FOR LT-A400/F)๏ฟฝ.......................................................................505
SPECIFICATIONS (FOR LT-F400/F)๏ฟฝ.......................................................................504
SERVICE DATA (FOR LT-A400/F)๏ฟฝ.........................................................................506
SERVICE DATA (FOR LT-F400/F)๏ฟฝ.........................................................................511
FRONT SUSPENSION๏ฟฝ.....................................................................................516S.S 31/03/2025
