Suzuki King Quad 500axi 500 Axi Lt a500 Lta500 2009 2011 2012 Service Repair Manual Download

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Suzuki King Quad 500axi 500 Axi Lt a500 Lta500 2009 2011 2012 Service Repair Manual Download

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SUZUKI KING QUAD 500AXI 500 AXI LT A500 LTA500 2009 2011 2012 SERVICE REPAIR MANUAL DOWNLOAD:

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Suzuki King Quad 500axi 500 Axi Lt a500 Lta500 2009 2011 2012 Service Repair Manual Download

FOREWORD:

This manual contains an introductory description on the SUZUKI LT-A500XP/Z 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. © COPYRIGHT SUZUKI MOTOR CORPORATION 2008
* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual vehicle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

TABLE OF CONTENTS:

Suzuki King Quad 500axi 500 Axi Lt a500 Lta500 2009 2011 2012 Service Repair Manual Download

FOREWORD.........................................................................................  1
TABLE OF CONTENTS................................................................................  3
00 Precautions...................................................................................  5
	Precautions..................................................................................  6
		Precautions..............................................................................  6
			Warning / Caution / Note.............................................................  6
			General Precautions..................................................................  6
			Precautions for Electrical Circuit Service...........................................  7
0 General Information............................................................................ 15
	General Information.......................................................................... 16
		General Description...................................................................... 16
			Symbols.............................................................................. 16
			Abbreviations........................................................................ 16
			SAE-to-Former SUZUKI Term............................................................ 17
			Vehicle Side View.................................................................... 18
			Vehicle Identification Number........................................................ 18
			Fuel and Oil Recommendation.......................................................... 18
			Engine Coolant Recommendation........................................................ 19
			BREAK-IN Procedures.................................................................. 19
			Country and Area Codes............................................................... 20
			Wire Color Symbols................................................................... 20
			Warning, Caution and Information Labels Location..................................... 21
		Component Location....................................................................... 22
			Electrical Components Location....................................................... 22
		Specifications........................................................................... 24
			Specifications....................................................................... 24
		Special Tools and Equipment.............................................................. 26
			Special Tool......................................................................... 26
	Maintenance and Lubrication.................................................................. 30
		Precautions.............................................................................. 30
			Precautions for Maintenance.......................................................... 30
		General Description...................................................................... 30
			Recommended Fluids and Lubricants.................................................... 30
		Scheduled Maintenance.................................................................... 30
			Periodic Maintenance Schedule Chart.................................................. 30
			Lubrication Points................................................................... 31
		Repair Instructions...................................................................... 32
			Air Cleaner Element Inspection and Cleaning.......................................... 32
			Exhaust Pipe Bolt and Muffler Bolt Inspection........................................ 33
			Valve Clearance Inspection and Adjustment............................................ 33
			Spark Plug Replacement............................................................... 35
			Spark Plug Inspection and Cleaning................................................... 35
			Spark Arrester Cleaning.............................................................. 36
			Fuel Line Inspection................................................................. 37
			Engine Oil and Filter Replacement.................................................... 37
			Front Differential Gear Oil Inspection............................................... 39
			Front Differential Gear Oil Replacement.............................................. 40
			Final Gear Oil Inspection............................................................ 41
			Final Gear Oil Replacement........................................................... 41
			Throttle Cable Play Inspection and Adjustment........................................ 42
			Throttle Body Inspection............................................................. 42
			Cooling System Inspection............................................................ 42
			Drive V-belt Inspection and Replacement.............................................. 44
			Drive Shaft Boots Inspection......................................................... 45
			Front Brake System Inspection........................................................ 45
			Rear Brake Pedal / Rear Brake (Parking Brake) Lever Inspection and Adjustment........ 46
			Rear Brake Friction Plate Wear Limit Inspection...................................... 48
			Tire Inspection...................................................................... 48
			Steering System Inspection........................................................... 49
			Toe Adjustment....................................................................... 49
			Suspensions Inspection............................................................... 50
			Chassis Bolt and Nut Inspection...................................................... 50
			Compression Pressure Check........................................................... 54
			Oil Pressure Check................................................................... 54
			SDS Check............................................................................ 54
			Automatic Clutch Inspection.......................................................... 54
		Specifications........................................................................... 55
			Tightening Torque Specifications..................................................... 55
		Special Tools and Equipment.............................................................. 55
			Recommended Service Material......................................................... 55
			Special Tool......................................................................... 56
	Service Data................................................................................. 57
		Specifications........................................................................... 57
			Service Data......................................................................... 57
			Tightening Torque List............................................................... 63
01 Engine........................................................................................ 67
	Precautions.................................................................................. 71
		Precautions.............................................................................. 71
			Precautions for Engine............................................................... 71
	Engine General Information and Diagnosis..................................................... 72
		General Description...................................................................... 72
			Injection Timing Description......................................................... 72
		Schematic and Routing Diagram............................................................ 75
			FI System Wiring Diagram............................................................. 75
			Terminal Alignment of ECM Coupler.................................................... 76
		Component Location....................................................................... 77
			FI System Parts Location............................................................. 77
		Diagnostic Information and Procedures.................................................... 78
			Engine Symptom Diagnosis............................................................. 78
			Self-Diagnostic Procedures........................................................... 81
			Use of SDS Diagnosis Reset Procedures................................................ 83
			Show Data When Trouble (Displaying Data at the Time of DTC).......................... 84
			SDS Check............................................................................ 86
			DTC Table............................................................................ 89
			Fail-Safe Function Table............................................................. 89
			FI System Troubleshooting............................................................ 90
			Malfunction Code and Defective Condition Table....................................... 92
			DTC “C12” (P0335): CKP Sensor Circuit Malfunction.................................... 94
			DTC “C13” (P0105-H/L): IAP Sensor Circuit Malfunction................................ 97
			DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction.................................104
			DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction................................111
			DTC “C20” (P1752): Diff-lock Relay Circuit Malfunction...............................116
			DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction................................118
			DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction.................................123
			DTC “C24” (P0351): Ignition Coil Circuit Malfunction.................................130
			DTC “C32” (P0201): Fuel Injector Circuit Malfunction.................................130
			DTC “C40” (P0505-H/L): ISC Valve Circuit Malfunction.................................133
			DTC “C41” (P230-H/L): FP Relay Circuit Malfunction...................................139
		Specifications...........................................................................141
			Service Data.........................................................................141
		Special Tools and Equipment..............................................................142
			Special Tool.........................................................................142
	Emission Control Devices.....................................................................143
		Precautions..............................................................................143
			Precautions for Emission Control Devices.............................................143
		Repair Instructions......................................................................143
			Crankcase Breather (PCV) Hose Inspection.............................................143
			Crankcase Breather (PCV) Hose Removal and Installation...............................143
	Engine Electrical Devices....................................................................144
		Precautions..............................................................................144
			Precautions for Engine Electrical Device.............................................144
		Component Location.......................................................................144
			Engine Electrical Components Location................................................144
		Diagnostic Information and Procedures....................................................144
			Engine Symptom Diagnosis.............................................................144
		Repair Instructions......................................................................144
			ECM Removal and Installation.........................................................144
			CKP Sensor Inspection................................................................144
			CKP Sensor Removal and Installation..................................................145
			IAP / TP / IAT Sensor Inspection.....................................................145
			IAP / TP / IAT Sensor Removal and Installation.......................................145
			ECT Sensor Removal and Installation..................................................145
			ECT Sensor Inspection................................................................146
			TO Sensor Inspection.................................................................146
			TO Sensor Removal and Installation...................................................146
			ISC Valve Inspection.................................................................146
			ISC Valve Removal and Installation...................................................147
			GP Switch Inspection.................................................................147
			GP Switch Removal and Installation...................................................147
		Specifications...........................................................................148
			Service Data.........................................................................148
			Tightening Torque Specifications.....................................................148
		Special Tools and Equipment..............................................................148
			Special Tool.........................................................................148
	Engine Mechanical............................................................................149
		Schematic and Routing Diagram............................................................149
			Throttle Cable Routing Diagram.......................................................149
		Diagnostic Information and Procedures....................................................150
			Engine Mechanical Symptom Diagnosis..................................................150
			Compression Pressure Check...........................................................150
		Repair Instructions......................................................................151
			Engine Components Removable with the Engine in Place.................................151
			Air Cleaner Element Removal and Installation.........................................153
			Air Cleaner Element Inspection and Cleaning..........................................153
			Air Cleaner Inlet Sheet Construction.................................................154
			Air Cleaner Inlet Sheet Removal and Installation.....................................154
			Air Cleaner Box Removal and Installation.............................................154
			Throttle Cable Removal and Installation..............................................155
			Throttle Cable Inspection............................................................156
			Throttle Cable Play Inspection and Adjustment........................................156
			Throttle Body Components.............................................................156
			Throttle Body Construction...........................................................157
			Throttle Body Removal and Installation...............................................157
			Throttle Body Disassembly and Assembly...............................................159
			Throttle Body Inspection and Cleaning................................................161
			Engine Assembly Removal..............................................................161
			Engine Assembly Installation.........................................................165
			Engine Top Side Disassembly..........................................................166
			Engine Top Side Assembly.............................................................170
			Valve Clearance Inspection and Adjustment............................................177
			Camshaft Inspection..................................................................177
			Camshaft Sprocket Inspection.........................................................179
			Cam Chain Tension Adjuster Inspection................................................179
			Cam Chain Guide Inspection...........................................................179
			Cam Chain Tensioner Inspection.......................................................180
			Cylinder Inspection..................................................................180
			Piston Ring Removal and Installation.................................................181
			Piston and Piston Ring Inspection....................................................182
			Cylinder Head Cover Disassembly and Assembly.........................................184
			Cylinder Head Cover Related Parts Inspection.........................................185
			Cylinder Head Disassembly and Assembly...............................................186
			Cylinder Head Related Parts Inspection...............................................189
			Valve Guide Replacement..............................................................192
			Valve Seat Repair....................................................................194
			Engine Bottom Side Disassembly.......................................................194
			Engine Bottom Side Assembly..........................................................200
			Conrod and Crankshaft Inspection.....................................................208
			Width Between Crankshaft Webs........................................................209
			Crankshaft Oil Seal and Driveshaft Spacer Oil Seal Inspection........................209
			Bearing (Crankcase and Generator Cover) Inspection...................................210
			Oil Seal / Bearing (Crankcase and Generator Cover) Removal and Installation..........210
		Specifications...........................................................................215
			Service Data.........................................................................215
			Tightening Torque Specifications.....................................................217
		Special Tools and Equipment..............................................................218
			Recommended Service Material.........................................................218
			Special Tool.........................................................................218
	Engine Lubrication System....................................................................222
		Precautions..............................................................................222
			Precautions for Engine Oil...........................................................222
		Schematic and Routing Diagram............................................................222
			Engine Lubrication System Chart Diagram..............................................222
			Engine Lubrication Circuit Diagram...................................................223
		Diagnostic Information and Procedures....................................................225
			Engine Lubrication Symptom Diagnosis.................................................225
			Oil Pressure Check...................................................................225
		Repair Instructions......................................................................226
			Engine Oil and Filter Replacement....................................................226
			Engine Oil Level Inspection..........................................................226
			Oil Sump Filter Removal and Installation.............................................226
			Oil Sump Filter Inspection and Cleaning..............................................227
			Oil Jet Removal and Installation.....................................................227
			Oil Pump Construction................................................................228
			Oil Jet Inspection...................................................................228
			Oil Pump Removal and Installation....................................................228
			Oil Pump Inspection..................................................................230
		Specifications...........................................................................231
			Service Data.........................................................................231
			Tightening Torque Specifications.....................................................231
		Special Tools and Equipment..............................................................231
			Recommended Service Material.........................................................231
			Special Tool.........................................................................232
	Engine Cooling System........................................................................233
		Precautions..............................................................................233
			Precautions for Engine Cooling System................................................233
			Precautions for Engine Coolant.......................................................233
		General Description......................................................................234
			Engine Coolant Description...........................................................234
		Schematic and Routing Diagram............................................................234
			Cooling Circuit Diagram..............................................................234
			Water Hose Routing Diagram...........................................................235
		Diagnostic Information and Procedures....................................................236
			Engine Cooling Symptom Diagnosis.....................................................236
		Repair Instructions......................................................................236
			Cooling Circuit Inspection...........................................................236
			Radiator Cap Inspection..............................................................237
			Radiator Inspection and Cleaning.....................................................237
			Radiator / Cooling Fan Assembly Removal and Installation.............................237
			Water Hose Removal and Installation..................................................238
			Cooling Fan Inspection...............................................................239
			Radiator Reservoir Tank Removal and Installation.....................................239
			Radiator Reservoir Tank Inspection...................................................240
			Water Hose Inspection................................................................240
			ECT Sensor Removal and Installation..................................................240
			ECT Sensor Inspection................................................................240
			Cooling Fan Thermo-switch Removal and Installation...................................240
			Cooling Fan Thermo-switch Inspection.................................................241
			Thermostat Removal and Installation..................................................242
			Thermostat Inspection................................................................243
			Water Pump Components................................................................244
			Water Pump Removal and Installation..................................................244
			Water Pump Disassembly and Assembly..................................................245
			Water Pump Related Parts Inspection..................................................249
		Specifications...........................................................................250
			Service Data.........................................................................250
			Tightening Torque Specifications.....................................................250
		Special Tools and Equipment..............................................................251
			Recommended Service Material.........................................................251
			Special Tool.........................................................................251
	Fuel System..................................................................................252
		Precautions..............................................................................252
			Precautions for Fuel System..........................................................252
		General Description......................................................................253
			Fuel System Description..............................................................253
		Schematic and Routing Diagram............................................................254
			Fuel Hose Routing Diagram............................................................254
			Fuel Tank Breather Hose Routing Diagram..............................................255
		Diagnostic Information and Procedures....................................................256
			Fuel System Diagnosis................................................................256
		Repair Instructions......................................................................257
			Fuel Pressure Inspection.............................................................257
			Fuel Pump Inspection.................................................................257
			Fuel Discharge Amount Inspection.....................................................257
			Fuel Pump Relay Inspection...........................................................258
			Fuel Hose Inspection.................................................................259
			Fuel Feed Hose Removal and Installation..............................................259
			Fuel Level Gauge Inspection..........................................................259
			Fuel Level Indicator Inspection......................................................259
			Fuel Tank Removal and Installation...................................................259
			Fuel Pump Components.................................................................260
			Fuel Pump Assembly Removal and Installation..........................................260
			Fuel Pump Disassembly and Assembly...................................................261
			Fuel Mesh Filter Inspection and Cleaning.............................................261
			Fuel Injector Inspection and Cleaning................................................261
			Fuel Injector / Fuel Delivery Pipe Removal and Installation..........................261
			Fuel Tank Pressure Control (FTPC) Valve Removal and Installation.....................263
			Fuel Tank Pressure Control (FTPC) Valve Inspection...................................264
		Specifications...........................................................................264
			Service Data.........................................................................264
			Tightening Torque Specifications.....................................................264
		Special Tools and Equipment..............................................................265
			Special Tool.........................................................................265
	Ignition System..............................................................................266
		General Description......................................................................266
			Override Switch Description..........................................................266
		Schematic and Routing Diagram............................................................266
			Ignition System Diagram..............................................................266
			Ignition System Components Location..................................................266
		Diagnostic Information and Procedures....................................................267
			Ignition System Symptom Diagnosis....................................................267
			No Spark or Poor Spark...............................................................267
		Repair Instructions......................................................................268
			Spark Plug Cap and Spark Plug Removal and Installation...............................268
			Spark Plug Inspection and Cleaning...................................................268
			Ignition Coil and Plug Cap Inspection................................................269
			Ignition Coil Removal and Installation...............................................270
			CKP Sensor Inspection................................................................270
			CKP Sensor Removal and Installation..................................................271
			Engine Stop Switch Inspection........................................................271
			Ignition Switch Inspection...........................................................272
			Ignition Switch Removal and Installation.............................................272
			Override Switch Inspection...........................................................272
			Emergency Switch Inspection (For P-17)...............................................273
			Emergency Switch Removal and Installation (For P-17).................................273
		Specifications...........................................................................273
			Service Data.........................................................................273
			Tightening Torque Specifications.....................................................273
		Special Tools and Equipment..............................................................273
			Special Tool.........................................................................273
	Starting System..............................................................................274
		Schematic and Routing Diagram............................................................274
			Starting System Diagram..............................................................274
		Component Location.......................................................................274
			Starting System Components Location..................................................274
		Diagnostic Information and Procedures....................................................274
			Starting System Symptom Diagnosis....................................................274
			Starter Motor will not Run...........................................................275
			Starter Motor Runs but Does not Crank the Engine.....................................275
			Engine Does not Turn Though the Starter Motor Runs...................................275
		Repair Instructions......................................................................276
			Starter Motor Components.............................................................276
			Starter Motor Removal and Installation...............................................276
			Starter Motor Disassembly and Assembly...............................................277
			Starter Motor Related Parts Inspection...............................................278
			Starter Relay Removal and Installation...............................................279
			Starter Relay Inspection.............................................................280
			Neutral Relay Removal and Installation...............................................280
			Neutral Relay Inspection.............................................................281
			Neutral Relay Diode Inspection.......................................................281
			Parking Brake Relay Removal and Installation.........................................281
			Parking Brake Relay Inspection.......................................................282
			Parking / Rear Brake Switch Inspection...............................................282
			Gear Position Switch Inspection......................................................282
			Starter Idle Gear / Starter Clutch Removal and Installation..........................283
			Starter Driven Gear Bearing Removal and Installation.................................285
			Starter Related Parts Inspection.....................................................285
			Starter Button Inspection............................................................286
		Specifications...........................................................................286
			Service Data.........................................................................286
			Tightening Torque Specifications.....................................................287
		Special Tools and Equipment..............................................................287
			Recommended Service Material.........................................................287
			Special Tool.........................................................................287
	Charging System..............................................................................288
		Schematic and Routing Diagram............................................................288
			Charging System Diagram..............................................................288
		Component Location.......................................................................288
			Charging System Components Location..................................................288
		Diagnostic Information and Procedures....................................................288
			Charging System Symptom Diagnosis....................................................288
			Battery Runs Down Quickly............................................................289
		Repair Instructions......................................................................290
			Battery Current Leakage Inspection...................................................290
			Regulated Voltage Inspection.........................................................290
			Generator Inspection.................................................................290
			Generator Removal and Installation...................................................291
			Regulator / Rectifier Inspection.....................................................295
			Battery Components...................................................................296
			Battery Charging.....................................................................296
			Battery Removal and Installation.....................................................298
			Battery Visual Inspection............................................................299
		Specifications...........................................................................299
			Service Data.........................................................................299
			Tightening Torque Specifications.....................................................300
		Special Tools and Equipment..............................................................300
			Recommended Service Material.........................................................300
			Special Tool.........................................................................300
	Exhaust System...............................................................................301
		Precautions..............................................................................301
			Precautions for Exhaust System.......................................................301
		Repair Instructions......................................................................301
			Exhaust System Construction..........................................................301
			Exhaust Pipe / Muffler Removal and Installation......................................302
			Exhaust System Inspection............................................................303
			Spark Arrester Inspection............................................................303
		Specifications...........................................................................303
			Tightening Torque Specifications.....................................................303
02 Suspension....................................................................................305
	Precautions..................................................................................306
		Precautions..............................................................................306
			Precautions for Suspension...........................................................306
	Suspension General Diagnosis.................................................................307
		Diagnostic Information and Procedures....................................................307
			Suspension and Wheel Symptom Diagnosis...............................................307
	Front Suspension.............................................................................308
		Repair Instructions......................................................................308
			Front Suspension Components..........................................................308
			Front Suspension Assembly Construction...............................................309
			Front Shock Absorber Removal and Installation........................................310
			Front Suspension Inspection..........................................................310
			Front Shock Absorber Inspection......................................................310
			Spring Pre-load Adjustment...........................................................311
			Front Wheel Hub / Steering Knuckle Removal and Installation..........................311
			Front Hub Bearing Inspection.........................................................314
			Front Hub Bearing Removal and Installation...........................................314
			Front Suspension Upper / Lower Arm Removal and Installation..........................316
			Steering Knuckle End Inspection......................................................317
			Steering Knuckle End Removal and Installation........................................318
			Front Suspension Arm Related Parts Inspection........................................319
			Front Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation......320
			Front Suspension Lower Arm Bushing Removal and Installation..........................321
		Specifications...........................................................................322
			Service Data.........................................................................322
			Tightening Torque Specifications.....................................................322
		Special Tools and Equipment..............................................................322
			Recommended Service Material.........................................................322
			Special Tool.........................................................................323
	Rear Suspension..............................................................................324
		Repair Instructions......................................................................324
			Rear Suspension Components...........................................................324
			Rear Suspension Assembly Construction................................................325
			Rear Shock Absorber Removal and Installation.........................................326
			Rear Suspension Inspection...........................................................327
			Rear Shock Absorber Inspection.......................................................327
			Spring Pre-load Adjustment...........................................................327
			Rear Wheel Hub / Suspension Knuckle Removal and Installation.........................328
			Rear Hub Bearing Inspection..........................................................329
			Rear Hub Bearing Removal and Installation............................................329
			Rear Suspension Arm Upper / Lower Removal and Installation...........................331
			Rear Suspension Arm Related Parts Inspection.........................................333
			Rear Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation.......334
			Rear Suspension Lower Arm Bushing and Inner Dust Seal Removal and Installation.......335
			Rear Suspension Knuckle Bushing and Inner Dust Seal Removal and Installation.........337
			Rear Stabilizer Removal and Installation.............................................338
			Stabilizer Parts Inspection..........................................................339
		Specifications...........................................................................340
			Service Data.........................................................................340
			Tightening Torque Specifications.....................................................340
		Special Tools and Equipment..............................................................340
			Recommended Service Material.........................................................340
			Special Tool.........................................................................341
	Wheels and Tires.............................................................................342
		Precautions..............................................................................342
			Precautions for Wheel and Tire.......................................................342
		Repair Instructions......................................................................342
			Front and Rear Wheel Components......................................................342
			Front / Rear Wheel Removal and Installation..........................................343
			Tire Removal and Installation........................................................343
		Specifications...........................................................................345
			Service Data.........................................................................345
			Tightening Torque Specifications.....................................................345
03 Driveline / Axle..............................................................................347
	Precautions..................................................................................349
		Precautions..............................................................................349
			Precautions for Driveline / Axle.....................................................349
	Drive Chain / Drive Train / Drive Shaft......................................................350
		Diagnostic Information and Procedures....................................................350
			Drive Shaft Symptom Diagnosis........................................................350
		Repair Instructions......................................................................350
			Front Drive Shaft Components.........................................................350
			Front Drive Shaft Assembly Removal and Installation..................................351
			Front Drive Shaft Disassembly and Assembly...........................................351
			Front Drive Shaft Inspection.........................................................354
			Rear Drive Shaft Components..........................................................355
			Rear Drive Shaft Assembly Removal and Installation...................................355
			Rear Drive Shaft Disassembly and Assembly............................................356
			Rear Drive Shaft Inspection..........................................................356
		Special Tools and Equipment..............................................................357
			Recommended Service Material.........................................................357
			Special Tool.........................................................................357
	Differential.................................................................................358
		Diagnostic Information and Procedures....................................................358
			Drive Train Symptom Diagnosis........................................................358
			DTC “C20” (P1752) Diff-lock Relay Circuit Malfunction................................358
		Repair Instructions......................................................................359
			Front Drive (Differential) Components................................................359
			Front Drive (Differential) Construction..............................................360
			Front Drive (Differential) Gear Oil Level Inspection.................................361
			Front Drive (Differential) Gear Oil Replacement......................................361
			Front Drive (Differential) Assembly Removal and Installation.........................361
			Front Drive (Differential) Assembly Disassembly and Assembly.........................362
			Front Drive (Differential) Related Parts Inspection..................................370
			Breather Rubber Case Inspection......................................................372
			Front Drive (Differential) Gear Shim Inspection and Adjustment.......................372
			2WD / 4WD / Diff-lock System Inspection..............................................375
			Rear Drive Breather Hose Routing Diagram.............................................379
			Final Gear Components................................................................380
			Final Gear Construction..............................................................381
			Final Gear Oil Level Inspection......................................................382
			Final Gear Oil Replacement...........................................................382
			Final Gear Assembly Removal and Installation.........................................382
			Final Gear Assembly Disassembly and Assembly.........................................383
			Final Gear Related Parts Inspection..................................................389
			Final Gear Shim Inspection and Selection.............................................390
		Specifications...........................................................................394
			Service Data.........................................................................394
			Tightening Torque Specifications.....................................................394
		Special Tools and Equipment..............................................................395
			Recommended Service Material.........................................................395
			Special Tool.........................................................................395
	Transfer.....................................................................................397
		Diagnostic Information and Procedures....................................................397
			Transfer Symptom Diagnosis...........................................................397
		Repair Instructions......................................................................398
			Transfer Components..................................................................398
			Transfer Removal and Installation....................................................399
			Transfer Construction................................................................402
			Transfer Disassembly and Assembly....................................................402
			Transfer Related Bearing Removal and Installation....................................404
			Transfer Related Parts Inspection....................................................404
			Gearshift Cam Components.............................................................405
			Gearshift System Construction........................................................406
			Gearshift Cam Disassembly and Assembly...............................................406
			Gear Position (GP) Switch Inspection.................................................407
			Gear Position (GP) Switch Removal and Installation...................................407
			HI / LO Position Diode Inspection....................................................408
			Gearshift Shaft No. 2 / Gearshift Cam Plate Removal and Installation.................409
			Gearshift Linkage Inspection.........................................................410
			Gearshift Shaft Oil Seal Removal and Installation....................................411
		Specifications...........................................................................411
			Service Data.........................................................................411
			Tightening Torque Specifications.....................................................412
		Special Tools and Equipment..............................................................412
			Recommended Service Material.........................................................412
			Special Tool.........................................................................412
	Propeller Shafts.............................................................................413
		Repair Instructions......................................................................413
			Front Output Shaft Components........................................................413
			Front Output Shaft Removal and Installation..........................................413
			Front Output Shaft Disassembly and Assembly..........................................414
			Front Output Shaft Related Parts Inspection..........................................417
			Rear Output Shaft Components.........................................................418
			Rear Output Shaft / Drive Bevel Gear Removal and Installation........................418
			Rear Output Shaft Disassembly and Assembly...........................................420
			Rear Output Shaft Related Parts Inspection...........................................424
			Driven / Drive Bevel Gear Shim Inspection and Adjustment.............................424
			Front Propeller Shaft Components.....................................................427
			Front Propeller Shaft Removal and Installation.......................................428
			Front Propeller Shaft Related Parts Inspection.......................................429
			Rear Propeller Shaft Components......................................................430
			Rear Propeller Shaft Removal and Installation........................................431
			Rear Propeller Shaft Related Parts Inspection........................................434
		Specifications...........................................................................435
			Service Data.........................................................................435
			Tightening Torque Specifications.....................................................435
		Special Tools and Equipment..............................................................436
			Recommended Service Material.........................................................436
			Special Tool.........................................................................437
04 Brake.........................................................................................439
	Precautions..................................................................................441
		Precautions..............................................................................441
			Precautions for Brake System.........................................................441
			Brake Fluid Information..............................................................441
	Brake Control System and Diagnosis...........................................................442
		Schematic and Routing Diagram............................................................442
			Front Brake Hose Routing Diagram.....................................................442
			Rear Brake Cable Routing Diagram.....................................................443
		Diagnostic Information and Procedures....................................................444
			Brake Symptom Diagnosis..............................................................444
		Repair Instructions......................................................................444
			Brake Pedal Height Inspection and Adjustment.........................................444
			Front Brake Light Switch Inspection..................................................444
			Rear Brake Light Switch Inspection...................................................445
			Rear Brake Light Switch Inspection and Adjustment....................................445
			Parking / Rear Brake Light Switch Inspection.........................................445
			Parking / Rear Brake Lever Switch Inspection.........................................445
			Brake Fluid Level Check..............................................................445
			Front Brake Hose Inspection..........................................................445
			Air Bleeding from Front Brake Fluid Circuit..........................................446
			Brake Fluid Replacement..............................................................447
			Front Brake Hose Removal and Installation............................................448
			Rear Brake Cable Removal and Installation............................................448
			Front Brake Master Cylinder Components...............................................450
			Front Brake Master Cylinder Assembly Removal and Installation........................450
			Front Brake Master Cylinder / Brake Lever Disassembly and Assembly...................452
			Front Brake Master Cylinder Parts Inspection.........................................453
			Rear Brake Pedal Construction........................................................454
			Rear Brake Pedal Removal and Installation............................................454
		Specifications...........................................................................456
			Service Data.........................................................................456
			Tightening Torque Specifications.....................................................456
		Special Tools and Equipment..............................................................457
			Recommended Service Material.........................................................457
			Special Tool.........................................................................457
	Front Brakes.................................................................................458
		Precautions..............................................................................458
			Precautions for Front Brakes.........................................................458
		Repair Instructions......................................................................458
			Front Brake Components...............................................................458
			Front Brake Pad Inspection...........................................................459
			Front Brake Pad Replacement..........................................................459
			Front Brake Caliper Removal and Installation.........................................460
			Front Brake Caliper Disassembly and Assembly.........................................461
			Front Brake Caliper Parts Inspection.................................................463
			Front Brake Disc Removal and Installation............................................464
			Front Brake Disc Inspection..........................................................464
		Specifications...........................................................................465
			Service Data.........................................................................465
			Tightening Torque Specifications.....................................................465
		Special Tools and Equipment..............................................................465
			Recommended Service Material.........................................................465
			Special Tool.........................................................................466
	Rear Brakes..................................................................................467
		Precautions..............................................................................467
			Precautions for Rear Brake...........................................................467
		Repair Instructions......................................................................467
			Rear Brake Components................................................................467
			Rear Brake Friction Plate Inspection.................................................468
			Rear Brake Friction Plate Replacement................................................468
			Rear Brake Assembly Removal and Installation.........................................468
			Rear Brake Disassembly and Assembly..................................................469
			Rear Brake Parts Inspection..........................................................473
		Specifications...........................................................................475
			Service Data.........................................................................475
			Tightening Torque Specifications.....................................................475
		Special Tools and Equipment..............................................................476
			Recommended Service Material.........................................................476
			Special Tool.........................................................................476
	Parking Brake................................................................................477
		Schematic and Routing Diagram............................................................477
			Parking / Rear Brake Cable Routing Diagram...........................................477
		Repair Instructions......................................................................479
			Parking / Rear Brake Inspection and Adjustment.......................................479
			Parking / Rear Brake Cable Removal and Installation..................................479
			Parking / Rear Brake Lever Components................................................480
			Parking / Rear Brake Lever Removal and Installation..................................480
			Parking / Rear Brake Light Switch Inspection.........................................480
			Parking / Rear Brake Relay Inspection................................................480
		Specifications...........................................................................481
			Tightening Torque Specifications.....................................................481
		Special Tools and Equipment..............................................................481
			Recommended Service Material.........................................................481
05 Transmission / Transaxle......................................................................483
	Precautions..................................................................................484
		Precautions..............................................................................484
			Precautions for Transmission / Transaxle.............................................484
	Automatic Transmission.......................................................................485
		Schematic and Routing Diagram............................................................485
			Drive Train System...................................................................485
		Diagnostic Information and Procedures....................................................486
			Automatic Transmission Symptom Diagnosis.............................................486
		Repair Instructions......................................................................487
			Automatic Transmission Components....................................................487
			V-belt Cooling Duct Construction.....................................................488
			V-belt Cooling Duct Removal and Installation.........................................488
			Clutch Engagement and Lock-up Speed Inspection.......................................489
			V-belt Type Continuously Variable Automatic Transmission Removal and Installation....489
			Movable Drive Face Disassembly and Assembly..........................................492
			Movable Driven Face Disassembly and Assembly.........................................494
			Drive V-belt Inspection..............................................................498
			Movable / Fixed Drive Face Parts Inspection..........................................498
			Movable / Fixed Driven Face Parts Inspection.........................................499
			Clutch Shoe Removal and Installation.................................................499
			Clutch Cover Disassembly and Assembly................................................502
			Clutch Related Parts Inspection......................................................504
			Movable Drive Face Cover Disassembly and Assembly....................................505
			Movable Driven Face Cover Parts Inspection...........................................506
			Shift Lever Assembly Components......................................................507
			Gearshift Knob Removal and Installation..............................................507
			Shift Lever Assembly Removal and Installation........................................507
			Shift Lever Disassembly and Assembly.................................................508
			Shift Rod Adjustment.................................................................509
		Specifications...........................................................................509
			Service Data.........................................................................509
			Tightening Torque Specifications.....................................................510
		Special Tools and Equipment..............................................................510
			Recommended Service Material.........................................................510
			Special Tool.........................................................................511
06 Steering......................................................................................513
	Precautions..................................................................................514
		Precautions..............................................................................514
			Precautions for Steering.............................................................514
	Steering General Diagnosis...................................................................515
		Diagnostic Information and Procedures....................................................515
			Steering Symptom Diagnosis...........................................................515
	Steering / Handlebar.........................................................................516
		Repair Instructions......................................................................516
			Steering / Handlebars Components.....................................................516
			Steering / Handlebars Assembly Construction..........................................517
			Handlebars Removal and Installation..................................................518
			Handlebars Inspection................................................................520
			Steering Shaft Removal and Installation..............................................520
			Tie-rod / Tie-rod End Removal and Installation.......................................523
			Steering Related Parts Inspection....................................................524
		Specifications...........................................................................524
			Service Data.........................................................................524
			Tightening Torque Specifications.....................................................525
		Special Tools and Equipment..............................................................525
			Recommended Service Material.........................................................525
			Special Tool.........................................................................526
	Power Assisted Steering System...............................................................527
		Precautions..............................................................................527
			Precautions for EPS..................................................................527
			P/S System Note......................................................................527
			Precautions in Diagnosing Troubles...................................................527
		General Description......................................................................528
			P/S System Description...............................................................528
			EPS Diagnosis General Description....................................................531
			Self Diagnostic System Description...................................................531
			Fail-safe Function Description.......................................................531
		Schematic and Routing Diagram............................................................532
			EPS Wiring Diagram...................................................................532
			EPS Control Unit Diagram.............................................................533
			EPS System Wiring Harness Routing Diagram............................................534
		Component Location.......................................................................534
			EPS Components Location..............................................................534
		Diagnostic Information and Procedures....................................................534
			EPS Troubleshooting..................................................................534
			Pre-diagnosis Inspection.............................................................535
			EPS System Check.....................................................................537
			DTC (Diagnostic Trouble Code) Output.................................................544
			DTC (Diagnostic Trouble Code) Deleting...............................................546
			SDS Check............................................................................549
			DTC Table............................................................................550
			DTC “C1111”: Torque Sensor (Main) Circuit Malfunction................................551
			DTC “C1113”: Torque Sensor (Main / Sub) Circuit Correlation Malfunction..............554
			DTC “C1114”: Torque Sensor Power Supply Circuit Malfunction..........................558
			DTC “C1115”: Torque Sensor (Sub) Circuit Malfunction.................................560
			DTC “C1121”: Vehicle Speed Signal Circuit Malfunction................................563
			DTC “C1122”: Engine Speed Signal Circuit Malfunction.................................566
			DTC “C1141”, “C1142”, “C1143”, “C1145” EPS Motor Circuit Malfunction.................569
			DTC “C1153” EPS Control Unit Supply Voltage Circuit Malfunction......................571
			DTC “C1152”, “C1154”, “C1155” EPS Control Unit Malfunction...........................573
		Repair Instructions......................................................................573
			EPS Control Unit Construction........................................................573
			EPS Control Unit Removal and Installation............................................574
			EPS Body Assembly Components.........................................................575
			EPS Body Assembly Removal and Installation...........................................575
			EPS Motor Inspection.................................................................578
		Specifications...........................................................................579
			Tightening Torque Specifications.....................................................579
		Special Tools and Equipment..............................................................579
			Recommended Service Material.........................................................579
			Special Tool.........................................................................580
09 Body and Accessories..........................................................................581
	Precautions..................................................................................583
		Precautions..............................................................................583
			Precautions for Electrical System....................................................583
		Component Location.......................................................................583
			Electrical Components Location.......................................................583
	Wiring Systems...............................................................................584
		Schematic and Routing Diagram............................................................584
			Wiring Diagram.......................................................................584
			Wiring Harness Routing Diagram.......................................................587
		Specifications...........................................................................590
			Service Data.........................................................................590
			Tightening Torque Specifications.....................................................590
	Lighting Systems.............................................................................591
		Repair Instructions......................................................................591
			Headlight Components.................................................................591
			Headlight Removal and Installation...................................................591
			Headlight Bulb Replacement...........................................................592
			Headlight Beam Adjustment............................................................592
			Rear Combination Light components....................................................592
			Rear Combination Light Removal and Installation......................................593
			Rear Combination Light Bulb Replacement..............................................593
			Reversing Light Bulb Replacement (For P-17)..........................................594
			Reversing Light Relay Inspection (For P-17)..........................................594
			Dimmer Switch Inspection.............................................................594
		Specifications...........................................................................595
			Service Data.........................................................................595
		Special Tools and Equipment..............................................................595
			Special Tool.........................................................................595
	Combination Meter / Fuel Meter / Horn........................................................596
		General Description......................................................................596
			Combination Meter System Description.................................................596
		Repair Instructions......................................................................597
			Combination Meter Components.........................................................597
			Combination Meter Removal and Installation...........................................597
			Combination Meter Disassembly and Assembly...........................................598
			Combination Meter Inspection.........................................................598
			Engine Coolant Temperature Indicator Light Inspection................................598
			Engine Coolant Temperature Removal and Installation..................................599
			Fuel Level Indicator Inspection......................................................599
			Fuel Level Gauge Inspection..........................................................600
			Speedometer Inspection...............................................................601
			Speed Sensor Removal and Installation................................................601
			Speed Sensor Inspection..............................................................601
			Ignition Switch Inspection...........................................................602
			Ignition Switch Removal and Installation.............................................602
			Horn Inspection (For P-17, 24).......................................................602
			Horn Removal and Installation (For P-17, 24).........................................603
		Specifications...........................................................................603
			Service Data.........................................................................603
			Tightening Torque Specifications.....................................................603
		Special Tools and Equipment..............................................................603
			Recommended Service Material.........................................................603
			Special Tool.........................................................................603
	Exterior Parts...............................................................................604
		Repair Instructions......................................................................604
			Exterior Parts Construction..........................................................604
			Rear Fender Heat Shield Construction.................................................606
			Fuel Tank Lower Cover Heat Shield Installation.......................................607
			Fastener Removal and Installation....................................................608
			Front Side Exterior Parts Removal and Installation...................................609
			Rear Side Exterior Parts Removal and Installation....................................612
			Seat Removal and Installation........................................................614
			Under Cover Components...............................................................615
			Under Cover Removal and Installation.................................................615
	Body Structure...............................................................................617
		Repair Instructions......................................................................617
			Body Frame Construction..............................................................617
			Footrest Construction................................................................618
			Footrest Removal and Installation....................................................618
			Carrier Construction.................................................................619
			Front Carrier Removal and Installation...............................................619
			Rear Carrier Removal and Installation................................................620
			Front Grip Bar Construction..........................................................621
			Front Grip Bar Removal and Installation..............................................621
			Trailer Towing Construction..........................................................622
			Trailer Towing Removal and Instruction...............................................622
		Specifications...........................................................................623
			Tightening Torque Specifications.....................................................623
		Special Tools and Equipment..............................................................623
			Recommended Service Material.........................................................623

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