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