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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
FOREWORDοΏ½................................................................................................. 1
TABLE OF CONTENTSοΏ½........................................................................................ 3
00 PRECAUTIONSοΏ½........................................................................................... 7
PRECAUTIONSοΏ½.......................................................................................... 8
PRECAUTIONSοΏ½...................................................................................... 8
WARNING / CAUTION / NOTEοΏ½..................................................................... 8
GENERAL PRECAUTIONSοΏ½.......................................................................... 8
PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICEοΏ½................................................... 9
0 GENERAL INFORMATIONοΏ½.................................................................................... 15
GENERAL INFORMATIONοΏ½.................................................................................. 16
GENERAL DESCRIPTIONοΏ½.............................................................................. 16
SYMBOLSοΏ½...................................................................................... 16
ABBREVIATIONSοΏ½................................................................................ 16
SAE-TO-FORMER SUZUKI TERMοΏ½.................................................................... 17
VEHICLE SIDE VIEWοΏ½............................................................................ 17
VEHICLE IDENTIFICATION NUMBERοΏ½................................................................ 18
FUEL AND OIL RECOMMENDATIONοΏ½.................................................................. 18
BREAK-IN PROCEDURESοΏ½.......................................................................... 19
COUNTRY AND AREA CODESοΏ½....................................................................... 19
WIRE COLOR SYMBOLSοΏ½........................................................................... 19
WARNING, CAUTION AND INFORMATION LABELS LOCATIONοΏ½............................................. 20
COMPONENT LOCATIONοΏ½............................................................................... 21
ELECTRICAL COMPONENTS LOCATIONοΏ½............................................................... 21
SPECIFICATIONSοΏ½................................................................................... 25
SPECIFICATIONSοΏ½............................................................................... 25
SPECIAL TOOLS AND EQUIPMENTοΏ½...................................................................... 29
SPECIAL TOOLοΏ½................................................................................. 29
MAINTENANCE AND LUBRICATIONοΏ½.......................................................................... 32
PRECAUTIONSοΏ½...................................................................................... 32
PRECAUTIONS FOR MAINTENANCEοΏ½.................................................................. 32
GENERAL DESCRIPTIONοΏ½.............................................................................. 32
RECOMMENDED FLUIDS AND LUBRICANTSοΏ½............................................................ 32
SCHEDULED MAINTENANCEοΏ½............................................................................ 32
PERIODIC MAINTENANCE SCHEDULE CHARTοΏ½.......................................................... 32
LUBRICATION POINTSοΏ½........................................................................... 33
REPAIR INSTRUCTIONSοΏ½.............................................................................. 34
AIR CLEANER ELEMENT INSPECTION AND CLEANINGοΏ½.................................................. 34
EXHAUST PIPE BOLT AND MUFFLER BOLT INSPECTIONοΏ½................................................ 35
VALVE CLEARANCE INSPECTION AND ADJUSTMENTοΏ½.................................................... 35
SPARK PLUG REPLACEMENTοΏ½....................................................................... 36
SPARK PLUG INSPECTION AND CLEANINGοΏ½........................................................... 37
SPARK ARRESTER CLEANINGοΏ½...................................................................... 38
FUEL LINE INSPECTIONοΏ½......................................................................... 38
ENGINE OIL AND FILTER REPLACEMENTοΏ½............................................................ 38
FRONT DIFFERENTIAL GEAR OIL INSPECTION (LT-A400F, LT-F400F)οΏ½.................................. 40
FRONT DIFFERENTIAL GEAR OIL REPLACEMENT (LT- A400F, LT-F400F)οΏ½................................ 41
FINAL GEAR OIL INSPECTIONοΏ½.................................................................... 42
FINAL GEAR OIL REPLACEMENTοΏ½................................................................... 42
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENTοΏ½................................................ 44
ENGINE IDLE SPEED ADJUSTMENTοΏ½................................................................. 44
DRIVE V-BELT INSPECTION (LT-A400/F)οΏ½.......................................................... 44
CLUTCH INSPECTION (LT-F400/F)οΏ½................................................................ 45
DRIVE SHAFT BOOTS INSPECTION (LT-A400F, LT- F400F)οΏ½........................................... 45
FRONT BRAKE SYSTEM INSPECTIONοΏ½................................................................ 46
REAR BRAKE PEDAL / REAR BRAKE (PARKING BRAKE) LEVER INSPECTION AND ADJUSTMENTοΏ½................ 47
TIRE INSPECTIONοΏ½.............................................................................. 48
STEERING SYSTEM INSPECTIONοΏ½................................................................... 49
TOE-IN ADJUSTMENTοΏ½............................................................................ 49
SUSPENSION INSPECTIONοΏ½........................................................................ 50
CHASSIS BOLT AND NUT INSPECTIONοΏ½.............................................................. 50
COMPRESSION PRESSURE CHECKοΏ½................................................................... 52
OIL PRESSURE CHECKοΏ½........................................................................... 52
AUTOMATIC CLUTCH INSPECTION (LT-A400/F)οΏ½...................................................... 52
SPECIFICATIONSοΏ½................................................................................... 53
TIGHTENING TORQUE SPECIFICATIONSοΏ½............................................................. 53
SPECIAL TOOLS AND EQUIPMENTοΏ½...................................................................... 53
RECOMMENDED SERVICE MATERIALοΏ½................................................................. 53
SPECIAL TOOLοΏ½................................................................................. 53
SERVICE DATAοΏ½......................................................................................... 55
SPECIFICATIONSοΏ½................................................................................... 55
SERVICE DATA (LT-A400/F)οΏ½..................................................................... 55
SERVICE DATA (LT-F400/F)οΏ½..................................................................... 59
TIGHTENING TORQUE LIST (LT-A400/F)οΏ½........................................................... 63
TIGHTENING TORQUE LIST (LT-F400/F)οΏ½........................................................... 65
01 ENGINEοΏ½................................................................................................ 69
PRECAUTIONSοΏ½.......................................................................................... 72
PRECAUTIONSοΏ½...................................................................................... 72
PRECAUTIONS FOR ENGINEοΏ½....................................................................... 72
ENGINE GENERAL INFORMATION AND DIAGNOSISοΏ½............................................................. 73
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................ 73
ENGINE SYMPTOM DIAGNOSISοΏ½..................................................................... 73
EMISSION CONTROL DEVICESοΏ½............................................................................. 75
PRECAUTIONSοΏ½...................................................................................... 75
PRECAUTIONS FOR EMISSION CONTROL DEVICESοΏ½..................................................... 75
GENERAL DESCRIPTIONοΏ½.............................................................................. 75
CARBURETOR SYSTEM DESCRIPTIONοΏ½................................................................ 75
REPAIR INSTRUCTIONSοΏ½.............................................................................. 76
CRANKCASE BREATHER (PCV) HOSE INSPECTIONοΏ½..................................................... 76
CRANKCASE BREATHER (PCV) HOSE REMOVAL AND INSTALLATIONοΏ½....................................... 76
ENGINE MECHANICALοΏ½.................................................................................... 77
SCHEMATIC AND ROUTING DIAGRAMοΏ½.................................................................... 77
THROTTLE CABLE ROUTING DIAGRAMοΏ½............................................................... 77
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................ 78
ENGINE MECHANICAL SYMPTOM DIAGNOSISοΏ½.......................................................... 78
COMPRESSION PRESSURE CHECKοΏ½................................................................... 78
REPAIR INSTRUCTIONSοΏ½.............................................................................. 79
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACEοΏ½......................................... 79
AIR CLEANER ELEMENT REMOVAL AND INSTALLATIONοΏ½................................................. 81
AIR CLEANER ELEMENT INSPECTION AND CLEANINGοΏ½.................................................. 81
AIR CLEANER BOX REMOVAL AND INSTALLATIONοΏ½..................................................... 81
ENGINE ASSEMBLY REMOVALοΏ½...................................................................... 82
ENGINE ASSEMBLY INSTALLATIONοΏ½................................................................. 85
ENGINE TOP SIDE DISASSEMBLYοΏ½.................................................................. 86
ENGINE TOP SIDE ASSEMBLYοΏ½..................................................................... 89
CYLINDER HEAD COVER DISASSEMBLY AND ASSEMBLYοΏ½................................................. 96
CYLINDER HEAD COVER RELATE PARTS INSPECTIONοΏ½.................................................. 97
CYLINDER HEAD DISASSEMBLY AND ASSEMBLYοΏ½....................................................... 98
CYLINDER HEAD RELATED PARTS INSPECTIONοΏ½....................................................... 99
VALVE GUIDE REPLACEMENTοΏ½......................................................................102
VALVE SEAT REPAIRοΏ½............................................................................104
CAMSHAFT INSPECTIONοΏ½..........................................................................104
CAM CHAIN TENSION ADJUSTER INSPECTIONοΏ½........................................................106
CAM CHAIN TENSIONER INSPECTIONοΏ½...............................................................106
CAM CHAIN GUIDE INSPECTIONοΏ½...................................................................106
CYLINDER INSPECTIONοΏ½..........................................................................106
PISTON RING REMOVAL AND INSTALLATIONοΏ½.........................................................107
PISTON AND PISTON RING INSPECTIONοΏ½............................................................108
ENGINE BOTTOM SIDE DISASSEMBLYοΏ½...............................................................110
ENGINE BOTTOM SIDE ASSEMBLYοΏ½..................................................................119
CONROD AND CRANKSHAFT INSPECTIONοΏ½.............................................................134
WIDTH BETWEEN CRANKSHAFT WEBSοΏ½................................................................135
CRANKSHAFT OIL SEAL INSPECTIONοΏ½...............................................................135
BEARING INSPECTIONοΏ½...........................................................................135
BEARING REMOVAL AND INSTALLATIONοΏ½.............................................................136
SPECIFICATIONSοΏ½...................................................................................143
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................143
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................145
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................145
RECOMMENDED SERVICE MATERIALοΏ½.................................................................145
SPECIAL TOOLοΏ½.................................................................................146
ENGINE LUBRICATION SYSTEMοΏ½............................................................................150
PRECAUTIONSοΏ½......................................................................................150
PRECAUTIONS FOR ENGINE OILοΏ½...................................................................150
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................150
ENGINE LUBRICATION SYSTEM CHART DIAGRAMοΏ½......................................................150
CYLINDER HEAD COOLING SYSTEM CHART DIAGRAMοΏ½...................................................152
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................153
ENGINE LUBRICATION SYMPTOM DIAGNOSISοΏ½.........................................................153
OIL PRESSURE CHECKοΏ½...........................................................................153
REPAIR INSTRUCTIONSοΏ½..............................................................................154
ENGINE OIL AND FILTER REPLACEMENTοΏ½............................................................154
ENGINE OIL LEVEL INSPECTIONοΏ½..................................................................154
OIL SUMP FILTER REMOVAL AND INSTALLATIONοΏ½.....................................................154
OIL SUMP FILTER INSPECTION AND CLEANINGοΏ½......................................................155
OIL JET REMOVAL AND INSTALLATION (LT-F400/F)οΏ½.................................................155
OIL JET INSPECTION (LT-F400/F)οΏ½...............................................................155
OIL PUMP DRIVE GEAR / OIL PUMP REMOVAL AND INSTALLATIONοΏ½......................................155
OIL PUMP INSPECTIONοΏ½..........................................................................157
OIL COOLER AND OIL HOSE COMPONENTSοΏ½...........................................................158
OIL COOLER / OIL COOLER HOSE INSPECTION AND CLEANINGοΏ½.........................................158
OIL COOLER / OIL COOLER HOSE REMOVAL AND INSTALLATIONοΏ½........................................159
OIL COOLER CLEANINGοΏ½..........................................................................160
COOLING FAN COMPONENTSοΏ½.......................................................................161
COOLING FAN INSPECTIONοΏ½.......................................................................161
COOLING FAN REMOVAL AND INSTALLATIONοΏ½.........................................................162
COOLING FAN THERMO-SWITCH REMOVAL AND INSTALLATIONοΏ½...........................................162
COOLING FAN THERMO-SWITCH INSPECTIONοΏ½.........................................................163
ENGINE OIL TEMPERATURE SWITCH REMOVAL AND INSTALLATIONοΏ½.......................................163
ENGINE OIL TEMPERATURE SWITCH INSPECTIONοΏ½.....................................................164
OIL PRESSURE REGULATOR REMOVAL AND INSTALLATIONοΏ½..............................................164
OIL PRESSURE REGULATOR INSPECTIONοΏ½............................................................165
SPECIFICATIONSοΏ½...................................................................................165
SERVICE DATA (LT-A400/F)οΏ½.....................................................................165
SERVICE DATA (LT-F400/F)οΏ½.....................................................................165
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................166
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................166
RECOMMENDED SERVICE MATERIALοΏ½.................................................................166
SPECIAL TOOLοΏ½.................................................................................166
FUEL SYSTEMοΏ½..........................................................................................168
PRECAUTIONSοΏ½......................................................................................168
PRECAUTIONS FOR FUEL SYSTEMοΏ½..................................................................168
GENERAL DESCRIPTIONοΏ½..............................................................................168
I.D. NO. LOCATIONοΏ½............................................................................168
FUEL SYSTEM DESCRIPTIONοΏ½......................................................................169
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................177
CARBURETOR HOSE ROUTING DIAGRAMοΏ½..............................................................177
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................178
CARBURETOR SYMPTOM DIAGNOSISοΏ½.................................................................178
REPAIR INSTRUCTIONSοΏ½..............................................................................179
FUEL TANK CONSTRUCTIONοΏ½.......................................................................179
FUEL TANK REMOVAL AND INSTALLATIONοΏ½...........................................................180
FUEL VALVE REMOVAL AND INSTALLATIONοΏ½..........................................................180
FUEL FILTER INSPECTION AND CLEANINGοΏ½..........................................................181
FUEL LEVEL GAUGE REMOVAL AND INSTALLATIONοΏ½....................................................181
FUEL LEVEL GAUGE INSPECTIONοΏ½..................................................................182
THROTTLE CABLE REMOVAL AND INSTALLATIONοΏ½......................................................182
THROTTLE CABLE INSPECTIONοΏ½....................................................................182
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENTοΏ½................................................182
STARTER CABLE REMOVAL AND INSTALLATIONοΏ½.......................................................182
STARTER CABLE INSPECTIONοΏ½.....................................................................182
STARTER CABLE PLAY INSPECTION AND ADJUSTMENTοΏ½.................................................182
CARBURETOR COMPONENTSοΏ½........................................................................183
CARBURETOR ASSEMBLY REMOVAL AND INSTALLATIONοΏ½.................................................184
CARBURETOR DISASSEMBLYοΏ½.......................................................................184
CARBURETOR ASSEMBLYοΏ½..........................................................................187
FLOAT HEIGHT INSPECTION AND ADJUSTMENTοΏ½.......................................................188
CARBURETOR INSPECTION AND CLEANINGοΏ½...........................................................188
ENGINE IDLE SPEED INSPECTIONοΏ½.................................................................189
FUEL LINE INSPECTIONοΏ½.........................................................................189
AIR CLEANER ELEMENT REMOVAL AND INSTALLATIONοΏ½.................................................189
AIR CLEANER ELEMENT INSPECTION AND CLEANINGοΏ½..................................................189
SPECIFICATIONSοΏ½...................................................................................189
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................189
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................190
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................190
RECOMMENDED SERVICE MATERIALοΏ½.................................................................190
SPECIAL TOOLοΏ½.................................................................................190
IGNITION SYSTEMοΏ½......................................................................................191
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................191
IGNITION SYSTEM DIAGRAMοΏ½......................................................................191
IGNITION SYSTEM COMPONENTS LOCATIONοΏ½..........................................................191
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................191
IGNITION SYSTEM SYMPTOM DIAGNOSISοΏ½............................................................191
NO SPARK OR POOR SPARKοΏ½.......................................................................192
REPAIR INSTRUCTIONSοΏ½..............................................................................193
SPARK PLUG REMOVAL AND INSTALLATIONοΏ½..........................................................193
SPARK PLUG INSPECTION AND CLEANINGοΏ½...........................................................193
IGNITION COIL AND PLUG CAP INSPECTIONοΏ½........................................................193
IGNITION COIL REMOVAL AND INSTALLATIONοΏ½.......................................................195
CKP SENSOR INSPECTIONοΏ½........................................................................195
CKP SENSOR REMOVAL AND INSTALLATIONοΏ½..........................................................196
ENGINE STOP SWITCH INSPECTIONοΏ½................................................................196
IGNITION SWITCH INSPECTIONοΏ½...................................................................196
IGNITION SWITCH REMOVAL AND INSTALLATIONοΏ½.....................................................196
SPECIFICATIONSοΏ½...................................................................................197
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................197
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................197
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................197
SPECIAL TOOLοΏ½.................................................................................197
STARTING SYSTEMοΏ½......................................................................................198
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................198
STARTING SYSTEM DIAGRAMοΏ½......................................................................198
COMPONENT LOCATIONοΏ½...............................................................................198
STARTING SYSTEM COMPONENTS LOCATIONοΏ½..........................................................198
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................198
STARTING SYSTEM SYMPTOM DIAGNOSISοΏ½............................................................198
STARTER MOTOR WILL NOT RUNοΏ½...................................................................199
STARTER MOTOR RUNS BUT DOES NOT CRANK THE ENGINEοΏ½.............................................199
ENGINE DOES NOT TURN THOUGH THE STARTER MOTOR RUNSοΏ½...........................................199
REPAIR INSTRUCTIONSοΏ½..............................................................................200
STARTER MOTOR COMPONENTSοΏ½.....................................................................200
STARTER MOTOR REMOVAL AND INSTALLATIONοΏ½.......................................................200
STARTER MOTOR DISASSEMBLY AND ASSEMBLYοΏ½.......................................................201
STARTER MOTOR INSPECTIONοΏ½.....................................................................201
STARTER RELAY REMOVAL AND INSTALLATIONοΏ½.......................................................202
STARTER RELAY INSPECTIONοΏ½.....................................................................203
NEUTRAL RELAY REMOVAL AND INSTALLATIONοΏ½.......................................................203
NEUTRAL RELAY INSPECTIONοΏ½.....................................................................204
NEUTRAL SWITCH DIODE INSPECTIONοΏ½..............................................................204
IGNITION / STARTER CONTROL RELAY REMOVAL AND INSTALLATIONοΏ½....................................205
IGNITION / STARTER CONTROL RELAY INSPECTIONοΏ½..................................................205
PARKING BRAKE SWITCH INSPECTIONοΏ½..............................................................205
GEAR POSITION SWITCH INSPECTIONοΏ½..............................................................205
STARTER CLUTCH REMOVAL AND INSTALLATIONοΏ½......................................................206
STARTER DRIVEN GEAR BEARING REMOVAL AND INSTALLATIONοΏ½.........................................208
STARTER RELATED PARTS INSPECTIONοΏ½.............................................................208
STARTER BUTTON INSPECTIONοΏ½....................................................................209
RECOIL STARTER COMPONENTSοΏ½....................................................................209
RECOIL STARTER ASSEMBLY REMOVAL AND INSTALLATIONοΏ½.............................................210
RECOIL STARTER DISASSEMBLY AND ASSEMBLYοΏ½......................................................210
RECOIL STARTER INSPECTIONοΏ½....................................................................212
SPECIFICATIONSοΏ½...................................................................................213
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................213
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................213
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................213
RECOMMENDED SERVICE MATERIALοΏ½.................................................................213
SPECIAL TOOLοΏ½.................................................................................214
CHARGING SYSTEMοΏ½......................................................................................215
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................215
CHARGING SYSTEM DIAGRAMοΏ½......................................................................215
COMPONENT LOCATIONοΏ½...............................................................................215
CHARGING SYSTEM COMPONENTS LOCATIONοΏ½..........................................................215
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................215
CHARGING SYSTEM SYMPTOM DIAGNOSISοΏ½............................................................215
BATTERY RUNS DOWN QUICKLYοΏ½....................................................................216
REPAIR INSTRUCTIONSοΏ½..............................................................................217
BATTERY CURRENT LEAKAGE INSPECTIONοΏ½...........................................................217
REGULATED VOLTAGE INSPECTIONοΏ½.................................................................217
GENERATOR INSPECTIONοΏ½.........................................................................218
GENERATOR REMOVAL AND INSTALLATIONοΏ½...........................................................219
REGULATOR / RECTIFIER INSPECTIONοΏ½.............................................................224
BATTERY COMPONENTSοΏ½...........................................................................225
BATTERY CHARGINGοΏ½.............................................................................225
BATTERY REMOVAL AND INSTALLATIONοΏ½.............................................................227
BATTERY VISUAL INSPECTIONοΏ½....................................................................227
SPECIFICATIONSοΏ½...................................................................................228
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................228
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................228
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................228
RECOMMENDED SERVICE MATERIALοΏ½.................................................................228
SPECIAL TOOLοΏ½.................................................................................228
EXHAUST SYSTEMοΏ½.......................................................................................230
PRECAUTIONSοΏ½......................................................................................230
PRECAUTIONS FOR EXHAUST SYSTEMοΏ½...............................................................230
REPAIR INSTRUCTIONSοΏ½..............................................................................230
EXHAUST SYSTEM COMPONENTSοΏ½....................................................................230
MUFFLER / EXHAUST PIPE REMOVAL AND INSTALLATIONοΏ½..............................................231
EXHAUST SYSTEM INSPECTIONοΏ½....................................................................232
SPARK ARRESTER INSPECTIONοΏ½....................................................................232
SPECIFICATIONSοΏ½...................................................................................233
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................233
02 SUSPENSIONοΏ½............................................................................................235
PRECAUTIONSοΏ½..........................................................................................236
PRECAUTIONSοΏ½......................................................................................236
PRECAUTIONS FOR SUSPENSIONοΏ½...................................................................236
SUSPENSION GENERAL DIAGNOSISοΏ½.........................................................................237
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................237
SUSPENSION AND WHEEL SYMPTOM DIAGNOSISοΏ½.......................................................237
FRONT SUSPENSIONοΏ½.....................................................................................238
REPAIR INSTRUCTIONSοΏ½..............................................................................238
FRONT SUSPENSION COMPONENTSοΏ½..................................................................238
FRONT SUSPENSION ASSEMBLY CONSTRUCTIONοΏ½.......................................................239
FRONT SUSPENSION INSPECTIONοΏ½..................................................................240
FRONT SHOCK ABSORBER INSPECTIONοΏ½..............................................................240
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATIONοΏ½................................................240
FRONT WHEEL HUB / STEERING KNUCKLE REMOVAL AND INSTALLATIONοΏ½..................................240
FRONT WHEEL HUB / STEERING KNUCKLE RELATED PARTS INSPECTIONοΏ½..................................243
STEERING KNUCKLE DUST SEAL / FRONT WHEEL HUB BEARING REMOVAL AND INSTALLATIONοΏ½................243
FRONT SUSPENSION UPPER / LOWER ARM REMOVAL AND INSTALLATIONοΏ½..................................245
FRONT SUSPENSION ARM RELATED PARTS INSPECTIONοΏ½................................................246
STEERING KNUCKLE END REMOVAL AND INSTALLATIONοΏ½................................................247
FRONT SUSPENSION UPPER / LOWER ARM BUSHING REMOVAL AND INSTALLATIONοΏ½..........................248
SPECIFICATIONSοΏ½...................................................................................249
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................249
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................249
RECOMMENDED SERVICE MATERIALοΏ½.................................................................249
SPECIAL TOOLοΏ½.................................................................................250
REAR SUSPENSIONοΏ½......................................................................................251
REPAIR INSTRUCTIONSοΏ½..............................................................................251
REAR SUSPENSION COMPONENTSοΏ½...................................................................251
REAR SHOCK ABSORBER REMOVAL AND INSTALLATIONοΏ½.................................................252
REAR SUSPENSION INSPECTIONοΏ½...................................................................252
REAR SHOCK ABSORBER INSPECTIONοΏ½...............................................................252
SWINGARM REMOVAL AND INSTALLATIONοΏ½............................................................252
SWINGARM INSPECTIONοΏ½..........................................................................253
SWINGARM BUSHING REMOVAL AND INSTALLATIONοΏ½....................................................254
SPECIFICATIONSοΏ½...................................................................................254
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................254
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................254
RECOMMENDED SERVICE MATERIALοΏ½.................................................................254
WHEELS AND TIRESοΏ½.....................................................................................255
PRECAUTIONSοΏ½......................................................................................255
PRECAUTIONS FOR WHEEL AND TIREοΏ½...............................................................255
REPAIR INSTRUCTIONSοΏ½..............................................................................256
FRONT AND REAR WHEEL COMPONENTSοΏ½..............................................................256
FRONT / REAR WHEEL REMOVAL AND INSTALLATIONοΏ½..................................................257
TIRE REMOVAL AND INSTALLATIONοΏ½................................................................257
SPECIFICATIONSοΏ½...................................................................................259
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................259
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................259
03 DRIVELINE / AXLEοΏ½......................................................................................261
PRECAUTIONSοΏ½..........................................................................................263
PRECAUTIONSοΏ½......................................................................................263
PRECAUTIONS FOR DRIVELINE / AXLEοΏ½.............................................................263
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFTοΏ½..............................................................264
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................264
DRIVE SHAFT SYMPTOM DIAGNOSISοΏ½................................................................264
REPAIR INSTRUCTIONSοΏ½..............................................................................264
FRONT DRIVE SHAFT COMPONENTS (LT-A400F, LT-F400F)οΏ½............................................264
FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION (LT-A400F, LT-F400F)οΏ½.....................265
FRONT DRIVE SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400F, LT-F400F)οΏ½..............................265
FRONT DRIVE SHAFT INSPECTION (LT-A400F, LT- F400F)οΏ½...........................................268
REAR AXLE COMPONENTSοΏ½.........................................................................269
REAR AXLE CONSTRUCTIONοΏ½.......................................................................270
REAR AXLE / AXLE HOUSING REMOVAL AND INSTALLATIONοΏ½............................................270
REAR AXLE / AXLE HOUSING INSPECTIONοΏ½..........................................................272
REAR AXLE HOUSING DISASSEMBLY AND ASSEMBLYοΏ½...................................................273
SPECIFICATIONSοΏ½...................................................................................274
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................274
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................274
RECOMMENDED SERVICE MATERIALοΏ½.................................................................274
SPECIAL TOOLοΏ½.................................................................................274
DIFFERENTIALοΏ½.........................................................................................276
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................276
DRIVE TRAIN SYMPTOM DIAGNOSISοΏ½................................................................276
REPAIR INSTRUCTIONSοΏ½..............................................................................277
FRONT DRIVE (DIFFERENTIAL) COMPONENTS (LT-A400F, LT-F400F)οΏ½...................................277
FRONT DRIVE (DIFFERENTIAL) CONSTRUCTION (LT-A400F, LT-F400F)οΏ½.................................278
FRONT DRIVE (DIFFERENTIAL) GEAR OIL LEVEL INSPECTION (LT-A400F, LT-F400F)οΏ½....................279
FRONT DRIVE (DIFFERENTIAL) GEAR OIL REPLACEMENT (LT-A400F, LT-F400F)οΏ½.........................279
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY REMOVAL AND INSTALLATION (LT-A400F, LT-F400F)οΏ½............279
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY DISASSEMBLY AND ASSEMBLY (LT-A400F, LT- F400F)οΏ½...........280
FRONT DRIVE (DIFFERENTIAL) RELATED PARTS INSPECTION (LT-A400F, LT-F400F)οΏ½.....................288
UNIVERSAL JOINT BEARING / PINION GEAR PILOT BEARING INSPECTIONοΏ½...............................289
FRONT DRIVE (DIFFERENTIAL) GEAR SHIM INSPECTION AND SELECTION (LT-A400F, LT-F400F)οΏ½...........290
FINAL GEAR COMPONENTSοΏ½........................................................................294
FINAL GEAR CONSTRUCTIONοΏ½......................................................................295
FINAL GEAR OIL LEVEL INSPECTIONοΏ½..............................................................296
FINAL GEAR OIL REPLACEMENTοΏ½...................................................................296
FINAL GEAR ASSEMBLY REMOVAL AND INSTALLATIONοΏ½.................................................296
FINAL GEAR ASSEMBLY DISASSEMBLY AND ASSEMBLYοΏ½.................................................298
FINAL GEAR RELATED PARTS INSPECTIONοΏ½..........................................................303
FINAL GEAR BACKLASH INSPECTION AND SHIM ADJUSTMENTοΏ½...........................................305
TRANSFER CABLE INSPECTION AND ADJUSTMENT (LT- A400F, LT-F400F)οΏ½...............................308
TRANSFER CABLE REMOVAL AND INSTALLATION (LT- A400F, LT-F400F)οΏ½................................308
SPECIFICATIONSοΏ½...................................................................................309
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................309
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................309
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................310
RECOMMENDED SERVICE MATERIALοΏ½.................................................................310
SPECIAL TOOLοΏ½.................................................................................310
TRANSFERοΏ½.............................................................................................312
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................312
TRANSFER SYMPTOM DIAGNOSIS (LT-A400/F)οΏ½.......................................................312
TRANSFER SYMPTOM DIAGNOSIS (LT-F400/F)οΏ½.......................................................312
REPAIR INSTRUCTIONSοΏ½..............................................................................313
TRANSFER COMPONENTS (LT-A400/F)οΏ½..............................................................313
TRANSFER COMPONENTS (LT-F400/F)οΏ½..............................................................314
TRANSFER REMOVAL AND INSTALLATION (LT-A400/F)οΏ½................................................315
TRANSFER REMOVAL AND INSTALLATION (LT-F400/F)οΏ½................................................318
TRANSFER CONSTRUCTION (LT-A400/F)οΏ½............................................................319
TRANSFER DISASSEMBLY AND ASSEMBLY (LT-A400/ F)οΏ½...............................................320
TRANSFER IDLE GEAR BEARING REMOVAL AND INSTALLATION (LT-F400/F)οΏ½..............................320
TRANSFER GEARSHIFT CAM COMPONENTS (LT-A400/F)οΏ½................................................321
TRANSFER GEARSHIFT CAM COMPONENTS (LT-F400/F)οΏ½................................................322
GEARSHIFT SYSTEM CONSTRUCTION (LT-A400/F)οΏ½....................................................323
GEARSHIFT SYSTEM CONSTRUCTION (LT-F400/F)οΏ½....................................................323
TRANSFER GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-A400/F)οΏ½..................................324
TRANSFER GEARSHIFT SHAFT NO.1 BEARING INSPECTION (LT-A400/F)οΏ½.................................324
TRANSFER GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-F400/F)οΏ½..................................325
TRANSFER RELATED PARTS INSPECTION (LT-A400/F)οΏ½................................................326
TRANSFER RELATED PARTS INSPECTION (LT-F400/F)οΏ½................................................326
GEAR POSITION (GP) SWITCH INSPECTIONοΏ½.........................................................327
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-A400/F)οΏ½...............................327
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-F400/F)οΏ½...............................328
TRANSFER GEARSHIFT SHAFT NO. 2 / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION (LT-A400/F)οΏ½....328
GEARSHIFT LINKAGE INSPECTION (LT-A400/F)οΏ½.....................................................330
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION (LT-A400/F)οΏ½................................330
TRANSFER RANGE LEVER COMPONENTS (LT-A400/F)οΏ½..................................................331
TRANSFER RANGE LEVER COMPONENTS (LT-F400/F)οΏ½..................................................331
TRANSFER RANGE LEVER REMOVAL AND INSTALLATIONοΏ½................................................331
TRANSFER RANGE LEVER DISASSEMBLY AND ASSEMBLYοΏ½................................................332
SHIFT ROD LENGTH ADJUSTMENTοΏ½..................................................................332
REVERSE SWITCH INSPECTION (LT-F400/F)οΏ½........................................................332
SPECIFICATIONSοΏ½...................................................................................333
SERVICE DATA (LT-A400/F)οΏ½.....................................................................333
SERVICE DATA (LT-F400/F)οΏ½.....................................................................333
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................334
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................334
RECOMMENDED SERVICE MATERIALοΏ½.................................................................334
SPECIAL TOOLοΏ½.................................................................................334
PROPELLER SHAFTSοΏ½.....................................................................................335
REPAIR INSTRUCTIONSοΏ½..............................................................................335
FRONT OUTPUT SHAFT COMPONENTSοΏ½................................................................335
OUTPUT SHAFT REMOVAL AND INSTALLATIONοΏ½........................................................337
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400/F)οΏ½.......................................338
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-F400/F)οΏ½.......................................341
FRONT OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY (LT-A400F, LT-F400F)οΏ½.............................344
REAR OUTPUT SHAFT RELATED PARTS INSPECTIONοΏ½...................................................345
FRONT OUTPUT SHAFT RELATED PARTS INSPECTION (LT- A400F, LT-F400F)οΏ½............................347
DRIVE BEVEL GEAR REMOVAL AND INSTALLATION (LT- A400/F)οΏ½.......................................347
DRIVE BEVEL GEAR REMOVAL AND INSTALLATION (LT- F400/F)οΏ½.......................................349
DRIVEN AND DRIVE BEVEL GEAR SHIM INSPECTION AND ADJUSTMENTοΏ½...................................350
DRIVEN AND DRIVE BEVEL GEAR SHIM ADJUSTMENT INFORMATIONοΏ½......................................354
SPECIFICATIONSοΏ½...................................................................................356
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................356
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................356
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................356
RECOMMENDED SERVICE MATERIALοΏ½.................................................................356
SPECIAL TOOLοΏ½.................................................................................356
04 BRAKEοΏ½.................................................................................................359
PRECAUTIONSοΏ½..........................................................................................361
PRECAUTIONSοΏ½......................................................................................361
PRECAUTIONS FOR BRAKE SYSTEMοΏ½.................................................................361
BRAKE FLUID INFORMATIONοΏ½......................................................................361
BRAKE CONTROL SYSTEM AND DIAGNOSISοΏ½...................................................................362
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................362
FRONT BRAKE HOSE ROUTING DIAGRAMοΏ½.............................................................362
BRAKE CABLE ROUTING DIAGRAMοΏ½..................................................................363
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................364
BRAKE SYMPTOM DIAGNOSISοΏ½......................................................................364
REPAIR INSTRUCTIONSοΏ½..............................................................................364
BRAKE PEDAL ADJUSTMENTοΏ½.......................................................................364
FRONT BRAKE LIGHT SWITCH INSPECTIONοΏ½..........................................................364
REAR BRAKE LIGHT SWITCH INSPECTIONοΏ½...........................................................365
REAR BRAKE LIGHT SWITCH INSPECTION AND ADJUSTMENTοΏ½............................................365
PARKING / REAR BRAKE LIGHT SWITCH INSPECTIONοΏ½.................................................366
PARKING BRAKE SWITCH INSPECTIONοΏ½..............................................................366
BRAKE FLUID LEVEL CHECKοΏ½......................................................................366
FRONT BRAKE HOSE INSPECTIONοΏ½..................................................................366
AIR BLEEDING FROM FRONT BRAKE FLUID CIRCUITοΏ½..................................................366
BRAKE FLUID REPLACEMENTοΏ½......................................................................367
FRONT BRAKE HOSE REMOVAL AND INSTALLATIONοΏ½....................................................368
REAR BRAKE CABLE REMOVAL AND INSTALLATIONοΏ½....................................................368
FRONT BRAKE MASTER CYLINDER COMPONENTSοΏ½.......................................................369
FRONT BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATIONοΏ½................................369
FRONT BRAKE MASTER CYLINDER / BRAKE LEVER DISASSEMBLY AND ASSEMBLYοΏ½...........................371
FRONT BRAKE MASTER CYLINDER PARTS INSPECTIONοΏ½.................................................372
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATIONοΏ½..........................................372
REAR BRAKE PEDAL CONSTRUCTIONοΏ½................................................................373
REAR BRAKE PEDAL REMOVAL AND INSTALLATIONοΏ½....................................................373
SPECIFICATIONSοΏ½...................................................................................374
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................374
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................375
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................375
RECOMMENDED SERVICE MATERIALοΏ½.................................................................375
SPECIAL TOOLοΏ½.................................................................................375
FRONT BRAKESοΏ½.........................................................................................376
PRECAUTIONSοΏ½......................................................................................376
PRECAUTIONS FOR FRONT BRAKESοΏ½.................................................................376
REPAIR INSTRUCTIONSοΏ½..............................................................................376
FRONT BRAKE COMPONENTSοΏ½.......................................................................376
FRONT BRAKE PAD INSPECTIONοΏ½...................................................................377
FRONT BRAKE PAD REPLACEMENTοΏ½..................................................................377
FRONT BRAKE CALIPER REMOVAL AND INSTALLATIONοΏ½.................................................378
FRONT BRAKE CALIPER DISASSEMBLY AND ASSEMBLYοΏ½.................................................379
FRONT BRAKE CALIPER PARTS INSPECTIONοΏ½.........................................................381
FRONT BRAKE DISC REMOVAL AND INSTALLATIONοΏ½....................................................382
FRONT BRAKE DISC INSPECTIONοΏ½..................................................................383
SPECIFICATIONSοΏ½...................................................................................383
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................383
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................384
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................384
RECOMMENDED SERVICE MATERIALοΏ½.................................................................384
SPECIAL TOOLοΏ½.................................................................................384
REAR BRAKESοΏ½..........................................................................................385
PRECAUTIONSοΏ½......................................................................................385
PRECAUTIONS FOR REAR BRAKEοΏ½...................................................................385
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................385
REAR BRAKE BREATHER HOSE ROUTING DIAGRAMοΏ½.....................................................385
REPAIR INSTRUCTIONSοΏ½..............................................................................386
REAR BRAKE COMPONENTSοΏ½........................................................................386
REAR BRAKE CONSTRUCTIONοΏ½......................................................................387
REAR BRAKE SHOE INSPECTIONοΏ½...................................................................387
REAR BRAKE DISASSEMBLY AND ASSEMBLYοΏ½..........................................................387
REAR BRAKE RELATED PARTS INSPECTIONοΏ½..........................................................392
SPECIFICATIONSοΏ½...................................................................................393
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................393
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................393
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................394
RECOMMENDED SERVICE MATERIALοΏ½.................................................................394
PARKING BRAKEοΏ½........................................................................................395
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................395
PARKING / REAR BRAKE CABLE ROUTING DIAGRAMοΏ½...................................................395
REPAIR INSTRUCTIONSοΏ½..............................................................................395
PARKING / REAR BRAKE LEVER COMPONENTSοΏ½........................................................395
PARKING / REAR BRAKE LIGHT SWITCH INSPECTIONοΏ½.................................................395
PARKING BRAKE SWITCH INSPECTIONοΏ½..............................................................395
IGNITION / STARTER CONTROL RELAY (PARKING BRAKE RELAY) INSPECTIONοΏ½............................395
PARKING / REAR BRAKE LEVER INSPECTION AND ADJUSTMENTοΏ½.........................................395
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATIONοΏ½..........................................396
PARKING / REAR BRAKE CABLE REMOVAL AND INSTALLATIONοΏ½..........................................397
SPECIFICATIONSοΏ½...................................................................................397
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................397
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................397
RECOMMENDED SERVICE MATERIALοΏ½.................................................................397
05 TRANSMISSION / TRANSAXLEοΏ½..............................................................................399
PRECAUTIONSοΏ½..........................................................................................401
PRECAUTIONSοΏ½......................................................................................401
PRECAUTIONS FOR TRANSMISSION / TRANSAXLEοΏ½.....................................................401
AUTOMATIC TRANSMISSIONοΏ½...............................................................................402
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................402
DRIVE TRAIN OPERATION (LT-A400/F)οΏ½............................................................402
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................405
AUTOMATIC TRANSMISSION SYMPTOM DIAGNOSISοΏ½.....................................................405
REPAIR INSTRUCTIONSοΏ½..............................................................................406
AUTOMATIC TRANSMISSION COMPONENTSοΏ½............................................................406
V-BELT COOLING DUCT CONSTRUCTIONοΏ½.............................................................407
V-BELT COOLING DUCT REMOVAL AND INSTALLATION (LT-A400/F)οΏ½.....................................407
CLUTCH ENGAGEMENT AND LOCK-UP SPEED INSPECTIONοΏ½...............................................408
V-BELT TYPE CONTINUOUSLY VARIABLE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATIONοΏ½............408
MOVABLE DRIVE FACE DISASSEMBLY AND ASSEMBLYοΏ½..................................................411
MOVABLE DRIVEN FACE DISASSEMBLY AND ASSEMBLYοΏ½.................................................412
DRIVE V-BELT INSPECTIONοΏ½......................................................................416
MOVABLE / FIXED DRIVE FACE PARTS INSPECTIONοΏ½..................................................416
MOVABLE / FIXED DRIVEN FACE PARTS INSPECTIONοΏ½.................................................417
CLUTCH SHOE REMOVAL AND INSTALLATIONοΏ½.........................................................417
V-BELT OUTER COVER BEARING REMOVAL AND INSTALLATIONοΏ½..........................................419
V-BELT INNER COVER DISASSEMBLY AND ASSEMBLYοΏ½..................................................420
CLUTCH RELATED PARTS INSPECTIONοΏ½..............................................................422
SPECIFICATIONSοΏ½...................................................................................423
SERVICE DATA (LT-A400/F)οΏ½.....................................................................423
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................424
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................424
RECOMMENDED SERVICE MATERIALοΏ½.................................................................424
SPECIAL TOOLοΏ½.................................................................................425
MANUAL TRANSMISSIONοΏ½..................................................................................426
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................426
MANUAL TRANSMISSION SYMPTOM DIAGNOSIS (LT-F400/F)οΏ½............................................426
REPAIR INSTRUCTIONSοΏ½..............................................................................427
TRANSMISSION COMPONENTS (LT-F400/F)οΏ½..........................................................427
TRANSMISSION REMOVAL AND INSTALLATION (LT- F400/F)οΏ½...........................................428
TRANSMISSION CONSTRUCTIONοΏ½....................................................................429
COUNTERSHAFT GEAR / DRIVESHAFT GEAR DISASSEMBLY AND ASSEMBLY (LT-F400/F)οΏ½.....................430
TRANSMISSION REVERSE GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY (LT-F400/F)οΏ½......................431
TRANSMISSION RELATED PARTS INSPECTION (LT- F400/F)οΏ½...........................................432
GEAR POSITION (GP) SWITCH INSPECTION (LT-F400/ F)οΏ½............................................432
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-F400/F)οΏ½...............................432
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION (LT-A400/F)οΏ½...............................433
GEARSHIFT LEVER REMOVAL AND INSTALLATION (LT- F400/F)οΏ½........................................433
GEARSHIFT LEVER HEIGHT INSPECTION AND ADJUSTMENT (LT-F400/F)οΏ½.................................434
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE COMPONENTS (LT-F400/F)οΏ½.................................435
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION (LT-F400/F)οΏ½...................436
GEARSHIFT LINKAGE INSPECTION (LT-F400/F)οΏ½.....................................................437
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION (LT-A400/F)οΏ½................................438
SPECIFICATIONSοΏ½...................................................................................438
SERVICE DATA (LT-F400/F)οΏ½.....................................................................438
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................439
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................439
RECOMMENDED SERVICE MATERIALοΏ½.................................................................439
SPECIAL TOOLοΏ½.................................................................................439
CLUTCHοΏ½...............................................................................................440
PRECAUTIONSοΏ½......................................................................................440
PRECAUTIONS FOR CLUTCH SYSTEMοΏ½................................................................440
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................440
CLUTCH SYSTEM SYMPTOM DIAGNOSISοΏ½..............................................................440
REPAIR INSTRUCTIONSοΏ½..............................................................................441
CLUTCH COMPONENTS (LT-F400/F)οΏ½................................................................441
CLUTCH REMOVAL AND INSTALLATION (LT-F400/F)οΏ½..................................................442
CLUTCH RELATED PARTS INSPECTION (LT-F400/F)οΏ½..................................................445
CLUTCH COVER DISASSEMBLY AND ASSEMBLY (LT- F400/F)οΏ½...........................................447
CLUTCH RELEASE ROLLER INSPECTION (LT-F400/F)οΏ½.................................................449
SPECIFICATIONSοΏ½...................................................................................449
SERVICE DATA (LT-F400/F)οΏ½.....................................................................449
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................449
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................450
RECOMMENDED SERVICE MATERIALοΏ½.................................................................450
SPECIAL TOOLοΏ½.................................................................................450
06 STEERINGοΏ½..............................................................................................451
PRECAUTIONSοΏ½..........................................................................................452
PRECAUTIONSοΏ½......................................................................................452
PRECAUTIONS FOR STEERINGοΏ½.....................................................................452
STEERING GENERAL DIAGNOSISοΏ½...........................................................................453
DIAGNOSTIC INFORMATION AND PROCEDURESοΏ½............................................................453
STEERING SYMPTOM DIAGNOSISοΏ½...................................................................453
STEERING / HANDLEBARοΏ½.................................................................................454
REPAIR INSTRUCTIONSοΏ½..............................................................................454
STEERING / HANDLEBARS COMPONENTSοΏ½.............................................................454
STEERING ASSEMBLY CONSTRUCTIONοΏ½...............................................................455
HANDLEBARS REMOVAL AND INSTALLATIONοΏ½..........................................................456
HANDLEBARS INSPECTIONοΏ½........................................................................458
STEERING SHAFT / TIE-ROD REMOVAL AND INSTALLATIONοΏ½............................................458
STEERING PARTS INSPECTIONοΏ½....................................................................463
SPECIFICATIONSοΏ½...................................................................................464
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................464
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................464
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................465
RECOMMENDED SERVICE MATERIALοΏ½.................................................................465
SPECIAL TOOLοΏ½.................................................................................465
09 BODY AND ACCESSORIESοΏ½..................................................................................467
PRECAUTIONSοΏ½..........................................................................................468
PRECAUTIONSοΏ½......................................................................................468
PRECAUTIONS FOR ELECTRICAL SYSTEMοΏ½............................................................468
COMPONENT LOCATIONοΏ½...............................................................................468
ELECTRICAL COMPONENTS LOCATIONοΏ½...............................................................468
WIRING SYSTEMSοΏ½.......................................................................................469
SCHEMATIC AND ROUTING DIAGRAMοΏ½....................................................................469
WIRING DIAGRAMοΏ½...............................................................................469
WIRING HARNESS ROUTING DIAGRAMοΏ½...............................................................476
SPECIFICATIONSοΏ½...................................................................................478
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................478
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................478
LIGHTING SYSTEMSοΏ½.....................................................................................479
REPAIR INSTRUCTIONSοΏ½..............................................................................479
HEADLIGHT CONSTRUCTIONοΏ½.......................................................................479
FRONT SIDE REFLECTOR CONSTRUCTIONοΏ½............................................................480
HEADLIGHT COMPONENTSοΏ½.........................................................................481
HEADLIGHT REMOVAL AND INSTALLATIONοΏ½...........................................................481
HEADLIGHT BULB REPLACEMENTοΏ½...................................................................482
HEADLIGHT BEAM ADJUSTMENTοΏ½....................................................................482
REAR COMBINATION LIGHT COMPONENTSοΏ½............................................................483
REAR COMBINATION LIGHT REMOVAL AND INSTALLATIONοΏ½..............................................483
REAR COMBINATION LIGHT BULB REPLACEMENTοΏ½......................................................484
REVERSING LIGHT BULB REPLACEMENT (FOR P-17)οΏ½..................................................484
REVERSING LIGHT RELAY INSPECTION (FOR P-17)οΏ½..................................................484
DIMMER SWITCH INSPECTIONοΏ½.....................................................................485
SPECIFICATIONSοΏ½...................................................................................485
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................485
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................485
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................485
SPECIAL TOOLοΏ½.................................................................................485
COMBINATION METER / FUEL METER / HORNοΏ½................................................................486
REPAIR INSTRUCTIONSοΏ½..............................................................................486
SPEEDOMETER COMPONENTSοΏ½.......................................................................486
SPEEDOMETER REMOVAL AND INSTALLATIONοΏ½.........................................................487
SPEEDOMETER DISASSEMBLY AND ASSEMBLYοΏ½.........................................................488
SPEEDOMETER LIGHT BULB / INDICATOR LIGHT BULB REPLACEMENTοΏ½....................................488
IGNITION SWITCH INSPECTIONοΏ½...................................................................488
IGNITION SWITCH REMOVAL AND INSTALLATIONοΏ½.....................................................488
HORN INSPECTION (FOR P-17, 24)οΏ½...............................................................489
HORN REMOVAL AND INSTALLATION (FOR P-17, 24)οΏ½.................................................489
SPECIFICATIONSοΏ½...................................................................................489
SERVICE DATA (LT-A400/F, LT-F400/F)οΏ½..........................................................489
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................489
SPECIAL TOOLοΏ½.................................................................................489
EXTERIOR PARTSοΏ½.......................................................................................490
REPAIR INSTRUCTIONSοΏ½..............................................................................490
REAR FENDER HEAT SHIELD CONSTRUCTIONοΏ½.........................................................490
FASTENER REMOVAL AND INSTALLATIONοΏ½............................................................491
EXTERIOR PARTS REMOVAL AND INSTALLATIONοΏ½......................................................492
BODY STRUCTUREοΏ½.......................................................................................496
REPAIR INSTRUCTIONSοΏ½..............................................................................496
BODY FRAME CONSTRUCTIONοΏ½......................................................................496
FOOTREST CONSTRUCTIONοΏ½........................................................................496
FOOTREST REMOVAL AND INSTALLATIONοΏ½............................................................497
CARRIER CONSTRUCTIONοΏ½.........................................................................498
FRONT CARRIER REMOVAL AND INSTALLATIONοΏ½.......................................................499
REAR CARRIER REMOVAL AND INSTALLATIONοΏ½........................................................499
FRONT GRIP BAR CONSTRUCTIONοΏ½..................................................................500
FRONT GRIP BAR REMOVAL AND INSTALLATIONοΏ½......................................................500
TRAILER TOWING REMOVAL AND INSTRUCTIONοΏ½.......................................................501
SPECIFICATIONSοΏ½...................................................................................502
TIGHTENING TORQUE SPECIFICATIONSοΏ½.............................................................502
SPECIAL TOOLS AND EQUIPMENTοΏ½......................................................................502
RECOMMENDED SERVICE MATERIALοΏ½.................................................................502
10 LT-A400F / LT-F400F K9 ('09 MODELS)οΏ½...................................................................503
SPECIFICATIONS (FOR LT-A400/F)οΏ½.......................................................................505
SPECIFICATIONS (FOR LT-F400/F)οΏ½.......................................................................504
SERVICE DATA (FOR LT-A400/F)οΏ½.........................................................................506
SERVICE DATA (FOR LT-F400/F)οΏ½.........................................................................511
FRONT SUSPENSIONοΏ½.....................................................................................516S.S 31/03/2025
