2009 Suzuki 400 LTZ Quad Sport Service Manual
Download the factory repair manual for the 2009 Suzuki 400 LTZ Quad Sport Service Manual.
Manual covers complete tear down and rebuild, pictures and part diagrams, torque specs, maintenance, troubleshooting, etc.
Part number: 99500-43080-03E
Manual chapters:
- PRECAUTIONS
- GENERAL INFORMATION
- ENGINE
- SUSPENSION
- DRIVELINE / AXLE
- BRAKE
- TRANSMISSION / TRANSAXLE
- STEERING
- BODY AND ACCESSORIES
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Full list of manual chapters:
FOREWORD
TABLE OF CONTENTS�
00 PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS�
WARNING / CAUTION / NOTE�
GENERAL PRECAUTIONS�
PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE�
0 GENERAL INFORMATION�
GENERAL INFORMATION�
GENERAL DESCRIPTION�
SYMBOLS�
ABBREVIATIONS�
SAE-TO-FORMER SUZUKI TERM�
VEHICLE SIDE VIEW�
VEHICLE IDENTIFICATION NUMBER�
FUEL AND OIL RECOMMENDATION�
ENGINE COOLANT RECOMMENDATION�
BREAK-IN PROCEDURES�
COUNTRY AND AREA CODES�
WIRE COLOR SYMBOLS�
WARNING, CAUTION AND INFORMATION LABELS LOCATION�
COMPONENT LOCATION�
ELECTRICAL COMPONENTS LOCATION�
SPECIFICATIONS�
SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
MAINTENANCE AND LUBRICATION�
PRECAUTIONS�
PRECAUTIONS FOR MAINTENANCE�
GENERAL DESCRIPTION�
RECOMMENDED FLUIDS AND LUBRICANTS�
SCHEDULED MAINTENANCE�
PERIODIC MAINTENANCE SCHEDULE CHART�
LUBRICATION POINTS�
REPAIR INSTRUCTIONS�
AIR CLEANER ELEMENT CLEANING�
EXHAUST PIPE NUTS AND MUFFLER BOLT INSPECTION�
VALVE CLEARANCE INSPECTION AND ADJUSTMENT�
SPARK PLUG REPLACEMENT�
SPARK PLUG INSPECTION AND CLEANING�
SPARK ARRESTER CLEANING�
ENGINE IDLE SPEED INSPECTION AND ADJUSTMENT�
THROTTLE BODY INSPECTION�
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT�
FUEL LINE REPLACEMENT�
FUEL LINE INSPECTION�
ENGINE OIL AND FILTER REPLACEMENT�
ENGINE OIL HOSES INSPECTION�
CLUTCH INSPECTION AND ADJUSTMENT�
COOLING SYSTEM INSPECTION�
DRIVE CHAIN INSPECTION AND ADJUSTMENT�
BRAKE SYSTEM INSPECTION�
TIRE INSPECTION�
FRONT AND REAR WHEEL SET NUTS INSPECTION�
REAR AXLE NUT AND LOCK-NUT INSPECTION�
SUSPENSIONS INSPECTION�
STEERING SYSTEM INSPECTION�
CHASSIS BOLTS AND NUTS INSPECTION�
COMPRESSION PRESSURE CHECK�
OIL PRESSURE CHECK�
SDS CHECK�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
SERVICE DATA�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
01 ENGINE�
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR ENGINE�
ENGINE GENERAL INFORMATION AND DIAGNOSIS�
GENERAL DESCRIPTION�
INJECTION TIMING DESCRIPTION�
SCHEMATIC AND ROUTING DIAGRAM�
FI SYSTEM WIRING DIAGRAM�
TERMINAL ALIGNMENT OF ECM COUPLER�
COMPONENT LOCATION�
FI SYSTEM PARTS LOCATION�
DIAGNOSTIC INFORMATION AND PROCEDURES�
ENGINE SYMPTOM DIAGNOSIS�
SELF-DIAGNOSTIC PROCEDURES�
USE OF SDS DIAGNOSIS RESET PROCEDURES�
SHOW DATA WHEN TROUBLE (DISPLAYING DATA AT THE TIME OF DTC)�
SDS CHECK�
DTC TABLE�
FAIL-SAFE FUNCTION TABLE�
FI SYSTEM TROUBLESHOOTING�
MALFUNCTION CODE AND DEFECTIVE CONDITION TABLE�
DTC "C12" (P0335): CKP SENSOR CIRCUIT MALFUNCTION�
DTC "C14" (P0120-H/L): TP SENSOR CIRCUIT MALFUNCTION�
DTC "C15" (P0115-H/L): ECT SENSOR CIRCUIT MALFUNCTION�
DTC "C17" (P1750-H/L): IAP SENSOR CIRCUIT MALFUNCTION�
DTC "C21" (P0110-H/L): IAT SENSOR CIRCUIT MALFUNCTION�
DTC "C23" (P1651-H/L): TO SENSOR CIRCUIT MALFUNCTION�
DTC "C24" (P0351): IGNITION COIL CIRCUIT MALFUNCTION�
DTC "C31" (P0705): GP SWITCH CIRCUIT MALFUNCTION�
DTC "C32" (P0201): FUEL INJECTOR CIRCUIT MALFUNCTION�
DTC "C41" (P0230): FP RELAY CIRCUIT MALFUNCTION�
DTC "C60" (P0480): COOLING FAN RELAY CIRCUIT MALFUNCTION�
SPECIFICATIONS�
SERVICE DATA�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
EMISSION CONTROL DEVICES�
PRECAUTIONS�
PRECAUTIONS FOR EMISSION CONTROL DEVICES�
SCHEMATIC AND ROUTING DIAGRAM�
OIL RETURN TANK HOSE ROUTING DIAGRAM�
REPAIR INSTRUCTIONS�
CRANKCASE BREATHER (PCV) HOSE INSPECTION�
CRANKCASE BREATHER (PCV) HOSE REMOVAL AND INSTALLATION�
OIL RETURN TANK REMOVAL AND INSTALLATION�
OIL RETURN TANK INSPECTION�
ENGINE ELECTRICAL DEVICES�
PRECAUTIONS�
PRECAUTIONS FOR ENGINE ELECTRICAL DEVICE�
COMPONENT LOCATION�
ENGINE ELECTRICAL COMPONENTS LOCATION�
DIAGNOSTIC INFORMATION AND PROCEDURES�
ENGINE SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
ECM REMOVAL AND INSTALLATION�
CKP SENSOR INSPECTION�
CKP SENSOR REMOVAL AND INSTALLATION�
IAP SENSOR INSPECTION�
IAP SENSOR REMOVAL AND INSTALLATION�
TP SENSOR INSPECTION�
TP SENSOR REMOVAL AND INSTALLATION�
TP SENSOR ADJUSTMENT�
IAT SENSOR INSPECTION�
IAT SENSOR REMOVAL AND INSTALLATION�
ECT SENSOR REMOVAL AND INSTALLATION�
ECT SENSOR INSPECTION�
TO SENSOR INSPECTION�
TO SENSOR REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
ENGINE MECHANICAL�
DIAGNOSTIC INFORMATION AND PROCEDURES�
ENGINE MECHANICAL SYMPTOM DIAGNOSIS�
COMPRESSION PRESSURE CHECK�
REPAIR INSTRUCTIONS�
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE�
AIR CLEANER ELEMENT REMOVAL AND INSTALLATION�
AIR CLEANER ELEMENT CLEANING�
AIR CLEANER BOX REMOVAL AND INSTALLATION�
THROTTLE CABLE REMOVAL AND INSTALLATION�
THROTTLE CABLE INSPECTION�
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT�
STARTER CABLE REMOVAL AND INSTALLATION�
THROTTLE BODY COMPONENTS�
THROTTLE BODY CONSTRUCTION�
THROTTLE BODY INSPECTION�
THROTTLE BODY REMOVAL AND INSTALLATION�
THROTTLE BODY DISASSEMBLY AND ASSEMBLY�
THROTTLE BODY INSPECTION AND CLEANING�
ENGINE ASSEMBLY REMOVAL�
ENGINE ASSEMBLY INSTALLATION�
ENGINE TOP SIDE DISASSEMBLY�
ENGINE TOP SIDE ASSEMBLY�
VALVE CLEARANCE INSPECTION AND ADJUSTMENT�
CAMSHAFT INSPECTION�
CAM CHAIN TENSION ADJUSTER INSPECTION�
CAM CHAIN GUIDE REMOVAL AND INSTALLATION�
CAM CHAIN GUIDE INSPECTION�
CAM CHAIN TENSIONER INSPECTION�
CYLINDER HEAD DISASSEMBLY AND ASSEMBLY�
CYLINDER HEAD RELATED PARTS INSPECTION�
VALVE GUIDE REPLACEMENT�
VALVE SEAT REPAIR�
CYLINDER INSPECTION�
PISTON RING REMOVAL AND INSTALLATION�
PISTON AND PISTON RING INSPECTION�
ENGINE BOTTOM SIDE DISASSEMBLY�
ENGINE BOTTOM SIDE ASSEMBLY�
OIL SUMP FILTER INSPECTION�
OIL PUMP INSPECTION�
GEARSHIFT SHAFT INSPECTION�
CONROD AND CRANKSHAFT INSPECTION�
BALANCER SHAFT INSPECTION�
CRANKSHAFT BEARING / BALANCER SHAFT BEARING INSPECTION�
CRANKSHAFT BEARING / BALANCER SHAFT BEARING REMOVAL AND INSTALLATION�
CRANKSHAFT OIL SEAL INSPECTION�
CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION�
CLUTCH RELEASE CAMSHAFT REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
ENGINE LUBRICATION SYSTEM�
PRECAUTIONS�
PRECAUTIONS FOR ENGINE OIL�
SCHEMATIC AND ROUTING DIAGRAM�
ENGINE OIL HOSE AND PIPE ROUTING DIAGRAM�
ENGINE LUBRICATION SYSTEM CHART DIAGRAM�
DIAGNOSTIC INFORMATION AND PROCEDURES�
ENGINE LUBRICATION SYMPTOM DIAGNOSIS�
OIL PRESSURE CHECK�
REPAIR INSTRUCTIONS�
ENGINE OIL AND FILTER REPLACEMENT�
ENGINE OIL LEVEL INSPECTION�
OIL SUMP FILTER REMOVAL AND INSTALLATION�
OIL SUMP FILTER INSPECTION AND CLEANING�
OIL PUMP COMPONENTS�
OIL PUMP REMOVAL AND INSTALLATION�
OIL PUMP INSPECTION�
ENGINE OIL HOSE AND PIPE CONSTRUCTION�
OIL TANK INSPECTION�
ENGINE OIL PIPE REMOVAL AND INSTALLATION�
OIL TANK REMOVAL AND INSTALLATION�
OIL PIPE REMOVAL AND INSTALLATION�
OIL PIPE INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
ENGINE COOLING SYSTEM�
PRECAUTIONS�
PRECAUTIONS FOR ENGINE COOLING SYSTEM�
PRECAUTIONS FOR ENGINE COOLANT�
GENERAL DESCRIPTION�
ENGINE COOLANT DESCRIPTION�
SCHEMATIC AND ROUTING DIAGRAM�
COOLING CIRCUIT DIAGRAM�
WATER HOSE ROUTING DIAGRAM�
DIAGNOSTIC INFORMATION AND PROCEDURES�
ENGINE COOLING SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
COOLING CIRCUIT INSPECTION�
RADIATOR CAP INSPECTION�
RADIATOR INSPECTION AND CLEANING�
RADIATOR REMOVAL AND INSTALLATION�
COOLING FAN MOTOR REMOVAL AND INSTALLATION�
WATER HOSE INSPECTION�
RADIATOR COVER REMOVAL AND INSTALLATION�
WATER HOSE REMOVAL AND INSTALLATION�
RADIATOR RESERVOIR TANK INSPECTION�
RADIATOR RESERVOIR TANK REMOVAL AND INSTALLATION�
COOLING FAN INSPECTION�
COOLING FAN RELAY INSPECTION�
ECT SENSOR REMOVAL AND INSTALLATION�
ECT SENSOR INSPECTION�
ENGINE COOLANT TEMPERATURE INDICATOR INSPECTION�
THERMOSTAT REMOVAL AND INSTALLATION�
THERMOSTAT INSPECTION�
WATER PUMP COMPONENTS�
WATER PUMP REMOVAL AND INSTALLATION�
WATER PUMP DISASSEMBLY AND ASSEMBLY�
WATER PUMP RELATED PARTS INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
FUEL SYSTEM�
PRECAUTIONS�
PRECAUTIONS FOR FUEL SYSTEM�
GENERAL DESCRIPTION�
FUEL SYSTEM DESCRIPTION�
SCHEMATIC AND ROUTING DIAGRAM�
FUEL HOSE ROUTING DIAGRAM�
DIAGNOSTIC INFORMATION AND PROCEDURES�
FUEL SYSTEM DIAGNOSIS�
REPAIR INSTRUCTIONS�
FUEL PRESSURE INSPECTION�
FUEL PUMP INSPECTION�
FUEL DISCHARGE AMOUNT INSPECTION�
FUEL PUMP RELAY INSPECTION�
FUEL HOSE INSPECTION�
FUEL LEVEL INDICATOR INSPECTION�
FUEL LEVEL INDICATOR SWITCH (THERMISTOR) INSPECTION�
FUEL LEVEL GAUGE REMOVAL AND INSTALLATION�
FUEL TANK CONSTRUCTION�
FUEL TANK REMOVAL AND INSTALLATION�
FUEL VALVE REMOVAL AND INSTALLATION�
FUEL FILTER INSPECTION AND CLEANING�
FUEL INJECTOR INSPECTION AND CLEANING�
FUEL INJECTOR / FUEL DELIVERY PIPE / L-JOINT REMOVAL AND INSTALLATION�
FUEL PUMP REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
IGNITION SYSTEM�
SCHEMATIC AND ROUTING DIAGRAM�
IGNITION SYSTEM DIAGRAM�
IGNITION SYSTEM COMPONENTS LOCATION�
DIAGNOSTIC INFORMATION AND PROCEDURES�
IGNITION SYSTEM SYMPTOM DIAGNOSIS�
NO SPARK OR POOR SPARK�
REPAIR INSTRUCTIONS�
SPARK PLUG CAP AND SPARK PLUG REMOVAL AND INSTALLATION�
SPARK PLUG INSPECTION AND CLEANING�
IGNITION COIL AND PLUG CAP INSPECTION�
CKP SENSOR INSPECTION�
CKP SENSOR REMOVAL AND INSTALLATION�
ENGINE STOP SWITCH INSPECTION�
IGNITION SWITCH INSPECTION�
IGNITION SWITCH REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
STARTING SYSTEM�
SCHEMATIC AND ROUTING DIAGRAM�
STARTING SYSTEM DIAGRAM�
COMPONENT LOCATION�
STARTING SYSTEM COMPONENTS LOCATION�
DIAGNOSTIC INFORMATION AND PROCEDURES�
STARTING SYSTEM SYMPTOM DIAGNOSIS�
STARTER MOTOR WILL NOT RUN�
STARTER MOTOR RUNS BUT DOES NOT CRANK THE ENGINE�
REPAIR INSTRUCTIONS�
STARTER MOTOR COMPONENTS�
STARTER MOTOR REMOVAL AND INSTALLATION�
STARTER MOTOR DISASSEMBLY AND ASSEMBLY�
STARTER MOTOR RELATED PARTS INSPECTION�
STARTER RELAY REMOVAL AND INSTALLATION�
STARTER RELAY INSPECTION�
GEAR POSITION (GP) SWITCH INSPECTION�
STARTER TORQUE LIMITER / STARTER CLUTCH REMOVAL AND INSTALLATION�
STARTER TORQUE LIMITER INSPECTION�
STARTER CLUTCH RELATED PARTS INSPECTION�
STARTER DRIVEN GEAR BEARING REMOVAL AND INSTALLATION�
STARTER BUTTON INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
CHARGING SYSTEM�
SCHEMATIC AND ROUTING DIAGRAM�
CHARGING SYSTEM DIAGRAM�
COMPONENT LOCATION�
CHARGING SYSTEM COMPONENTS LOCATION�
DIAGNOSTIC INFORMATION AND PROCEDURES�
CHARGING SYSTEM SYMPTOM DIAGNOSIS�
BATTERY RUNS DOWN QUICKLY�
REPAIR INSTRUCTIONS�
BATTERY CURRENT LEAKAGE INSPECTION�
REGULATED VOLTAGE INSPECTION�
GENERATOR INSPECTION�
GENERATOR REMOVAL AND INSTALLATION�
REGULATOR / RECTIFIER INSPECTION�
BATTERY COMPONENTS�
BATTERY CHARGING�
BATTERY REMOVAL AND INSTALLATION�
BATTERY VISUAL INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
EXHAUST SYSTEM�
PRECAUTIONS�
PRECAUTIONS FOR EXHAUST SYSTEM�
REPAIR INSTRUCTIONS�
EXHAUST SYSTEM CONSTRUCTION�
MUFFLER / EXHAUST PIPE REMOVAL AND INSTALLATION�
EXHAUST SYSTEM INSPECTION�
SPARK ARRESTER INSPECTION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
02 SUSPENSION�
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR SUSPENSION�
SUSPENSION GENERAL DIAGNOSIS�
DIAGNOSTIC INFORMATION AND PROCEDURES�
SUSPENSION AND WHEEL SYMPTOM DIAGNOSIS�
FRONT SUSPENSION�
REPAIR INSTRUCTIONS�
FRONT SUSPENSION COMPONENTS�
FRONT SUSPENSION / STEERING ASSEMBLY CONSTRUCTION�
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATION�
FRONT SUSPENSION INSPECTION�
FRONT SHOCK ABSORBER PARTS INSPECTION�
FRONT SUSPENSION ADJUSTMENT�
FRONT SHOCK ABSORBER DISPOSAL�
FRONT WHEEL HUB / STEERING KNUCKLE REMOVAL AND INSTALLATION�
FRONT WHEEL HUB PARTS INSPECTION�
STEERING KNUCKLE INSPECTION�
FRONT WHEEL HUB DUST SEAL / BEARING REMOVAL AND INSTALLATION�
FRONT SUSPENSION UPPER / LOWER WISHBONE ARM REMOVAL AND INSTALLATION�
KNUCKLE END BOOT INSPECTION�
KNUCKLE END REMOVAL AND INSTALLATION�
FRONT SUSPENSION WISHBONE ARM DUST SEAL / BEARING REMOVAL AND INSTALLATION�
FRONT SUSPENSION WISHBONE ARM RELATED PARTS INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
REAR SUSPENSION�
REPAIR INSTRUCTIONS�
REAR SUSPENSION COMPONENTS�
REAR SUSPENSION ASSEMBLY CONSTRUCTION�
REAR SHOCK ABSORBER REMOVAL AND INSTALLATION�
REAR SUSPENSION INSPECTION�
REAR SHOCK ABSORBER INSPECTION�
REAR SUSPENSION ABSORBER ADJUSTMENT�
REAR SHOCK ABSORBER DISPOSAL�
REAR WHEEL HUB REMOVAL AND INSTALLATION�
REAR WHEEL HUB INSPECTION�
CUSHION ROD / CUSHION LEVER REMOVAL AND INSTALLATION�
CUSHION LEVER DUST SEAL / BEARING REMOVAL AND INSTALLATION�
CUSHION ROD DUST SEAL / BEARING REMOVAL AND INSTALLATION�
CUSHION LEVER / CUSHION ROD RELATED PARTS INSPECTION�
SWINGARM REMOVAL AND INSTALLATION�
SWINGARM DUST SEAL / BEARING REMOVAL AND INSTALLATION�
SWINGARM RELATED PARTS INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
WHEELS AND TIRES�
PRECAUTIONS�
PRECAUTIONS FOR WHEEL AND TIRE�
REPAIR INSTRUCTIONS�
FRONT AND REAR WHEEL COMPONENTS�
FRONT / REAR WHEEL REMOVAL AND INSTALLATION�
TIRE REMOVAL AND INSTALLATION�
WHEEL / TIRE INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
03 DRIVELINE / AXLE�
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR DRIVELINE / AXLE�
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT�
DIAGNOSTIC INFORMATION AND PROCEDURES�
DRIVE CHAIN AND SPROCKET SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
DRIVE CHAIN / REAR AXLE RELATED COMPONENTS�
REAR AXLE ASSEMBLY CONSTRUCTION�
ENGINE SPROCKET REMOVAL AND INSTALLATION�
REAR SPROCKET REMOVAL AND INSTALLATION�
REAR AXLE NUT AND LOCK-NUT TIGHTENING TORQUE�
DRIVE CHAIN RELATED PARTS INSPECTION�
DRIVE CHAIN REPLACEMENT�
DRIVE CHAIN ROLLER CONSTRUCTION�
DRIVE CHAIN ROLLER INSPECTION�
DRIVE CHAIN ROLLER REMOVAL AND INSTALLATION�
REAR AXLE HOUSING REMOVAL AND INSTALLATION�
REAR AXLE RELATED PARTS INSPECTION�
REAR AXLE DUST SEAL / BEARING REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
04 BRAKE�
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR BRAKE SYSTEM�
BRAKE FLUID INFORMATION�
BRAKE CONTROL SYSTEM AND DIAGNOSIS�
SCHEMATIC AND ROUTING DIAGRAM�
FRONT BRAKE HOSE ROUTING DIAGRAM�
REAR BRAKE HOSE ROUTING DIAGRAM�
HOSE AND CABLE ROUTING DIAGRAM�
DIAGNOSTIC INFORMATION AND PROCEDURES�
BRAKE SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
BRAKE PEDAL HEIGHT INSPECTION AND ADJUSTMENT�
FRONT BRAKE LIGHT SWITCH INSPECTION�
REAR BRAKE LIGHT SWITCH INSPECTION�
REAR BRAKE SWITCH INSPECTION AND ADJUSTMENT�
BRAKE FLUID LEVEL CHECK�
BRAKE HOSE INSPECTION�
AIR BLEEDING FROM BRAKE FLUID CIRCUIT�
BRAKE FLUID REPLACEMENT�
BRAKE HOSE REMOVAL AND INSTALLATION�
FRONT BRAKE MASTER CYLINDER COMPONENTS�
FRONT BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION�
FRONT BRAKE MASTER CYLINDER / BRAKE LEVER DISASSEMBLY AND ASSEMBLY�
FRONT BRAKE MASTER CYLINDER PARTS INSPECTION�
REAR BRAKE PEDAL CONSTRUCTION�
REAR BRAKE PEDAL REMOVAL AND INSTALLATION�
REAR BRAKE MASTER CYLINDER COMPONENTS�
REAR BRAKE MASTER CYLINDER ASSEMBLY REMOVAL AND INSTALLATION�
REAR BRAKE MASTER CYLINDER DISASSEMBLY AND ASSEMBLY�
REAR BRAKE MASTER CYLINDER PARTS INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
FRONT BRAKES�
REPAIR INSTRUCTIONS�
FRONT BRAKE COMPONENTS�
FRONT BRAKE PAD INSPECTION�
FRONT BRAKE PAD REPLACEMENT�
FRONT BRAKE CALIPER REMOVAL AND INSTALLATION�
FRONT BRAKE CALIPER DISASSEMBLY AND ASSEMBLY�
FRONT BRAKE CALIPER PARTS INSPECTION�
FRONT BRAKE DISC REMOVAL AND INSTALLATION�
FRONT BRAKE DISC INSPECTION�
FRONT BRAKE DISC COVER INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
REAR BRAKES�
REPAIR INSTRUCTIONS�
REAR BRAKE COMPONENTS�
REAR BRAKE PAD INSPECTION�
REAR BRAKE PAD REPLACEMENT�
REAR BRAKE CALIPER REMOVAL AND INSTALLATION�
REAR BRAKE CALIPER DISASSEMBLY AND ASSEMBLY�
REAR BRAKE CALIPER PARTS INSPECTION�
REAR BRAKE DISC REMOVAL AND INSTALLATION�
REAR BRAKE DISC INSPECTION�
REAR BRAKE DISC PLATE HOUSING INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
PARKING BRAKE�
REPAIR INSTRUCTIONS�
PARKING BRAKE INSPECTION AND ADJUSTMENT�
PARKING BRAKE CABLE REMOVAL AND INSTALLATION�
PARKING BRAKE COMPONENTS�
PARKING BRAKE LOCK / KNOB REMOVAL AND INSTALLATION�
PARKING BRAKE REMOVAL AND INSTALLATION�
PARKING BRAKE INSPECTION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
05 TRANSMISSION / TRANSAXLE�
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR TRANSMISSION / TRANSAXLE�
MANUAL TRANSMISSION�
DIAGNOSTIC INFORMATION AND PROCEDURES�
MANUAL TRANSMISSION SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
REVERSE LOCK CABLE PLAY INSPECTION AND ADJUSTMENT�
REVERSE LOCK CABLE REMOVAL AND INSTALLATION�
TRANSMISSION COMPONENTS�
TRANSMISSION REMOVAL AND INSTALLATION�
TRANSMISSION CONSTRUCTION�
COUNTERSHAFT GEAR / DRIVESHAFT GEAR / REVERSE IDLE GEAR DISASSEMBLY AND ASSEMBLY�
TRANSMISSION RELATED PARTS INSPECTION�
TRANSMISSION OIL SEAL / BEARING INSPECTION�
TRANSMISSION OIL SEAL / BEARING REMOVAL AND INSTALLATION�
GEAR POSITION (GP) SWITCH INSPECTION�
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION�
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE COMPONENTS�
GEARSHIFT CONSTRUCTION�
GEARSHIFT SHAFT / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION�
GEARSHIFT LINKAGE INSPECTION�
GEARSHIFT SHAFT OIL SEAL / BEARING REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
CLUTCH�
PRECAUTIONS�
PRECAUTIONS FOR CLUTCH SYSTEM�
DIAGNOSTIC INFORMATION AND PROCEDURES�
CLUTCH SYSTEM SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
CLUTCH LEVER POSITION SWITCH INSPECTION�
CLUTCH CABLE INSPECTION AND ADJUSTMENT�
CLUTCH CABLE REMOVAL AND INSTALLATION�
CLUTCH LEVER COMPONENTS�
CLUTCH LEVER REMOVAL AND INSTALLATION�
CLUTCH RELEASE CAMSHAFT REMOVAL AND INSTALLATION�
CLUTCH COMPONENTS�
CLUTCH REMOVAL�
CLUTCH INSTALLATION�
CLUTCH PARTS INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
06 STEERING
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR STEERING�
STEERING GENERAL DIAGNOSIS�
DIAGNOSTIC INFORMATION AND PROCEDURES�
STEERING SYMPTOM DIAGNOSIS�
STEERING / HANDLEBAR�
REPAIR INSTRUCTIONS�
STEERING / HANDLEBARS COMPONENTS�
HANDLEBAR CONSTRUCTION�
HANDLEBARS REMOVAL AND INSTALLATION�
HANDLEBARS INSPECTION�
STEERING SHAFT / TIE-ROD REMOVAL AND INSTALLATION�
STEERING PARTS INSPECTION�
TOE-OUT ADJUSTMENT�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
09 BODY AND ACCESSORIES�
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR ELECTRICAL SYSTEM�
COMPONENT LOCATION�
ELECTRICAL COMPONENTS LOCATION�
WIRING SYSTEMS�
SCHEMATIC AND ROUTING DIAGRAM�
WIRING DIAGRAM�
WIRING HARNESS ROUTING DIAGRAM�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
LIGHTING SYSTEMS�
REPAIR INSTRUCTIONS�
HEADLIGHT COMPONENTS�
HEADLIGHT REMOVAL AND INSTALLATION�
HEADLIGHT BULB REPLACEMENT�
HEADLIGHT BEAM ADJUSTMENT�
REAR COMBINATION LIGHT COMPONENTS�
REAR COMBINATION LIGHT REMOVAL AND INSTALLATION�
REAR COMBINATION LIGHT BULB REPLACEMENT�
DIMMER SWITCH INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
COMBINATION METER / FUEL METER / HORN�
REPAIR INSTRUCTIONS�
INDICATOR LIGHT COMPONENTS�
INDICATOR LIGHT REMOVAL AND INSTALLATION�
INDICATOR LIGHT REPLACEMENT�
INDICATOR LIGHT INSPECTION�
FUEL LEVEL INDICATOR SWITCH (THERMISTOR) INSPECTION�
ENGINE COOLANT TEMPERATURE INDICATOR LIGHT INSPECTION�
ENGINE COOLANT TEMPERATURE REMOVAL AND INSTALLATION�
NEUTRAL INDICATOR SWITCH INSPECTION�
REVERSE INDICATOR SWITCH INSPECTION�
IGNITION SWITCH INSPECTION�
IGNITION SWITCH REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
EXTERIOR PARTS�
REPAIR INSTRUCTIONS�
EXTERIOR PARTS CONSTRUCTION�
FUEL TANK COVER CUSHION INSTALLATION�
FASTENER REMOVAL AND INSTALLATION�
EXTERIOR PARTS REMOVAL AND INSTALLATION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
BODY STRUCTURE�
REPAIR INSTRUCTIONS�
BODY FRAME CONSTRUCTION�
FOOTREST REMOVAL AND INSTALLATION�
FRONT GRIP REMOVAL AND INSTALLATION�
REAR GRIP REMOVAL AND INSTALLATION�
SEAT RAIL REMOVAL AND INSTALLATION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
