2008-2009 Suzuki 750 King Quad Service Manual
Instant download of the factory repair manual for the 2008-2009 Suzuki King Quad 750AXi 4x4 with fuel injection.
Covers models with power steering. Covers complete tear down and rebuild, pictures and part diagrams, torque specs, maintenance, troubleshooting, etc.
Part number: 99500-47021-03E
Manual chapters:
- PRECAUTIONS
- GENERAL INFORMATION
- ENGINE
- SUSPENSION
- DRIVELINE / AXLE
- BRAKE
- TRANSMISSION / TRANSAXLE
- STEERING
- BODY AND ACCESSORIES
Manual also includes supplements manuals:
- LT-A750XK9 ('09-MODEL)
- LT-A750XPK9 ('09-MODEL)
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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 INSPECTION AND CLEANING�
EXHAUST PIPE BOLT AND MUFFLER BOLT INSPECTION�
VALVE CLEARANCE INSPECTION AND ADJUSTMENT�
SPARK PLUG REPLACEMENT�
SPARK PLUG INSPECTION AND CLEANING�
SPARK ARRESTER CLEANING�
FUEL LINE INSPECTION�
ENGINE OIL AND FILTER REPLACEMENT�
FRONT DIFFERENTIAL GEAR OIL INSPECTION�
FRONT DIFFERENTIAL GEAR OIL REPLACEMENT�
FINAL GEAR OIL INSPECTION�
FINAL GEAR OIL REPLACEMENT�
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT�
THROTTLE BODY INSPECTION�
COOLING SYSTEM INSPECTION�
DRIVE V-BELT INSPECTION AND REPLACEMENT�
DRIVE SHAFT BOOTS INSPECTION�
FRONT BRAKE SYSTEM INSPECTION�
REAR BRAKE PEDAL / REAR BRAKE (PARKING BRAKE) LEVER INSPECTION AND ADJUSTMENT�
REAR BRAKE FRICTION PLATE WEAR LIMIT INSPECTION�
TIRE INSPECTION�
STEERING SYSTEM INSPECTION�
TOE ADJUSTMENT�
SUSPENSIONS INSPECTION�
CHASSIS BOLT AND NUT INSPECTION�
COMPRESSION PRESSURE CHECK�
OIL PRESSURE CHECK�
SDS CHECK�
AUTOMATIC CLUTCH INSPECTION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
SERVICE DATA�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE LIST�
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 "C13" (P0105-H/L): IAP SENSOR CIRCUIT MALFUNCTION�
DTC "C14" (P0120-H/L): TP SENSOR CIRCUIT MALFUNCTION�
DTC "C15" (P0115-H/L): ECT SENSOR CIRCUIT MALFUNCTION�
DTC "C20" (P1752): DIFF-LOCK RELAY 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 "C32" (P0201): FUEL INJECTOR CIRCUIT MALFUNCTION�
DTC "C40" (P05057): ISC VALVE CIRCUIT MALFUNCTION�
DTC "C41" (P230-H/L): FP RELAY CIRCUIT MALFUNCTION�
SPECIFICATIONS�
SERVICE DATA�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
EMISSION CONTROL DEVICES�
PRECAUTIONS�
PRECAUTIONS FOR EMISSION CONTROL DEVICES�
REPAIR INSTRUCTIONS�
CRANKCASE BREATHER (PCV) HOSE INSPECTION�
CRANKCASE BREATHER (PCV) HOSE REMOVAL AND INSTALLATION�
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�
ISC VALVE INSPECTION�
ISC VALVE REMOVAL AND INSTALLATION�
GP SWITCH INSPECTION�
GP SWITCH REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
ENGINE MECHANICAL�
SCHEMATIC AND ROUTING DIAGRAM�
THROTTLE CABLE ROUTING DIAGRAM�
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 INSPECTION AND CLEANING�
AIR CLEANER BOX REMOVAL AND INSTALLATION�
THROTTLE CABLE REMOVAL AND INSTALLATION�
THROTTLE CABLE INSPECTION�
THROTTLE CABLE PLAY INSPECTION AND ADJUSTMENT�
THROTTLE BODY COMPONENTS�
THROTTLE BODY CONSTRUCTION�
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�
CAMSHAFT SPROCKET 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�
CAM DRIVE IDLE GEAR / SPROCKET THRUST CLEARANCE INSPECTION AND ADJUSTMENT�
CYLINDER DISASSEMBLY AND ASSEMBLY�
CYLINDER INSPECTION�
PISTON RING REMOVAL AND INSTALLATION�
PISTON AND PISTON RING INSPECTION�
ENGINE BOTTOM SIDE DISASSEMBLY�
ENGINE BOTTOM SIDE ASSEMBLY�
CONROD AND CRANKSHAFT INSPECTION�
WIDTH BETWEEN CRANKSHAFT WEBS�
CRANKSHAFT OIL SEAL INSPECTION�
BEARING INSPECTION�
BEARING 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 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 JET REMOVAL AND INSTALLATION�
OIL JET INSPECTION�
OIL PUMP REMOVAL AND INSTALLATION�
OIL PUMP 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�
COOLING FAN ASSEMBLY / RADIATOR REMOVAL AND INSTALLATION�
WATER HOSE REMOVAL AND INSTALLATION�
COOLING FAN INSPECTION�
RADIATOR RESERVOIR TANK REMOVAL AND INSTALLATION�
RADIATOR RESERVOIR TANK INSPECTION�
WATER HOSE INSPECTION�
ECT SENSOR REMOVAL AND INSTALLATION�
ECT SENSOR INSPECTION�
COOLING FAN THERMO-SWITCH REMOVAL AND INSTALLATION�
COOLING FAN THERMO-SWITCH 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�
FUEL TANK BREATHER 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 FEED HOSE REMOVAL AND INSTALLATION�
FUEL LEVEL GAUGE INSPECTION�
FUEL LEVEL INDICATOR INSPECTION�
FUEL TANK REMOVAL AND INSTALLATION�
FUEL PUMP COMPONENTS�
FUEL PUMP ASSEMBLY REMOVAL AND INSTALLATION�
FUEL PUMP DISASSEMBLY AND ASSEMBLY�
FUEL MESH FILTER INSPECTION AND CLEANING�
FUEL INJECTOR INSPECTION AND CLEANING�
FUEL INJECTOR / FUEL DELIVERY PIPE REMOVAL AND INSTALLATION�
FUEL TANK PRESSURE CONTROL (FTPC) VALVE REMOVAL AND INSTALLATION�
FUEL TANK PRESSURE CONTROL (FTPC) VALVE INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
IGNITION SYSTEM�
GENERAL DESCRIPTION�
OVERRIDE SWITCH DESCRIPTION�
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�
OVERRIDE SWITCH INSPECTION�
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�
ENGINE DOES NOT TURN THOUGH THE STARTER MOTOR RUNS�
REPAIR INSTRUCTIONS�
STARTER MOTOR COMPONENTS�
STARTER MOTOR REMOVAL AND INSTALLATION�
STARTER MOTOR DISASSEMBLY AND ASSEMBLY�
STARTER MOTOR INSPECTION�
STARTER RELAY REMOVAL AND INSTALLATION�
STARTER RELAY INSPECTION�
NEUTRAL RELAY REMOVAL AND INSTALLATION�
NEUTRAL RELAY INSPECTION�
NEUTRAL RELAY DIODE INSPECTION�
PARKING BRAKE RELAY REMOVAL AND INSTALLATION�
PARKING BRAKE RELAY INSPECTION�
PARKING BRAKE SWITCH INSPECTION�
GEAR POSITION SWITCH INSPECTION�
STARTER TORQUE LIMITER / STARTER CLUTCH REMOVAL AND INSTALLATION�
STARTER DRIVEN GEAR BEARING REMOVAL AND INSTALLATION�
STARTER RELATED PARTS INSPECTION�
STARTER BUTTON INSPECTION�
RECOIL STARTER COMPONENTS�
RECOIL STARTER ASSEMBLY REMOVAL AND INSTALLATION�
RECOIL STARTER DISASSEMBLY AND ASSEMBLY�
RECOIL STARTER 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�
EXHAUST PIPE / MUFFLER REMOVAL AND INSTALLATION�
EXHAUST SYSTEM INSPECTION�
SPARK ARRESTER INSPECTION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
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 ASSEMBLY CONSTRUCTION�
FRONT SHOCK ABSORBER REMOVAL AND INSTALLATION�
FRONT SUSPENSION INSPECTION�
FRONT SHOCK ABSORBER INSPECTION�
SPRING PRE-LOAD ADJUSTMENT�
FRONT WHEEL HUB / STEERING KNUCKLE REMOVAL AND INSTALLATION�
FRONT HUB BEARING INSPECTION�
FRONT HUB BEARING REMOVAL AND INSTALLATION�
FRONT SUSPENSION UPPER / LOWER ARM REMOVAL AND INSTALLATION�
STEERING KNUCKLE END INSPECTION�
STEERING KNUCKLE END REMOVAL AND INSTALLATION�
FRONT SUSPENSION ARM RELATED PARTS INSPECTION�
FRONT SUSPENSION UPPER ARM BUSHING AND INNER DUST SEAL REMOVAL AND INSTALLATION�
FRONT SUSPENSION LOWER ARM BUSHING REMOVAL AND INSTALLATION�
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�
SPRING PRE-LOAD ADJUSTMENT�
REAR WHEEL HUB / SUSPENSION KNUCKLE REMOVAL AND INSTALLATION�
REAR HUB BEARING INSPECTION�
REAR HUB BEARING REMOVAL AND INSTALLATION�
REAR SUSPENSION ARM UPPER / LOWER REMOVAL AND INSTALLATION�
REAR SUSPENSION ARM RELATED PARTS INSPECTION�
REAR SUSPENSION UPPER ARM BUSHING REMOVAL AND INSTALLATION�
REAR SUSPENSION LOWER ARM BUSHING REMOVAL AND INSTALLATION�
REAR SUSPENSION KNUCKLE BUSHING REMOVAL AND INSTALLATION�
REAR STABILIZER REMOVAL AND INSTALLATION�
STABILIZER 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�
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 SHAFT SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
FRONT DRIVE SHAFT COMPONENTS�
FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION�
FRONT DRIVE SHAFT DISASSEMBLY AND ASSEMBLY�
FRONT DRIVE SHAFT INSPECTION�
REAR DRIVE SHAFT COMPONENTS�
REAR DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION�
REAR DRIVE SHAFT DISASSEMBLY AND ASSEMBLY�
REAR DRIVE SHAFT INSPECTION�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
DIFFERENTIAL�
DIAGNOSTIC INFORMATION AND PROCEDURES�
DRIVE TRAIN SYMPTOM DIAGNOSIS�
DTC "C20" (P1752) DIFF-LOCK RELAY CIRCUIT MALFUNCTION�
REPAIR INSTRUCTIONS�
FRONT DRIVE (DIFFERENTIAL) COMPONENTS�
FRONT DRIVE (DIFFERENTIAL) CONSTRUCTION�
FRONT DRIVE (DIFFERENTIAL) GEAR OIL LEVEL INSPECTION�
FRONT DRIVE (DIFFERENTIAL) GEAR OIL REPLACEMENT�
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY REMOVAL AND INSTALLATION�
FRONT DRIVE (DIFFERENTIAL) ASSEMBLY DISASSEMBLY AND ASSEMBLY�
FRONT DRIVE (DIFFERENTIAL) RELATED PARTS INSPECTION�
BREATHER RUBBER CASE INSPECTION�
FRONT DRIVE (DIFFERENTIAL) GEAR SHIM INSPECTION AND SELECTION�
2WD/4WD/DIFF-LOCK SYSTEM INSPECTION�
REAR DRIVE BREATHER HOSE ROUTING DIAGRAM�
FINAL GEAR COMPONENTS�
FINAL GEAR CONSTRUCTION�
FINAL GEAR OIL LEVEL INSPECTION�
FINAL GEAR OIL REPLACEMENT.�
FINAL GEAR ASSEMBLY REMOVAL AND INSTALLATION�
FINAL GEAR ASSEMBLY DISASSEMBLY AND ASSEMBLY�
FINAL GEAR RELATED PARTS INSPECTION�
FINAL GEAR SHIM INSPECTION AND SELECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
TRANSFER�
DIAGNOSTIC INFORMATION AND PROCEDURES�
TRANSFER SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
TRANSFER COMPONENTS�
TRANSFER REMOVAL AND INSTALLATION�
TRANSFER CONSTRUCTION�
COUNTER SHAFT / REVERSE IDLE GEAR DISASSEMBLY AND ASSEMBLY�
GEARSHIFT CAM COMPONENTS�
GEARSHIFT SYSTEM CONSTRUCTION�
GEARSHIFT CAM DISASSEMBLY AND ASSEMBLY�
TRANSFER GEAR BEARING REMOVAL AND INSTALLATION�
TRANSFER GEAR BEARING INSPECTION�
TRANSFER RELATED PARTS INSPECTION�
TRANSFER RELATED BEARING INSPECTION�
GEAR POSITION (GP) SWITCH INSPECTION�
GEAR POSITION (GP) SWITCH REMOVAL AND INSTALLATION�
GEARSHIFT SHAFT NO. 2 / GEARSHIFT CAM PLATE REMOVAL AND INSTALLATION�
GEARSHIFT LINKAGE INSPECTION�
GEARSHIFT SHAFT OIL SEAL REMOVAL AND INSTALLATION�
SPECIFICATIONS�
SERVICE DATA�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
PROPELLER SHAFTS�
REPAIR INSTRUCTIONS�
FRONT OUTPUT SHAFT COMPONENTS�
FRONT OUTPUT SHAFT REMOVAL AND INSTALLATION�
FRONT OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY�
FRONT OUTPUT SHAFT RELATED PARTS INSPECTION�
REAR OUTPUT SHAFT COMPONENTS�
REAR OUTPUT SHAFT REMOVAL AND INSTALLATION�
REAR OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY�
REAR OUTPUT SHAFT RELATED PARTS INSPECTION�
REAR OUTPUT SHAFT DRIVE BEVEL GEAR SHIM INSPECTION AND ADJUSTMENT�
FRONT PROPELLER SHAFT COMPONENTS�
FRONT PROPELLER SHAFT REMOVAL AND INSTALLATION�
FRONT PROPELLER SHAFT RELATED PARTS INSPECTION�
REAR PROPELLER SHAFT COMPONENTS�
REAR PROPELLER SHAFT REMOVAL AND INSTALLATION�
REAR PROPELLER SHAFT RELATED PARTS INSPECTION�
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 BLAKE 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�
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION�
PARKING BRAKE LEVER SWITCH INSPECTION�
BRAKE FLUID LEVEL CHECK�
FRONT BRAKE HOSE INSPECTION�
AIR BLEEDING FROM FRONT BRAKE FLUID CIRCUIT�
BRAKE FLUID REPLACEMENT�
FRONT BRAKE HOSE REMOVAL AND INSTALLATION�
REAR BRAKE CABLE 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�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
FRONT BRAKES�
PRECAUTIONS�
PRECAUTIONS FOR 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�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
REAR BRAKES�
PRECAUTIONS�
PRECAUTIONS FOR REAR BRAKE�
REPAIR INSTRUCTIONS�
REAR BRAKE COMPONENTS�
REAR BRAKE FRICTION PLATE INSPECTION�
REAR BRAKE FRICTION PLATE REPLACEMENT�
REAR BRAKE ASSEMBLY REMOVAL AND INSTALLATION�
REAR BRAKE DISASSEMBLY AND ASSEMBLY�
REAR BRAKE PARTS INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
PARKING BRAKE�
SCHEMATIC AND ROUTING DIAGRAM�
PARKING / REAR BRAKE CABLE ROUTING DIAGRAM�
REPAIR INSTRUCTIONS�
PARKING / REAR BRAKE INSPECTION AND ADJUSTMENT�
PARKING / REAR BRAKE CABLE REMOVAL AND INSTALLATION�
PARKING / REAR BRAKE LEVER COMPONENTS�
PARKING / REAR BRAKE LEVER REMOVAL AND INSTALLATION�
PARKING / REAR BRAKE LIGHT SWITCH INSPECTION�
PARKING / REAR BRAKE RELAY INSPECTION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
05. TRANSMISSION / TRANSAXLE�
PRECAUTIONS�
PRECAUTIONS�
PRECAUTIONS FOR TRANSMISSION / TRANSAXLE�
AUTOMATIC TRANSMISSION�
SCHEMATIC AND ROUTING DIAGRAM�
DRIVE TRAIN SYSTEM�
DIAGNOSTIC INFORMATION AND PROCEDURES�
AUTOMATIC TRANSMISSION SYMPTOM DIAGNOSIS�
REPAIR INSTRUCTIONS�
AUTOMATIC TRANSMISSION COMPONENTS�
V-BELT COOLING DUCT CONSTRUCTION�
V-BELT COOLING DUCT REMOVAL AND INSTALLATION�
CLUTCH ENGAGEMENT AND LOCK-UP SPEED INSPECTION�
V-BELT TYPE CONTINUOUSLY VARIABLE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION�
MOVABLE DRIVE FACE DISASSEMBLY AND ASSEMBLY�
MOVABLE DRIVEN FACE DISASSEMBLY AND ASSEMBLY�
DRIVE V-BELT INSPECTION�
MOVABLE / FIXED DRIVE FACE PARTS INSPECTION�
MOVABLE / FIXED DRIVEN FACE PARTS INSPECTION�
CLUTCH SHOE REMOVAL AND INSTALLATION�
CLUTCH HOUSING CASE DISASSEMBLY AND ASSEMBLY�
CLUTCH PARTS INSPECTION�
MOVABLE DRIVE FACE COVER DISASSEMBLY AND ASSEMBLY�
CLUTCH HOUSING COVER PARTS INSPECTION�
SHIFT LEVER ASSEMBLY COMPONENTS�
GEAR SHIFT KNOB REMOVAL AND INSTALLATION�
SHIFT LEVER ASSEMBLY REMOVAL AND INSTALLATION�
SHIFT LEVER DISASSEMBLY AND ASSEMBLY�
SHIFT ROD ADJUSTMENT�
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�
STEERING / HANDLEBARS ASSEMBLY CONSTRUCTION�
HANDLEBARS REMOVAL AND INSTALLATION�
HANDLEBARS INSPECTION�
STEERING SHAFT REMOVAL AND INSTALLATION�
TIE-ROD / TIE-ROD END REMOVAL AND INSTALLATION�
STEERING PARTS INSPECTION�
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�
LIGHTING SYSTEMS�
REPAIR INSTRUCTIONS�
HEADLIGHT COMPONENTS�
HEADLIGHT REMOVAL AND INSTALLATION�
HEADLIGHT BULB REPLACEMENT�
HEADLIGHT BEAM ADJUSTMENT�
AUXILIARY HEADLIGHT COMPONENTS�
AUXILIARY HEADLIGHT REMOVAL AND INSTALLATION�
AUXILIARY HEADLIGHT BULB REPLACEMENT�
AUXILIARY HEADLIGHT BEAM ADJUSTMENT�
REAR COMBINATION LIGHT COMPONENTS�
REAR COMBINATION LIGHT REMOVAL AND INSTALLATION�
REAR COMBINATION LIGHT BULB REPLACEMENT�
REVERSING LIGHT BULB REPLACEMENT (FOR P-17)�
REVERSING LIGHT RELAY INSPECTION (FOR P-17)�
DIMMER SWITCH INSPECTION�
SPECIFICATIONS�
SERVICE DATA�
SPECIAL TOOLS AND EQUIPMENT�
SPECIAL TOOL�
COMBINATION METER / FUEL METER / HORN�
GENERAL DESCRIPTION�
COMBINATION METER SYSTEM DESCRIPTION�
REPAIR INSTRUCTIONS�
COMBINATION METER COMPONENTS�
COMBINATION METER REMOVAL AND INSTALLATION�
COMBINATION METER DISASSEMBLY AND ASSEMBLY�
COMBINATION METER INSPECTION�
ENGINE COOLANT TEMPERATURE INDICATOR LIGHT INSPECTION�
ENGINE COOLANT TEMPERATURE REMOVAL AND INSTALLATION�
FUEL LEVEL INDICATOR INSPECTION�
FUEL LEVEL GAUGE INSPECTION�
SPEEDOMETER INSPECTION�
SPEED SENSOR REMOVAL AND INSTALLATION�
SPEED SENSOR INSPECTION�
IGNITION SWITCH INSPECTION�
IGNITION SWITCH REMOVAL AND INSTALLATION�
HORN INSPECTION (FOR P-17, 24)�
HORN REMOVAL AND INSTALLATION (FOR P-17, 24)�
SPECIFICATIONS�
SERVICE DATA�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
SPECIAL TOOL�
EXTERIOR PARTS�
REPAIR INSTRUCTIONS�
EXTERIOR PARTS CONSTRUCTION�
REAR FENDER HEAT SHIELD CONSTRUCTION�
FUEL TANK LOWER COVER HEAT SHIELD INSTALLATION�
FASTENER REMOVAL AND INSTALLATION�
FRONT SIDE EXTERIOR PARTS REMOVAL AND INSTALLATION�
REAR SIDE EXTERIOR PARTS REMOVAL AND INSTALLATION�
SEAT REMOVAL AND INSTALLATION�
UNDER COVER COMPONENTS�
UNDER COVER REMOVAL AND INSTALLATION�
BODY STRUCTURE�
REPAIR INSTRUCTIONS�
BODY FRAME CONSTRUCTION�
FOOTREST CONSTRUCTION�
FOOTREST REMOVAL AND INSTALLATION�
CARRIER CONSTRUCTION�
FRONT CARRIER REMOVAL AND INSTALLATION�
REAR CARRIER REMOVAL AND INSTALLATION�
FRONT GRIP BAR CONSTRUCTION�
FRONT GRIP BAR REMOVAL AND INSTALLATION�
TRAILER TOWING CONSTRUCTION�
TRAILER TOWING REMOVAL AND INSTRUCTION�
SPECIFICATIONS�
TIGHTENING TORQUE SPECIFICATIONS�
SPECIAL TOOLS AND EQUIPMENT�
RECOMMENDED SERVICE MATERIAL�
10. LT-A750XK9 ('09-MODEL)
SPECIFICATIONS�
11. LT-A750XPK9 ('09-MODEL)
FOREWORD�
TABLE OF CONTENTS�
00. PRECAUTIONS�
PRECAUTIONS�
0. GENERAL INFORMATION�
GENERAL INFORMATION�
MAINTENANCE AND LUBRICATION�
SERVICE DATA�
01. ENGINE�
STARTING SYSTEM�
CHARGING SYSTEM�
03. DRIVELINE / AXLE�
DRIVE CHAIN / DRIVE TRAIN / DRIVE SHAFT�
04. BRAKE�
BRAKE CONTROL SYSTEM AND DIAGNOSIS�
06. STEERING�
PRECAUTIONS�
STEERING GENERAL DIAGNOSIS�
STEERING / HANDLEBAR�
POWER ASSISTED STEERING SYSTEM�
09. BODY AND ACCESSORIES�
WIRING SYSTEMS�
BODY STRUCTURE�
