2002-2007 SUZUKI EIGER LT-A400 400F ATV Repair Manual

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FOREWORD This manual contains an introductory description on the SUZUKI LT-A400/400F and procedures for its inspection/seNiee and overhaul of its main compo- nents. Other information considered as generally known is nol included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle 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 motorcycle bet- ter so that you can assure your customers of fast and reliable service. "This manual has been prepared on the basis of the latest specifications al the time 01 publication. If modificatioos have been made since then, differ- ences may exist between the content of this manual and the actual motorcycle. "Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle ex· actiy in detail. "This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do nol have the proper knowledge and tools, ask your authorized SUZUKI mo torcycle dealer to help you. WARNING Inexperienced mechanics or mechanics with- out the proper tools and equipment may not be able to properly perform the services de- scribed in this manual. Improper repair may result In Injury to the mechanic and may ren- der the motorcycle unsafe for the rIder and passenger. GROUP INDEX GENERAL INFORMA TION PERIODIC MAINTENANCE ENGINE DRIVE TRAIN FUEL SYSTEM OIL COOLING AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMA TlON

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r SUPPLEMENTS L T-A400K3/FK3 ('03-MODEL) L T-A400K4/FK4 ('04-MODEL) L T-A400KS/FKS ('OS-MODEL) I LT-A400K6/FK6 ('06-MODEL) II I L T-A400K7/FK7 ('07-MODEL) III

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HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown altha right will allow you to find the first page of the section easity. 4. The contents are listed on the first page of ea ch secti on to help you fi nd the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides work instructions and other service information (e.g.; tightening torque, lubricating points, and locking agent poinls). Example: Rear suspension (J) Ra;or shod< absorber 1%1 S,...;ngarm (JlBoshing ® Rea, &hock a~r mounting upper nut IBI Rev 5hoci. abso<tler Jl\OU'l ting ~ ..... C SII/inoa rm pivoI nut I!l , .... " " C , .. '''~ ,~ " " " '" ., " 43.5 '" 10.2 74 .0

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the lable. SYMBOL DEFINITION SYMBOL DEFINITION ~ T orque contro l required. = Apply THREAD LOCK SUPER "1322", Data beside it indicates specified 99000-32110 (Except USA) torque. Indicates service data. Apply THREAD LOCK "1342", - = 99000-32050 ~ Apply oil. Use engine oil unless 1= Apply THREAD LOCK SUPER "1360", otherwise specified. 99000-32130 Jill Apply hypoid gear oi l. a Apply or use brake fluid . 1rr Apply molybdenum oil solution. ~ Measure in voltage rang e. (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 ; 1) ~ Apply SUZUKI SUPER GREASE "A", ~ Measure in r esistan ce range. 99000-25030 (USA) 99000-25010 (Others) J0i Apply SUZUKI SILICONE GREASE, ~ Measure in current range. 99000-25100 ~ Apply SUZUKI MOLY PASTE, ~ Measu re in diode test range. 99000-25140 J0i Apply WATER RE SISTANCE GREASE, ~ Measure in co ntinuit y t est r ange. 99000-25160 ~ Apply SUZUKI BOND "1207B" .foot! Use special tool. 99104-3 11 40 (USA) 99000-31 140 (Others) -cmJ Apply SUZUKI BOND "1215", 99000-31110 (Except USA) e Apply SUZUKI BOND "12 16B", 99000-31230 = Apply THREAD LOCK SUPER "1303", 99000-32030

GENERALINFORMATION 1-1 GENERAL INFORMA TION ,-------------------- CONTENTS WARNING/CAUTION/NOTE ................. .. ................................... ........ 1- 2 GENERAL PRECAUTIONS ........._ .. .. .. ......... _ ............................ .......... 1- 2 SUZUKI LT-A400K2I400FK2 (2002-MODELj .................................... 1- 4 SERIAL NUMBER LOCATION .................... _ ...................................... 1- 4 FUEL AND OIL RECOMMENDA TlON ............................................... 1- 4 FUEL .......................... _ . .. ........................ ....................... .. .............. 1- 4 ENGINE OIL.. ...... .... ......................................... ............................. 1- 5 FRONT AND REAR DRIVE GEAR OIL ....................................... 1- 5 BRAKE FLUID ...................................................... ....................... 1- 5 BREAK-IN PROCEDURES ...................................................... .......... 1- 5 INFORMATION LABELS ...................................................... . .. ... .. ...... 1- 6 SPECIFICATIONS ...................................................... ........................ 1- 7 COUNTRY AND AREA CODES ....................... .. ........................... .. ... 1- 9

1 ·2 GENERALINFORMAnON WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information. the symbol and the words WARNING, CAU TI ON and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. A WARNING Indicates a potential hazard that could result In death or Injury. I CAUTION I Indicates a potential hazard that could result In vehicle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings an d cautions contained in th is man ual cannot possibly cover all potential hazards relati ng to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS and CAUTIONS slaled, you must use good judgemenl and basic mechanical safety principles. If you are unsure about how to perform a pa rt icular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS A WARNING • Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle. • When two or more persons work together, pay aHentlon to the safety of each other. • When it Is necessary to run the engine indoors , make sure that exhaust gas is forced out· doors. • When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer's Instructions. • Never use gasoline as a cleaning solvent. • To avoid geHlng burned, do not touch the engine, engine 011. radiator, and exhaust system until they have cooled. • After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fiHings related to the system for leaks.

2002-2007 SUZUKI EIGER LT-A400 400F ATV Repair Manual

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