Suzuki LT-Z400 QuadSport Repair Service Manual 2009

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This workshop repair service manual PDF download for the Suzuki 2009 LT-Z400 QuadSport has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

SUZUKI LT-Z400 (2009-model)

TABLE OF CONTENTS :

00 PRECAUTIONS
0 GENERAL INFORMATION
01 ENGINE
02 SUSPENSION
03 DRIVELINE / AXLE
04 BRAKE
05 TRANSMISSION / TRANSAXLE
06 STEERING
09 BODY AND ACCESSORIES

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 99500-43080-03E
Total Pages : 492

This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service Suzuki Vehicles. Apprentice mechanics and “do it yourself” mechanics will also find this manual to be an extremely useful guide.

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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

 

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Suzuki LT-Z400 QuadSport Repair Service Manual 2009.pdf

Source : Sitelux.com

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