Handlebars Inspection; Steering Shaft / Tie-Rod Removal And Installation - Suzuki ltz 400 Service Manual

6B-5 Steering / Handlebar:
• Connect the starter cable (3) to the starter lever.
• Apply grease to the end of starter cable (3).
: Grease 99000–25160 (Water resistance
grease or equivalent)
• Insert the projection "D" of the handlebar switch box
into the hole of the handlebars.
"D"
• Install the clutch lever assembly. Refer to "Clutch
Lever Removal and Installation in Section 5C
(Page 5C-3)".
• Install the right grip as the same manner of left grip.
• Install the front brake master cylinder. Refer to "Front
Brake Master Cylinder Assembly Removal and
Installation in Section 4A (Page 4A-11)".
• Align the punch mark "E" on the handlebars with the
mating surface of the throttle lever case.
• Tighten the throttle lever case bolts.
"E"
• Check the wiring harness routing and cable routing.
Refer to "Wiring Harness Routing Diagram in Section
9A (Page 9A-3)", "Hose and Cable Routing Diagram
in Section 4A (Page 4A-3)".
3
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Handlebars Inspection

Refer to "Handlebars Removal and Installation
(Page 6B-3)".
Inspect the handlebars for distortion or damage.
If any defects are found, replace the handlebars with a
new one.
Steering Shaft / Tie-rod Removal and
Installation
Refer to "Front Suspension / Steering Assembly
Construction in Section 2B (Page 2B-2)".
Removal
1) Remove the radiator assembly. Refer to "Radiator
Reservoir Tank Removal and Installation in Section
1F (Page 1F-9)".
2) Remove the oil tank. Refer to "Oil Tank Removal and
Installation in Section 1E (Page 1E-9)".
3) Remove the handlebars. Refer to "Handlebars
Removal and Installation (Page 6B-3)".
4) Remove the fuel tank cover. Refer to "Exterior Parts
Removal and Installation in Section 9D (Page 9D-
4)".
5) Remove cotter pins, tie-rod end nuts and spring
washers.
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