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Summary of Contents for Suzuki LT-4WD 1990

  • Page 2 This manual contains up-to-date information at the time of its issue. Later made modifica­ tions and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about updated information, if any.
  • Page 3 LT-4WDH ('87-MODEL) V I EW O F S U Z U K I R IG H T S I D E L E F T SI D E...
  • Page 4 GENERAL INFORMATION PERIODIC MAINTANANCE AND TUNE-UP PROCEDURES ENGINE SHAFT DRIVE AND DIFFERENTIAL GEARS FUEL AND LUBLICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SEARVICING INFORMATION LT-F4WDH APPENDIX (L T-4WD AND L T-F4WD) L T-4WDJ AND L T-F4WDJ T-4WDK AND L T-F4WDK ('89-MODEL) L T-4WDL AND L T-F4WDL ('90-MODEL) T-4WDM AND L T-F4WDM ('91-MODEL) L T-F4WDXM ('91-MODEL) LT-F4WDV!W AND LT-F4WDXV/W ('97 AND '98-MODELS)
  • Page 7 G E N E R A L I N F O R M AT I O N V I N AND S E R I AL N U M B E R LOCAT I ONS The V I N n u m ber CD is sta m ped o n the left fra me member as s hown in photog ra ph.
  • Page 8 SUZUKI MOLY PASTE SUZUKI MOLY PASTE 99000-25140 99000-25140 • Oil filter m o u nti n g bo lt Cyli n de r h ead cover 3-77 Spark plu g cap SUZUKI BOND No. 1207B SUZUKI BOND N o. 1207B 99000-31140 99104-31140...
  • Page 9 Mag neto lead wire gro m m et 3-48 • Mati n g su rface of rig ht 3-58 crankcase SUZUKI BON D N o . 1215 SUZUKI BON D N o . 1207 B 99000-3111 0 99104-31140 • 3-58 Blow-by gas pipe •...
  • Page 10 Star-te r m ot o r h o u sing screws THREAD LOCK "1342 " THREAD LOCK "1342" 99000-32050 99000-32050 • 7-12 F r o n t brake sh oe back plate SUZUKI SILICO N E GREASE SUZUKI SI LICO N E GREASE 99000-2 51 00 99000-25100...
  • Page 11 When you rep l a c e a n y p a rt s , u s e o n l y g e n u i n e SUZUKI re p l a c e m e n t p a rts , o r t h e i r e q u iv a l e nt.
  • Page 13 1 -7 G E N E R A L I N F OR M AT I O N ELECTRICAL I g n it i o n type ......S U Z U K I " P E l " I g n it i o n t i m i ng .
  • Page 14 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · � l' f: fl / () l) / (; � � / � ]r f: � � � (;f: � (; fl f:l) {} l. f: ·...
  • Page 15 P ER I O D I C M A I N T E N A N C E A N D TU N E-U P P R O C E DU R E S PERIODIC MAINTENANCE SCHEDULE The cha rt bel ow l ists the reco mmended i n terva l s for a l l the req u i red period i c service work necessa ry to keep the veh icle operat i n g at peak perfo rmance a n d economy.
  • Page 16 P E R I O D I C M A I N T E N A N C E A N D TU N E-U P P R O C E DU R ES MA I NT ENANCE P ROCEDU R E S This section descri bes the service p roced u res fo r each sect i o n of Period ic M a i ntenance .
  • Page 17 2- 3 PE R I O D I C M A I N TE N A N CE A N D TU N E-UP P R O C E DU RE S AIR CLEANER ELE M E N T Clean and oil Every 1 0 0 0 (600 miles)
  • Page 19 2- 5 P ER I O D I C M A I N T E N A N C E A N D TU N E-U P PR O C E DUR E S VAlVE ClEARANCE I nspect I n it i a l m i l es) and ( 1 00 E very...
  • Page 21 PE R I O D I C M A I NTE N A N CE A N D TU NE-U P P R O CE DU RE S SPARK PLUG Inspect Every 1 000 km ( 600 miles) and Replace Every 6 000 km 000 miles) or 1 8 months R e m ove the ca rbo n deposits with w i re o r p i n and...
  • Page 22 P E R I O D I C M A I N T E N A N C E A N D TU N E-U P P R O C E DU R E S T H R OTT L E C A B L E Inspect Initial ( 1 00 miles) and...
  • Page 24 P E R I O D I C M A I N T E N A N C E A N D TU N E-U P P R O C E DU R E S 2- 1 0 • B efore putt i ng o n the o i l fi lter cap, check to be su re that the spri ng @ and a n ew 0- r i n g ®...
  • Page 25 2- 1 1 P E R I O D I C M A I N T E N A N C E A N D TU N E-U P P R O C E DU R E S CLUTCH I n spect I n it i a l 200 k m (100 m i les) a n d E very 2 000 km ( 1 200 m i l es ) •...
  • Page 27 P ER I O D I C M A I N T E N A N C E A N D TU N E-U P PR O C E DUR E S 2- 1 3 • The b rake l eve r p lay © as measu red at the l ever h o lder shou ld be i n ) when 3 - 7...
  • Page 28 P E R I O D I C M A I NT E N A N C E A N D TU N E-U P P R O C E DU R E S 2- 1 4 Co nsidering the d a nger to w h i ch such tra p ped a i r ex poses the mach i ne a n d rider, i t i s essent i a l th at, after remou nt i ng the brake a nd resto r i ng the brake syste m to the norma l cond ition, the brake f l u id...
  • Page 30 P E R I O D I C M A I N T E N A N C E A N D TU N E-U P P R O C E DU R E S 2- 1 6 STEERING I nspect I n itial 200 km (100 m i les) and Every 1 000 km (600 m i l es) S tee r i n g syste m s h o u l d be ad j u sted p ro pe r l y f o r s m oo t h...
  • Page 31 2- 1 7 P E R I O D I C M A I N T E N A N C E A N D TU N E-U P P R O C E DU R E S C H A S S I S N U T S A N D B O LT S Tighten I n itial 2 0 0 km ( 1 00 m i l es) and Every 1 000 k m (600 m i les ) E N G I N E MO U NT I N G B O LTS A N D N UTS...
  • Page 34 P E R I O D I C M A I N T E N A N C E A N D T U N E- U P P R O C E D U R E S 2- 2 0 GENERAL LUBRICATION L u b r i cate E very 1 000 k m (600 m i l es) P ro p er l u b ri ca tio n i s i m p ort a n t f o r s m oot h op e r a tio n and l o n g l i f e o f e ach w or k i ng p a rt o f t h e v e h i c l e .
  • Page 36: Table Of Contents

    · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3- 1 C O MPR E SSI O N CH E C K ·...
  • Page 37: C O Mpr E Ssi O N Ch E C K

    3- 1 E N G I N E CO M P R E S S I ON CH ECK C O M PRESSION TEST PROCEDURE N OT E : Before test i n g t h e engine for c omp ress i o n p ressu re, make s u re that t h e cy l i nd e r h ead n uts are tightened to specified torq u e val u es a n d valves a r e p ro perly adj u sted .
  • Page 38: Initi A L Eng A Ge M E Nt A N D C L U T Ch L Oc K - U P Insp E C Ti O N

    E N G I N E I N I T I AL ENG A G E M ENT AN D C L U T C H LOC K- U P I N S P E C T I ON CLUTCH LOCK -UP INSPECTION The L T-4W D is equ i pped with a centrifu ga l type Perform th i s i nspection to determ i n e i f the c l u tch automatic c l utch.
  • Page 40: E Ngine R E M O V A L A N D R Em Ou Nting

    E N G I N E E N G I N E R EMOVAL A N D R EMOU N T I N G ENGINE REM OVAL Befo re tak ing the engine out of the frame, thorou g h l y clean the engine with a su ita b l e c l ea n e r. The p roced u re of engine rem ova l is seq uenti a l l y exp l a i n ed i n the fo l l ow i n g steps.
  • Page 41 E N G I N E 3 - 5 • Suppo rt the veh ic l e by j ack o r b l ock . • R emove the rear whee ls, right and l eft, by l oos­ e n i n g n uts.
  • Page 43 E N G I N E • Loosen two screws and take out the carbu reto r assemb l y . • Loosen a n a i r c lea ner i n take p i pe c l a m p screw G) .
  • Page 44 E N G I N E • Pu l l o u t the l ever mou nting b rac kets CD . • D iscon nect the speedom ete r cab l e . • D i scon nect the l ead wi res. ®...
  • Page 46 E N G I N E 3- 1 0 ENGINE RE MOUNTING N OT E : The e n g i n e ca n be mou nted i n the reverse order of T h e eng i ne m o u n t i n g n uts a re sel f- l oc k n u t . re mova l .
  • Page 47 3- 1 1 E N G I N E • I nsta l l the u n iversa l j o i n t correctl y . • W h e n i nsta l l i n g the reverse l ever, t ra n sm issio n l ever a nd su b-tra nsm ission l ever, a l i g n t h e g roove with sl it ®...
  • Page 48 E N G I N E 3- 1 2 T i g hten t h e r ea r suspensi o n m o u nt i n g b o l t CD ® a nd s u spens i o n a r m m o u nt i ng b o l ts t o t h e spec i f i ed t o rq u e .
  • Page 50 E N G I N E 3- 1 4 • R e m o ve t h e va l ve i n specti o n caps a n d spa r k p l u g . • L oo se n the cy l i nd e r head c o ve r b o l ts i n t h e or d e r i nd icated i n p h o t o a n d d etach t h e cy l i n d e r h e a d c o ve r .
  • Page 51 3- 1 5 E N G I N E • R e m o v e t h e C- r i n g CD . N OT E : ® T he cam cha i n ten s i o n e r bolt i s t o b e removed o n l y w h e n d isasse m b l i n g t h e e ng i ne .
  • Page 52 E N G I N E 3 - 1 6 • P l ace a clean rag over the cy l i nd e r base to p revent piston p i n ci rc l i p from d ro p p i n g i nto cra n kcase, and then remove the p i sto n p i n ci rcl i p with l ong-nose p l i e rs.
  • Page 53 3- 1 7 E N G I N E • R emove the c l utch re l ease ba l l asse m b l y and bracket ® . • R emove the b o l t a nd then rem ove the c l utch rel ease arm @ .
  • Page 55 3- 1 9 E N G I N E • R e move t h e washer CD a nd p r i m a ry d riven gear asse m b l y ® . • Remove the spacer @ a n d washer @ . •...
  • Page 56 E N G I N E 3 - 2 0 R e m ove t h e b o l t a n d w a s h e r, t h e n r e m ov e ® . t h e g e a rs h i f t e r ®...
  • Page 57 3-2 1 E N G I N E • R emove the speedo meter d ri ve gea rbox. • R emove the sta rter cu p nut with the specia l too l . 099 1 0-20 1 1 5 Con rad h o l de r N O T E : To prevent the con ro d sma l l end from getti n g...
  • Page 58 E N G I N E 3 - 2 2 • R e m ove the was h e r a n d s u b- t ra n s m i s s i o n d rive N o. gea r ®...
  • Page 60 E N G I N E 3 - 2 4 • R e m ove the mag n eto n u t w i t h the spec i a l too l w h i le h o ld i ng t h e mag neto w i t h offset wren c h .
  • Page 61 3-25 E N G I N E • Remove the ca m cha i n . • Remove the neutra l switc h . 0-ri ng CD : ® : Spri n g • R emove t h e reverse l ever b rac ket. •...
  • Page 62 E N G I N E 3-26 • R e m ove the cran kcase secu ri n g bo lts fo r left side. N OT E : B e s u re to remove a bolt Q) i nside. •...
  • Page 63 3-27 E N G I N E • Pu l l out the s h i ft cam CD and reverse ca m ® I and then take out the reve rse s h i ft fork a n d s h i ft fo rks.
  • Page 64 E N G I N E 3-28 R e m ove t h e seco n d a ry d ri ve n o u t p u t s h a ft CD . asse m b l y e��...
  • Page 66 E N G I N E 3 - 3 0 • Com p ress the va l ve spri n g . 099 1 6- 1 45 1 0 Va l ve spri n g c o m p resso r 099 1 6- 1 49 1 0 Attachment •...
  • Page 67: Cy L I Nder Head

    3-3 1 E N G I N E C Y L I N D E R H EA D C OV E R D I S T O R T I O N Afte r re moving sea l a n t ( S U Z U K I B O N D No. 1 20 7 8 ) from the fitt i n g s u rface of the cy l i n d e r h e a d cover, p l ace t h e cy l i nd e r h ead cove r o n a su rface plate and check for d i stort i o n with a...
  • Page 69 3-33 E N G I N E VALVE STEM WEAR I f the va l ve ste m is worn d own to the l i m it, when measu red with a m i cromete r, and the cleara nce is fo u nd to be in excess of the l i m it i nd i cated above, rep l ace the va l ve, if the stem is with i n the l i m it, then rep l ace the g u ide.
  • Page 70 E N G I N E 3 - 3 4 • After fitting va l ve g u i d es, re-f i n ish thei r g u i d i n g bores with a 5 . 5 m m rea mer CD a n d h a nd l e ® . Be s u re to c l ea n and o i l the g u i des after rea m i n g .
  • Page 72 E N G I N E 3-36 CA U T I O N : C o n tact a r e a too h i g h a n d t o o w i d e o n face o f Cut the m i n i m u m a m o u nt necessa ry from the va l ve seat to prevent the possi b i l ity of the valve...
  • Page 73 3-37 E N G I N E VALVE SPRINGS Check the spri n gs for st re n gth by measu r i n g thei r free l en gths and a l so the fo rce req u i red to com p ress t h e m .
  • Page 74 E N G I N E 3 - 3 8 • F it a va lve spri n g reta i ner, compress the spri n gs with a va lve spri n g com p resso r a n d i n se rt the cotte rs .
  • Page 75 D o not a p p l y SUZUKI N D N o . 1 2078 u nt i l after the o i l c l ear­ a nce has been determ i ned .
  • Page 76: Cam Cha In

    E N G I N E 3-40 CAM CH AIN 2 0 -PITCH LENGTH Pu l l the chain tight to rem ove any sl ack, then usi n g ven ier ca l i pe rs, measu re the 20- p itch ( 2 1 p i n s ) l e n gth o f cam cha i n .
  • Page 77 E N G I N E 3-4 1 P I ST O N - C Y L I N D E R C L EA R A N C E As a resu lt of the previous m easure m ent, i f the p i ston to cy l i nder cleara nce exceeds the l i m it s h own in t h e ta b l e be l ow, ove rh a u l the cy l i nd e r a nd use a n ove rsize p isto n, o r rep l ace both cy l i nder...
  • Page 78: Pist O N Ring

    E N G I N E 3-42 PISTON RING FREE END GAP AND PISTON RING END GAP Befo re i n sta l l i n g pisto n r i n gs, meas u re the free end gap of each ri ng usi ng ve rn i e r ca l i pers . N ext, fit t h e r i n g i n the cy l i n de r, a n d measu re each ri n g end gap usi n g a th ickness gauge.
  • Page 79 3-43 E N G I N E P I S TO N P I N A N D P I N BO RE U s i n g a cal i per gauge, measu re the p i ston p i n b o re i n s i d e d i a m ete r, a n d u s i n g a m icro meter measu re the pisto n p i n outside d ia mete r .
  • Page 80: Cra N K S Haf T

    E N G I N E 3-44 Push t h e big end of the con rad to one side a nd measu re the side clea ra nce with a th ick n ess gauge. 09900-20803 Th i ckness gauge Sta ndard Serv i ce L i m it 0 .
  • Page 81 E N G I N E 3-45 C LUTCH DRIVEN PLATE Meas u re each d riven p l ate for d i stort i o n with a t h i ckness gauge. R e p l ace driven p l ates w h i ch ex­ ceed the l i m it.
  • Page 82 E N G I N E 3-46 ONE- WAY CLUTCH I nspect the one-way c l utch CD by hand wh i l e fixi n g i t i n the c l utch h o u s i n g . R otate the i n ne r ®...
  • Page 83 3-47 E N G I N E S TA RT E R C L U T C H • Hold the rotor with 2 9 m m off-set wren ch, a n d remove the th ree A l l e n bolts. •...
  • Page 88: Transmiss I On

    E N G I N E 3 - 5 2 TRANSMISS I ON N OT E : I n reassem b l i n g the transm i ssi o n , attention m u st be g iven to the l ocat i o n s and pos i t i o n s of washers a n d c i rcl i ps.
  • Page 90 E N G I N E 3- 5 4 When i n sta l l i n g the bush i n g on the shaft, a l i g n t h e o i hole CD of the sh aft w i t h the bush i n g o i l h o l e ®...
  • Page 91 3 - 5 5 E N G I N E A M A N D' FI�O�R�K�- -- - · G ea rs h i ft e r · G e a r s h l t m g s h a ft G ea rsh ift l ev e r ( E n g m e s "...
  • Page 92 E N G I N E 3 - 5 6 • F it the gea rsh i ft forks N o. 1 Q) , No. 2 @ and N o . 3 ® i nto the gea rsh i ft i n g g rooves. •...
  • Page 93 3- 5 7 E N G I N E • Afte r i nsta l l i n g t h e gears h i ft fo r ks and gea rs, tu rn the gears h i ft ca m and check to see that gears e n gage positive l y .
  • Page 94 E N G I N E 3- 5 8 CAUT I O N : U se a new 0 - r i n g to p revent o i l l ea kage. N O T E : Coat t h e 0- r i n g o f su m p f i l ter c a p w i t h g rease. •...
  • Page 95: R Eve Rs E Swit Ch A N D R Eve Rs E Ca M St O Pp E R B O L T

    E N G I N E 3 - 5 9 • After the cran kcase b o l ts h ave been t i g htened, check if cra n kshaft, cou ntershaft, d r iveshaft, su b-tra nsm iss i o n output s haft, rea r f i n a l d r i ve n s haft a nd secondary d riven output s haft rotate smoot h l y .
  • Page 96: Starte R C L U T Ch A N D Ma Gneto Ro T Or

    3 - 6 0 E N G I N E STA RT E R C L UTC H A N D M AG N ETO R OTO R • E n gage the ca m d ri ve c h a i n o n the sprocket. •...
  • Page 97: Sub-Transmission

    3-6 1 E N G I N E • I n sta l l the s pace r, sta rte r i d l e gear CD a nd shaft ® . SUB-TRANSMISSION N OT E : I n reasse m b l i ng t h e su b-tra n s m i ss i o n , attention m u st be g iven t o the l ocat i o n s a n d positi o n s of washers a n d c i rc l i ps.
  • Page 99: S U B - Transmissi O N Ge Ar S H I Ft Cam And For K

    3-6 3 E N G I N E S U B -T RAN S M I S S I O N G EA R S H I FT CA M A N D F O R K S u b- t r a n sm i s s i o n s h i ft c a m sto p pe r ®...
  • Page 100: M Agneto Cover

    E N G I N E 3-6 4 • H o o k the ca m stoppe r s p r i n g CD . N OT E : After the su b-transm iss i o n gea rsh i ft i n g fork shafts gearsh ift i n g forks have...
  • Page 102: Oil Pump Drive Gear

    3-6 6 E N G I N E • F it the spr i n g to the gearsh ift i n g shaft co rrect l y. • I n sta l l the gea rsh ift i n g shaft so that the p i n CD is positi oned between the s p ri n g .
  • Page 103: Oil Pu M P

    3-67 E N G I N E OIL PU M P • Before mou nt i n g t h e o i l pu m p , a p p l y e n g i n e o i l t o t h e s l i d i n g s u rfaces o f t h e case, outer rotor, i n ne r roto r and shaft.
  • Page 104 E N G I N E 3-68 CLUTCH • I nsta l l the washe r, spacer, pri m a ry drive n gea r and washe r. • I nsta l l the c l utch p l ates to the c l utch s l eeve h u b and en gage the c l utch pressu re p l ate to the s l eeve hub.
  • Page 106 E N G I N E • T h e o n e-wa y c l u t c h m u st b e i n s ta l l e d i n t h e p ro p e r d i rect i o n a s s h o w n i n F i g . NOT E : W h e n i n sta l l i n g t h e one-way c l u tc h to t h e c l u tc h housi n g, face t h e c u t...
  • Page 107 3-7 1 E N G I N E • I nsta l l the c l utch re l ease b a l l asse m b l y a s s h own i n F ig. • I nsta l l jet CD .
  • Page 108: Oil Ring

    E N G I N E 3-72 • Tighten the rel ease adj u st i n g bolt u nt i l resi st­ ance is fe lt, t h en l oosen it 0 - 1 /8 tu r n . •...
  • Page 109: Pist O In Ad In D C Yl Iind E R

    3- 7 3 E N G I N E Position the gaps of the th ree ri n gs as sh own . Befo re i nse rt i n g p i ston i n to the cy l i n d e r, check th at the gaps a re so l ocated .
  • Page 110 E N G I N E 3-74 N OT E : There is a h o l der for the botto m end of the cam chain guide cast in the crankcase. B e sure that the gu ide i s i n serted p ro perly or b i nd i ng of the cam cha i n and guide may res u l t .
  • Page 111 3- 7 5 E N G I N E • Afte r tig hte n i ng the cy l i nder h ead n uts to the s peci fied torq ue, ti ghten the cy l i nd e r head and base n uts CD .
  • Page 112: A L Ve R O C K E R Ar M And Sh Aft

    E N G I N E 3 - 7 6 • Bend u p the washer tong u e positive l y to l o c k the b o l ts. • App l y S U Z U K I M O LY PAST E to the cams h aft u r n 99000-25 1 40 S U Z U K I M o ly Paste...
  • Page 113 E N G I N E 3- 7 7 CYLI NDER HEA D T h o ro u g h l y w i pe off o i l "f r o m t h e f i tt i n g s u rfa ce s o f cy l i n d e r h e a d a n d c ove r .
  • Page 114: Cam Drive Chain Tensioner

    3 - 7 8 E N G I N E CAM DRIVE CHAIN TENSIONER I n sta l l t h e cam d rive cha i n te nsioner fo l low i ng the p roced u re be l ow. •...
  • Page 116 E N G I N E 3 - 8 0 REASSEMBLY Asse m b l e the recoi l sta rter, i n the reverse order of d isasse m b ly. Pay attention to the fo l l owi n g poi n ts. •...
  • Page 121 4 -3 S H A F T D R I V E A N D D I F F E R E N T I A L REMOVAL • R emove the engi ne. ( R efer to page 3-4. ) •...
  • Page 123 S H A FT D R I V E A N D D I F F E R E N T I A L • Remove the bea r i ng a n d s h i m s with t h e hyd ra u l ic p ress.
  • Page 124 S H A F T D R I V E A N D D I F F E R E N T I A L I N S P ECTI O N • I nsert the u n iversa l J O i nt t o the bea r i n g and check the p lay by mov i n g the u n iversa l j o i nt.
  • Page 125 S H A F T D R I V E A N D D I F F E R E N T I A L • I n sta l l the removed sh i m o n the secondary d riven output shaft, and then press-fit the bearing o n the secondary d riven output shaft.
  • Page 127 S H A FT D R I V E A N D D I F F E R E N T I A L SECONDARY GEARS SH I M ADJ U STMENT BAC K LASH NOTE: When m easu r i ng the bac k lash or c h ec k i ng tooth contact, it is u nnecessary that u n iversa l joint is insta l l ed and thread l oc k is a p p l ied to...
  • Page 128 S H A F T D R I V E A N D D I F F E R E N T I A L 4- 1 0 TOOTH C O N TACT CD I N CO R R E CT ( Co ntact at tooth top ) •...
  • Page 129 4- 1 1 S H A F T D R I V E A N D D I F F E R E N T I A L L ist of sh i m @ ( Secondary d r i ve gear sh i m ) L i st of s h i m ®...
  • Page 130 S H A F T D R I V E A N D D I F F E R E N T I A L 4- 1 2 N O T E : Before insta l l i n g t h e front d r ive o u tput shaft, asse m b le the u n iversa l j o i nt.
  • Page 131 S H A F T D R I V E A N D D I F F E R E N T I A L 4- 1 3 R EA R AX L E R E M OVA L A N D D I SASS E M B LY •...
  • Page 132 S H A F T D R I V E A N D D I F F E R E N T I A L 4- 1 4 D I F F E R E N T I A L B EV E l G EA R S C O N ST R U CT I O N CD F ro n t d rive bev e l g e a r h o u s i ng ®...
  • Page 134 S H A F T D R I V E A N D D I F F E R E N T I A L 4- 1 6 • R e m ove the cotter p i ns, a n d then l oosen the right a n d left tie rod end n u ts.
  • Page 135 S H A F T D R I V E A N D D I F F E R E N T I A L 4- 1 7 F R O N T D R I VE B EVEL G EA R H O U S I NG D I SASS E MB LY •...
  • Page 136 S H A F T D R I V E A N D D I F F E R E N T I A L 4- 1 8 • Remove the d u st sea l w i t h the speci a l too l. 099 1 3-50 1 2 1 O i l sea l remover •...
  • Page 138 S H A F T D R I V E A N D D I F F E R E N T I A L 4-20 • M easu re the bea r i ng pre- l oad with the specia l too l s .
  • Page 139 4-2 1 S H A F T D R I V E A N D D I F F E R E N T I A L F R O N T D R I VEN BEVEL GEAR A N D D I F F EREN T I A L GEARS D I SASS E MB LY •...
  • Page 140 4-22 S H A F T D R I V E A N D D I F F E R E N T I A L • Remove the cam shaft and sh i ft fork shaft. • Remove the cam and washer . •...
  • Page 141 4-2 3 S H A F T D R I V E A N D D I F F E R E N T I A L • Remove the fro nt d r iven o u tp u t shaft a n d sh i m s. •...
  • Page 143 4-2 5 S H A F T D R I V E A N D D I F F E R E N T I A L • I nsta l l a new front d riven bevel gear housing right beari ng with the specia l too l.
  • Page 144 S H A F T D R I V E A N D D I F F E R E N T I A L 4-26 • I n sp e ct the boot a n d boot b a n d s fo r crack o r d ete r i o rat ion o r b reakage .
  • Page 145 4-27 S H A F T D R I V E A N D D l F F E R E N T I A L • Remove the p i n w i t h the magnet i c ha nd . T h ru st washer ®...
  • Page 146 S H A F T D R I V E A N D D I F F E R E N T I A L 4-28 • (0.02 I n se rt the i n ) d ia m ete r so l d e r between cente r teeth o f r i g ht s i d e g e a r a n d ce n t e r teeth of p i n io n .
  • Page 150 S H A F T D R I V E A N D D I F F E R E N T I A L 4-32 • ® M easu re the h e i g ht of t h e mat i n g s u rface of g ear case and d riven g ear back s i d e with t h e spec i a l t o o l and strai g hted g e .
  • Page 151 S H A F T D R I V E A N D D I F F E R E N T I A L 4-33 TOOTH CONTACT CD I N CO R R E CT (Contact at tooth top) •...
  • Page 152 S H A F T D R I V E A N D D I F F E R E N T I A L 4-34 ® L ist of sh i ms ( Refer to page 4-38 . ) N OT E : U n it : m m I f i t i s necessary to adj u st the sh i m th ick ness...
  • Page 153 4-35 S H A F T D R I V E A N D D I F F E R E N T I A L • T ighten t h e fro nt d r ive bevel gear housing bo lts to the spec ified to rq u e .
  • Page 154 S H A F T D R I V E A N D D I F F E R E N T I A L 4-36 • I nsta l l the gasket a n d d owe l p i n s, a n d t h en i n sta l l t h e cove r a n d cam sto p p e r .
  • Page 155 S H A F T D R I V E A N D D I F F E R E N T I A L 4-37 • App l y SU Z U K I S U P E R G R E A S E "A " t o the sp l i ne of p ro pe l ler shaft and u n iversa l j o i nt.
  • Page 159 5- 1 F U E L A N D L U B R I C AT I O N S Y ST E M F U E L S Y S T E M A vacu u m-operated fue l pu m p is used to su pply fuel from the fuel ta n k to the ca rb u retor. The p u m p is n ecessa ry as the fuel tan k is mou nted l owe r than the ca rbu reto r fuel bow l .
  • Page 161 F U E L A N D L U B R I C AT I O N S Y ST E M FUEL COCK RE MOVAL AND INSPECTION • D ra i n fu e l co m p lete l y . WA R N I N G : G aso l i ne i s very exp l osive.
  • Page 162 F U E L A N D L U B R I C AT I O N S Y ST E M F U E L P U M P F U E L P U M P M EC HA N I S M Vacu u m pu lsations from the ca rb u retor i n ta ke tract a re used to operate the p u m p d i a p h ra g m .
  • Page 165 F U E L A N D L U B R I C AT I O N S Y S T E M S P EC I F I CATI O N I T E M S P EC I F I CAT I O N Carb u reto r type M I K U N I V M 24SS B o re size...
  • Page 166 F U E L A N D L U B R I C AT I O N S Y ST E M 5- 8 S L OW S Y S T E M This system su p p l ies fuel d u ri n g engi n e o pe rati on with piston va l ve cl osed or s l i g h t l y opened. The fue l m ete red by the p i l ot jet is m i xed with the proper a m o u nt of a i r m etered by the p i l ot a i r jet and is sepa rate d into f i n e partic l es.
  • Page 167 F U E L A N D L U B R I C A T I O N S Y S T E M M AIN SYSTE M This syste m su p p l ies f u e l d u ri n g e n g i n e operation when the piston va l ve is 1 /4- F u l l open . The fue l passes th rough the m a i n jet and m i xes with a i r metered by the ma i n a i r jet.
  • Page 168 F U E L A N D L U B R I C AT I O N S Y ST E M 5- 1 0 STARTER SYSTE M WITH LI MITER When the sta rte r va l ve is p u l led u p, the f u e l mete red by the sta rte r jet is m i xed with a i r com i ng from the f l oat cha m ber.
  • Page 169 F U E L A N D L U B R I C AT I O N S Y ST E M 5- 1 1 F LO AT S YS TE M F l oats a n d need l e val ve a re associated w i t h t h e sam e mech a n i s m , so that, as t h e f l oats m ove u p and down , the need l e va l ve too m oves l i kewise.
  • Page 172 F U E L A N D L U B R I C AT I O N S Y ST E M 5- 1 4 INSPECTION Check fo l lowi n g items for any damage o r c l ogg i n g . P i l ot jet G as ket Main jet...
  • Page 173 F U E L A N D L U B R I C AT I O N S Y S T E M 5- 1 5 C A R B U R ETOR R EAS S E M B LY A N D R E M O U NTI N G R eassemb le a nd...
  • Page 175 F U E L A N D L U B R I C A T I O N S Y ST E M 5- 1 7 L U B R I C AT I O N S Y ST E M OI L PRESSURE •...
  • Page 177 F U E L A N D L U B R I C A T I O N S Y ST E M 5- 1 9 L U B R I CAT I O N SYSTE M...
  • Page 178 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · I GN I T I ON S Y S TE M ·...
  • Page 179 E L E C T R I C A L S Y ST E M 6- 1 I G N I T I O N S Y S T E M DESCRIPTION I n the capacito r d isch a rged igmt1on system, the e l ectrica l energy gen e rated by the magneto cha rges the ca pacitor.
  • Page 180 E L E C T R I C A L S Y ST E M INSPECTION MAG N E TO CO I L • R e m ove the seat. • D iscon nect the p ic k-u p and power sou rce lead wi re coup lers at the magneto.
  • Page 181 E L E CT R I C A L S Y ST E M S PA R K P L UG • C l ean the p l ug with a wi re b rush a nd p i n . Use the p i n to remove ca rbon, ta k i n g care not to d a mage the porce l a i n .
  • Page 182 E L E C T R I C A L S Y ST E M C H A R G I N G S Y S T E M I NS P E C T I O N C H A R G I N G O UT PUT •...
  • Page 183 E L E CT R I C A L S Y ST E M A C G E N E RATO R CO N T I N U I TY • U sing the pocket tester, check the conti n u ity o r resistance between the th ree ye l low lead wi res.
  • Page 184 E L E CT R I C A L S Y ST E M S TA RTE R S Y S T E M D ES C R I PTI O N The sta rter system is shown i n the d iagra m be l ow : namely, the sta rter motor, sta rter rel ay, neutra l relay, reverse switch , neutra l switc h , sta rte r button , engine stop switch , i g n ition switch a n d battery .
  • Page 185 E L E CT R I C A L S Y ST E M S TA RT E R M OTO R I N S P ECTI O N CA R B O N B R US H When t h e b rushes a re wo rn, the motor w i l l be u n a b l e to prod uce sufficient torque, and the eng i n e wi l l be d i fficu l t to turn over.
  • Page 187 E L E C T R I C A L S Y ST E M • I nstal l t h e a rmatu re t o t h e housing end. N OT E : Be sure t o check that t h e brushes are seated on the com m u tator proper ly.
  • Page 188 E L E CT R I C A L S Y ST E M 6- 1 0 STARTE R RELAY INSPECTION • R e m ove the seat, head l ig h t cover, battery a n d fro n t fender. R efer t o page 7-2 .
  • Page 190 E L E CT R I C A L S Y ST E M 6- 1 2 S W I T C H E S I N S PECT I O N I nspect each switch fo r co nt i n u ity with the pocket teste r referring to the chart.
  • Page 191 E L E C T R I C A L S Y ST E M 6- 1 3 NEUTRAL SWITCH G ro u nd O F F REVERSE SWITCH B I/ B B I/ R N E UT R A L R E V E R S E W I R E CO LO R B/W .
  • Page 192 6- 1 4 E L E C T R I C A L S Y ST E M B ATT E RY SPECIFICATIONS B attery Type d esignat ion F B 1 4A-A2 B attery breather hose 1 2V, 50.4 kC ( 1 4 A h ) / Capacity 1 0 H R Sta nd a rd el ectrol yte...
  • Page 193 E L E C T R I C A L S Y ST E M 6- 1 5 C heck t h e e l ectro l yte l eve l and add d ist i l l ed water, as necessa ry to ra ise the e l ectro lyte to each cel l's M AX .
  • Page 194 E L E CT R I C A L S Y ST E M 6- 1 6 SERVICE LIFE Lead oxide is a p p l ied to the po l e p l ates of the When a battery is l eft fo r a l o ng term without battery w h i ch w i l l come off g rad ua l l y d u r i ng the using, it is a pt to subj ect to su l fati o n .
  • Page 196 · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7 - F RO NT C AR RI E R AND FRONT F E ND E R · · · · F RONT AND RE AR ..,fi EEL �...
  • Page 197 l- l C H ASS I S F R O N T CA R R I E R A N D F R O N T F E N D E R...
  • Page 198 C H ASS I S REM OVAL • Remove the front carrier mouting bo lts. • R e m ove the front carrier. • R e m ove the h ead l ight cover. • D i scon nect the battery 8 l ead w i re, and then battery Et>...
  • Page 202 C H ASS I S • M o u nt the t i re o n the whee l by h a n d as shown in the i l l ustrat ion . N OT E : Before mou nt i ng the t i re o n the wheel, in­ spect the sea l i ng port i o n of w h ee l .
  • Page 205 C H ASS I S • R emove t h e two shoe h o l d e r sp r i n gs by t u rn i n g the p i n s 9 0 ° and t h e n remove t h e shoes. •...
  • Page 206 C H ASS I S 7- 1 0 • Loosen the wheel cy l i nder mou nting bolts, and then remove the whee l cy l i nder. WH E E L CYL I N DE R • Rem ove the gasket, dust sea l , pisto ns and spr i n g . G asket Dust sea l ®...
  • Page 208 C H ASS I S 7- 1 2 • Tighten the whee l cy l i nder bo lts to the specified to rq ue. 1 0 - 13 N · m Tighte n i ng torque 1 .0 - 1 . 3 kg- m 7.0 - 9 .
  • Page 209 C H ASS I S 7 - 1 3 • I nsta l l the shoes CD , strut ® and spr i n gs ® , @ , @ to the p roper position as shown i n figu re. WA R N I N G : After c om p l et i ng the above steps, make s u re that the stopper CD i s h itched o n the h o l der...
  • Page 210 7- 1 4 C H ASS I S • Before insta l l i n g b rake d ru m , to m ax i m ize brake shoe-to-d rum c l ea ra nce, put screwd river between strut and ratchet, and push d own ratchet as show n in F igu re.
  • Page 211 7- 1 5 C H ASS I S M A S T E R CYL I N D E R R E MOVA L • P l ace a c l oth u nderneath the u n io n bolt o n the m aste r cy l inder to catch sp i l l ed d rops of b rake f l u id .
  • Page 212 C H ASS I S 7- 1 6 INSP ECTION • I n spect m aste r cy l i nd e r b o re fo r a n y scratch es o r oth e r d a m age. •...
  • Page 214 C H ASS I S 7- 1 8 • R e move the front whee l . ( R efer to page 7-4. ) • R e m ove the front b rake. ( R efer to page 7-8. ) •...
  • Page 215 7- 1 9 C H ASS I S • Loosen t h e shock absorber l ower b o l t CD . • Loosen the k n u c k l e u pper/ l ower bolts ® . •...
  • Page 217 C H AS S I S 7-2 1 I N S P E CT I O N S H O C K ABSO R B E R I nspect the shock abso rber for o i l l eakage o r oth e r damage.
  • Page 219 7-2 3 C H ASS I S • I nsta l l t h e wheel beari ngs with the spec i a l too l . 09924-845 1 0 Bearing i nsta l l e r set • I nsta l l the out side bea r i n g fi rst. N O T E : W hen i nsta l l i n g t h e bea r i ng, seal ed s i d e of bearing comes o u tside.
  • Page 220 C H AS S I S 7-24 T i g h te n th e ste e r i n g k n u c k l e en d u p p e r a n d l owe r bo l ts t o t h e spec i f i e d torq u e by h o l d i n g t h e stee r i n g k n u c k l e e n d w i t h vise.
  • Page 221 C H AS S I S 7-2 5 S T E E R I N G Stee r i ng shaft h o l d e r ® T ie- rod end ( outer) @ T ie- rod end ( i nner) D ust seal Dust seal Dust sea l...
  • Page 222 C H ASS I S 7-26 RE M O VAL • R e m ove the front fender. ( R efer to page 7 -2J • Remove the speedometer l ower cover. • D iscon nect the l ead wi res a n d speedo m eter cab l e.
  • Page 223 7-27 C H AS S I S • Loosen t h e h a n d l e b a rs c l a m p bo lts. • R emove t h e l ever case. { R efer to page 7 - 52 . ) •...
  • Page 224 C H ASS I S 7-28 • Afte r removing the cotter p i ns, l oosen the tie­ rod end nuts. • Rem ove the tie-rods, right and l eft, wh i l e p u l l i ng the fuel ta n k backward . •...
  • Page 225 C H ASS I S 7-2 9 • Loosen t h e knuckle bolt, a n d then separate the t i e- rod and steering knuckle arm. • Separate the tie- rod ends CD , n uts , ® and t i e rods @ .
  • Page 226 C H AS S I S 7-30 B US H I nspect the bush for wea r or other damage. ST E E R I N G S H A F T A N D H O L D E R I n spect the steer i n g sh aft fo r d isto rtion o r bend.
  • Page 227 7-3 1 C H ASS I S ST E E R I N G D UST S E A L • App l y grease to the d u st sea l a n d i n sta l l i t t o the steering shaft .
  • Page 229 C H AS S I S 7-33 HAN D L EBARS • Set the h a n d l ebars to m atch its p u nched m ark CD to the m at i ng face of the hand l ebars c l a m ps. •...
  • Page 230 C H ASS I S 7-34 T O E - I N A D J U S T M E N T The p rocedu re fo r adj u st i n g the toe- i n i s a s fo l lows. •...
  • Page 231 C H AS S I S 7-3 5 F R O N T W H E E L , F R O N T S U S P E N S I O N A N D S T E E R I N G R EAS S E M B L I N G I N F O R M AT I O N \' \ Ac:)
  • Page 232 C H ASS I S 7-36 T I G HT N I N G TO R QU E N O T E I T E M N - m k g-m l b-ft F o r U . S. m od e l F o r other m od e l s CD H a n d lebars 1 8-28...
  • Page 233 C H AS S I S 7-37 R EA R B RA K E B rake d ru m ® 0- r i ng @ Rear wheel h ub B ra ke shoe B rake cam shaft ® 0- r i ng (j) B reather hose 0- r i n g ®...
  • Page 235 7-39 C H AS S I S • Remove the 0- r i n g. • Remove the spring, and then remove the b rake cam lever bo lt. I N S P E C T I O N • I nspect the d ust sea l a nd 0-r i n g for wear o r other damage.
  • Page 236 C H AS S I S 7-40 I nspect the fo l l owi ng items • B ra ke d ru m ( R efer to page 7- 1 0. ) 1 65 . 7 m m Servi ce Li m it ( 6 .
  • Page 239 7-43 C H ASS I S R E MOVAL AN D D I SAS S E M B LY • Remove the rear whee l . ( Refer t o page 7-4. ) • R emove the rear brake. ( Refer to page 7-3 7 . ) •...
  • Page 240 C H ASS I S 7-44 • Then remove the outer and i n ne r beari ngs with the specia l too ls. B ea r i n g remover 099 1 3-607 1 0 09930-30 1 02 S l i d i n g shaft INSPECTION S H O C K ABSO R B E R •...
  • Page 241 C H ASS I S 7-45 H U B B E A R I N G I nspect the p l ay of h u b bea r i n gs i n n e r race by hand wh i l e it is i n the suspension a rm . R o tate the i n ner race b y hand t o i n spect for abnormal no ise a n d smooth rotatio n .
  • Page 246 C H ASS I S 7-5 0 R EA R B RA K E , R EA R S U S P E N S I O N A N D R EA R AX L E S H A F T R EAS S E M B L I N G I N F O R M AT I O N Tighte n i ng torq u e kg-m...
  • Page 248 C H ASS I S 7-52 L EV E R C A S E R E M O VAL • Remove the front fender. ( Refer to page 7-2. ) • D i scon nect the sel ection l ever cab l e, reverse cab l e and ra nge l ever cable.
  • Page 250 C H ASS I S 7-5 4 • R e m ove the d u st sea l . • R e m ove the spacer and 0- ring. INSPECTION • I nspect the shaft for wea r, d istortion o r othe r damage .
  • Page 251 7-55 C H AS S I S R EASS E M BLY • R eassem b l e and remo u n t the l ever case i n the a l so carry o u t t h e fo l l ow i n g steps : •...
  • Page 252 C H AS S I S 7-56 P U S H - P U L L C A B L E I N S TA L L AT I O N A N D A D J U S T M E N T [ 1 ] S E L E C T I O N L EV E R C A B L E I nsta l l the lever a n d a cable o n to the d ifferenti a l...
  • Page 253 7-57 C H AS S I S Adjust the cab l e as fo l l ows. position notch By tu rn i n g th e adjust i n g n u ts @ , a l ig n the cab l e h o l e of t h e sh i ft lever with cab l e eye rod h o l e , a n d then f i x t h e cab l e t o the stopper of t h e sh ift l ever side by t i g h ten i n g the adjust i n g n u ts @ .
  • Page 255 C H ASS I S 7- 59 B RA K E H O S E R O U T I N G Master cylinder ---- B r a ke fluid bolt Front b r a ke hose No c ontact b etween the f ro nt brake hose and H a rness steering plate.
  • Page 256 T ROUB LE S H OOT I N G · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8 - 1 W I R I N G D I A G R A M ·...
  • Page 257 S E R V I C I N G I N F O R M AT I O N 8- 1 T R O U B L E S H OO T I N G E N G I N E Com p l a i nt Sym ptom a n d possi b l e causes R emedy...
  • Page 258 S E R V I C I N G I N F O R M AT I O N C o m p l a i n t S y m p t o m a nd poss i b l e causes R e m ed y N o i sy e n g i ne.
  • Page 259 S E R V I C I N G I N F O R M AT I O N Com p l a i n t Sym p fo m a n d poss i b l e causes R e m edy E ng i ne i d l es p oo r l y .
  • Page 261 8- 5 S E R V I C I N G I N F O R M AT I O N C om p l a i nt Sym ptom a n d poss i b l e causes R em ed y Sp ark p l u g e l ectrodes S p a r k p l u g t o o h o t .
  • Page 262 S E R V I C I N G I N F O R M AT I O N C o m p l a i n t Sym ptom a n d poss i b l e causes R e m ed y 1 .
  • Page 263 S E R V I C I N G I N F O R M AT I O N Co m p l a i nt S y m p to m a n d poss i b l e causes R em e d y Loose bo l ts a n d n u ts .
  • Page 265 8- 9 S E R V I C I N G I N F O R M AT I O N CA B L E , H A R N E S S A N D H O S E R O U T I N G C A B L E R O U T I N G R e a r brake c a b l e C l a m p the range...
  • Page 266 V I C I N G I N F 0 I 0 N S E R R M AT 8- 1 0 S P E E D O M ET E R C A B L E R O U T I N G F ace t h e c a b l e fo rwa r d .
  • Page 268 S E R V I C I N G I N F O R M AT I O N 8- 1 2 B ATT E R Y 8 L EA D W I R E Sta rter m otor l ea d w i re B attery l e a d w i r e Sta rte r m otor...
  • Page 270 S E R V I C I N G I N F O R M AT ! O N 8- 1 4 F RO N T B RA K E P I P I N G Master c y l i n d e r N o contact between the front b r a ke hose a n d H a r ness...
  • Page 271 S E R V I C I N G I N F O R M AT I O N 8- 1 5 REA R B RAKE BREATHE R HOSE RO U T I N G Clamp Rear brake drain hose Clamp plug C l i p...
  • Page 273 8 - 1 7 S E R V I C I N G I N F O R M A T I O N � F R O N T F u e l t a n k A i r c l e a n e r i n l et F ra m e A i r c l e a n e r i n l et m u d g u a rd...
  • Page 274 S E R V I C I N G I N F O R M A T I O N 8 - 1 8 S P E C I A L T O O L S I T E M PA R T N O .
  • Page 276 S E R V I C I N G I N F O R M AT I O N 8-20 ® ® ® ® ® ® "' .
  • Page 277 8-2 1 S E R V I C I N G I N F O R M AT I O N ® ® ® ® ® ® �� ® ® ® ®...
  • Page 278 S E R V I C I N G I N F O R M AT I O N 8 - 2 2 T I G H T E N I N G TO R Q U E ENGINE I T E M N ·...
  • Page 279 8-23 S E R V I C I N G I N F O R M AT I O N C H A SS I S I T E M N · m kg-m l b-ft F rame bridge b o l t 43 .5 - 50 .
  • Page 280 S E R V I C I N G I N F O R M AT I O N 8-24 T I G H T E N I N G T O R Q U E C H A RT F o r oth e r bolts and n u ts not l isted p resc ri bed , refer to t h i s c h a rt.
  • Page 281 8-25 S E R V I C I N G I N F O R M A T I O N S E RV I C E DATA V A l V E + G U I D E U n i t : m m ( i n ) I T E M S TA N D A R D L I M I T...
  • Page 282 S E R V I C I N G I N F O R M AT I O N 8-26 I T E M STA N DA R D l i M I T C a m s h aft j o u r n a l h o l d e r I . D . 2 2 .
  • Page 283 8-27 S E R V I C I N G I N F O R M A T I O N L I M I T I T E M STA N DA R D Pisto n p i n b o r e 1 6 .
  • Page 284 S E R V I C I N G I N F O R M AT I O N 8-28 T RA N S M I S S I O N U n it : m m ( i n ) Except r a t i o I T E M STA N DA R D LI M IT...
  • Page 285 8-29 S E R V I C I N G I N F O R M A T I O N CAR B U R E T O R S P E C I FICATI O N I T E M C a r b u retor t y p e M I K U N I V M 2 4 S S B o r e s i ze...
  • Page 286 S E R V I C I N G I N F O R M AT I O N 8-30 ITEM S P E C I F I CATI O N N O T E R e g u l ated v o l t a g e 1 4, 0 - 1 5 , 5 V at 5 0 0 0 r/m i n .
  • Page 287 8-3 1 S E R V I C I N G I N F O R M A T I O N LIMIT STA N DARD ITEM 1 2 ° K i n g p i n i n c l i n a t i o n 3 °...
  • Page 290 V I E W OF S U Z U K I LT - F 4 W D H (' 8 7 - MODEL ) - · · · · · · · · · · · · · · · · · · · · · · · · · · · 9- 1 S P E C I F IC AT I O N S ·...
  • Page 292 L T-F4W O H ( '8 7- M O O E L ) S P E C I F I CAT I O N S D I M E N S I O N S A N D D RY M A S S * Overa l l length .
  • Page 293 LT-4W D H ( '87- M D D E L) E L E CT R I CA L I gn it i o n type ......S U Z U K I "P E l " °...
  • Page 294 L T - F 4W D H ( '87-M O D E L ) C A R R I E R F R O N T C A R R I E R T i g h te n i ng tor q u e N ·m kg-m lb-ft...
  • Page 295 LT- F4W D H ( '87- M O D E L) S E RVI C E D ATA E L E CT R I CA L I TEM SPEC I F I CATI O N N OTE * Battery Type des i gnati o n F B 1 4A-A2 Ca pacity 1 2V 50.4 kC ( 1 4 Ah ) / 1 0 H R...
  • Page 297 1 0- 1 A P P E N D I X ( L T-4W D A N D L T- F4W D ) R EA S S E M B LY R EA R AX L E Pro p e r l y a l i g n t h e u n i v e r s a l j o i nt a n d r e a r a x l e w h e n m o u n t i n g t h e r e a r a x l e to t h e u n i v e r s a l j o i n t . O t h e r w i s e a l a r g e f l u c t u at i o n o f t h e t o r q u e t r a n s m i t t e d t o t h e w h e e l d u r i n g re a r a x l e rotat i o n t a k e s p l ace a n d p ro d u ce s v i b r a ti o n .
  • Page 299 1 1 - 1 LT-4W DJ A N D L T- F 4 W D J ( ' 8 8 -M O D E L ) S P E C I F I CATI O N S D I M E N S I O N S A N D D RY M A S S Overa l l length .
  • Page 300 L T-4W DJ A N D L T- F 4W D J ( '8 8 - M O D E L ) 1 1 - 2 E L E CT R I CA L I gn it i o n ty pe ....... . S UZ U K I " P E I " I gn it i on ti m i n g .
  • Page 301 1 1 -3 L T-4W D J A N D L T - F 4W D J ( '8 8- M O D E L ) S E RV I C E DATA VALVE G U I D E U n i t : m m ( i n ) ITEM STA N DARD L I M I T...
  • Page 302 LT-4W D J A N D L T - F 4W D J ( '8 8- M O D E L ) 1 1 -4 I T E M STA N DA R D L I M IT 2 2 . 0 1 2 - 2 2 . 0 2 5 C a m s h aft j o u r n a l h o l d e r I .
  • Page 303 1 1 -5 LT-4 W D J A N D L T- F 4W D J ( '88-M O D E L ) ITEM STA N DARD L I M I T P i s t o n p i n b o r e 1 6 .
  • Page 304 LT-4W DJ A N D L T- F 4W OJ ( '8 8- M O O E L ) 1 1 - 6 T RA N S M I S S I O N U n i t : m m ( i n ) E x c e pt ratio I T E M S TA N DA R D li M I T...
  • Page 305 1 1 - 7 L T-4W D J A N D L T- F 4W DJ ( '88-M O D E L ) CAR B U RETO R I T E M S PE C I F I CATI O N Ca r b u retor ty p e M I K U N I V M 2 4 S S Bore s i z e...
  • Page 306 L T-4W DJ A N D LT- F 4W D J ('88- M O D E L ) 1 1 -8 I T E M S P E C I F I CA T I O N N O T E 1 4 .
  • Page 307 1 1 - 9 LT-4W D J A N D LT- F4W D J ( '8 8- M O D E L ) I T E M STA N DARD LIMIT K i n g p i n i n c l i n a t i o n 1 2 °...
  • Page 308 LT-4W D J A N D L T- F 4W D J ( '88-M O D E L ) 1 1 - 1 0 S PE C I FICAT I O N I T E M N O T E H y p o i d gear o i l SAE #90, A P I g ra d e G L- 5 D if f e renti a l g e a r o i l typ e 1 50 ml...
  • Page 309 1 1 - 1 1 L T-4W D J A N D L T- F 4W D J ( '8 8 - M O D E L ) C H A N G E A I R C L EA N E R •...
  • Page 310 LT-4W D J A N D L T- F 4W D J ( ' 8 8 - M O O E L ) 1 1 - 1 2 P R I M A R Y D R I V E G EA R The bearing for p ri m a ry d rive gea r is c h a n ged to Spacer Beari ng...
  • Page 311 1 1 - 1 3 L T-4W D J A N D LT- F 4W D J ( ' 88- M O D E L ) I n accorda nce with th i s m od if i cati o n , the ti gh ten­ Tigh ten i n g torque ing torq u e of the shoe nut i s a lso c h a nged as i n d i ­...
  • Page 314 L T-4W DJ A N 0 L T - F 4W D J ('88- M 0 D E L) 1 1 - 1 6 F R O N T D I F F E R E N T I A L D R I V E N O U T P U T S H A FT ®...
  • Page 315 1 1 - 1 7 LT-4WD J A N D L T- F4W DJ ( ' 8 8 - M O D E L ) U n it: m m ( i n ) ® H model J model ® ( 1 .
  • Page 316 1 1 - 1 8 LT-4W OJ A N D L T- F 4W D J ( ' 8 8- M O D E L ) W H E E L C E N T E R CA P The wheel center cap is cha n ged as show n i n the photog ra p h .
  • Page 317 1 1 - 1 9 LT-4W D J A N D L T- F4WDJ ( ' 88-M O D E L ) D I S M O U N T I N G • R emove the front wheel . •...
  • Page 318 L T-4W DJ A N D L T- F 4W D J ( '8 8-M O D E L ) 1 1 -2 0 • S l ide the boot towa rd the center of the shaft and remove the snap r i n g from the outer race. •...
  • Page 320 LT-4WDJ A N D LT- F 4W D J ( ' 8 8- M D D E L ) 1 1 - 22 C L EA N I N G • Wash the d isassem b l ed pa rts ( except for the boot ) .
  • Page 321 1 1 -23 L T-4WDJ A N D L T- F 4W D J ( '88- M O D E L ) • D o not fo rget t o fit a c i rc l i p when fitti ng t h e cage.
  • Page 322 LT-4W DJ A N D L T- F 4W D J ( ' 8 8 - M O D E L ) 1 1 -24 • Afte r fitting t h e boot o n the outer race, i nsert a driver i nto the boot o n the outer race side a n d a l l ow the ai r to e nter th e boot s o th at t h e a i r pressu re in the boot becom es the same a s the...
  • Page 323 1 1 - 2 5 LT-4W D J A N D L T- F 4W D J ( '88-M O D E L ) R EAS S E M B LY I N F O R M AT I O N F ront d r ive sh aft assy D ifferential side j o i nt set...
  • Page 326 L T-4W D J A N D L T- F 4W D J ( '8 8 - M O D E L ) 1 1 -28 C RA N KCAS E B R EAT H E R H OS E R O U T I N G B r e a t h e r h os e C l a m p Pass t h e b r e a t h e r h ose u nd er...
  • Page 327 1 1 - 29 LT-4W D J A N D L T- F 4W DJ ( ' 8 8- M O D E L ) R EA R B RA K E D RA I N H OS E A N D B R EAT H E R H OS E R O UTI N G D r a i n h os e Speedo meter ca b l e...
  • Page 329 L T-4W D J A N D L T- F 4W D J ( '88- M O D E L ) 1 1 - 3 1 T I G H T E N I N G TO R Q U E E N G I N E I T E M N ·...
  • Page 330 LT-4W D J A N D LT- F 4W D J ('88-M O D E L ) 1 1 - 32 C H A S S I S N · m I T E M kg-m l b-ft F rame bridge bolt 60 - 7 0 6 .
  • Page 331 1 1 - 3 3 LT-4W D J A N D LT- F 4W D J ( '88- M O D E L ) I TEM N · m kg-m l b-ft Rear bra ke d ru m cover bolt 1 8 - 28 1 .8 - 2 .
  • Page 332 CONTENTS 1 2- 1 SPEC/FICA TIONS .............
  • Page 333 1 2·1 L T-4WDK AND L T-F4WDK ('89-MODEL) S PE C I F I CATI O N S D I M E N S I O N S A N D DRY M A S S E l E C T R I CA l Overall l e ngth 1 9 40 mm ( 7 6 .
  • Page 334 L T-4WDK AND L T-F4WDK ('89-MODEL) 1 2-2 S E RV I C E OAT A VAlVE + G U I D E U n it : mm ( i n ) STA N DA RD L I M I T ITEM Va lve d i a m .
  • Page 335 1 2-3 L T-4WDK AND L T-F4WDK ('89-MODEL) ITEM STAN DARD LIMIT Ca m s haft runout 0 . 1 0 0. 004 Ca m chain 2 0-pitch length 1 29 . 0 5 . 08 Roc ker a rm I . D . 1 2 .
  • Page 336 LT-4WD K AND LT-F4WDK ('89-M O D E L) 1 2·4 C O N RO D + C RA N KSHAFT U n it : mm ( i n ) ITE M STA N DA R D L I M I T C o n rod sma l l end I.
  • Page 337 1 2-5 L T-4WDK AND L T-F4WDK ('89-MODEL) ITEM L I M IT STAN DAR D Sub-transmission S u per low 3 . 1 7 6 ( 1 7/ 1 8 2 5 / 1 1 3 7/2 5 red ucti on rati o 1 .
  • Page 338 LT-4WD K AND L T-F4WDK ('89-MODEL) 1 2-6 S P E C I F I CATION ITEM Others Canada 1 . 0 . N o . 1 9 802 1 9 8 5 0 +--- I d l e r/m i n . 1 400 ±...
  • Page 339 1 2-7 LT-4WDK AND LT-F4WDK ('89-MODE L) S PECIFICATION N OTE I T E M Battery Type designation F B 1 4A-A2 F o r U . K . Capacity 1 2V 5 0 . 4 kC ( 1 4 A h ) / 1 0 H R a n d U .
  • Page 340 LT-4WDK A N D L T-F4WDK ('89-MODEL) 1 2-8 ITEM S TA N D A R D L I M I T Tire size F ront 8 . 00- 1 0 Rear 1 2 . 00- 1 0 Tire tread d e pth 4 .
  • Page 341 1 2·9 LT-4WDK AND LT-F4WDK ('89-MODEL) C HA N G ES C RAN KCASE A p p l y S U Z U K I BO N D N o . 1 2 1 6 . LT-4W DJ A N D LT-4W DJ I nsta l l the cran kcase o i l s e p a rato r .
  • Page 343 1 2- 1 1 LT-4WDK AND L T- F4WDK ('89-MODEL) F R O N T B R A K E R e se r v o i r . ta n k cap ® D i a p h ragm Boot 1 ·...
  • Page 345 1 2- 1 3 L T-4WDK A N D L T-F4WDK ('89-MODEL) C A B L E , H A R N E S S A N D H O S E R O U T I N G C A B L E R O U T I N G brake c a b l e W i r i n g h a rness C l a m p t h e range...
  • Page 347 1 2-1 5 L T-4WDK AND L T-F4WDK ('89-MODEL) HARNESS ROUTI N G Powe r sou rce fuse To s p e e d o m eter B atte ry l ead M e t e r ( b a c k s i d e ) B attery l ead C l a m p...
  • Page 350 L T-4WDK AND L T-F4WDK ('89-MODEL) 1 2- 1 8 C RA N KCAS E B R EAT H E R H O S E R O U T I N G -� .._.
  • Page 351 1 2- 1 9 L T-4WDK A N D L T-F4WDK ('89-MODEL) FRONT B RAKE PI PI NG Master c y l i n d e r Front brake h ose N o c ontact between t h e front brake h ose and H a r n ess stee r i n g plate.
  • Page 352 LT-4WDK AND LT-F4WDK ('89-MODEL) 1 2-20 R E A R B R A K E B R E AT H E R H O S E R O U T I N G C l a m p Rear b r a ke dra i n hose C l a m p plug C l i p...
  • Page 354 LT-4WDK AND LT-F4WDK ('89-MODEL) 1 2-22 � F R O N T F u e l t a n k A i r c l e a n e r i n l e t F ra m e A i r c l e a n e r i n l et m u d g u a rd C l a m p F ro n t d iffe re n t i a l case b r e a t h e r h o se...
  • Page 356 CON TENTS 1 3- 1 SPEC/FICA T/ONS ............. 1 3- 2 SERVICE DA TA .
  • Page 358 LT-4WDL AND LT-F4WDL ('90-MODEL) 1 3 -2 S E RV I C E D ATA VA L V E + G U I D E U n i t : m m ( i n ) ITEM S TA N DARD L I M I T V a l v e d i a m .
  • Page 359 1 3-3 LT-4WDL AND LT-F4WDL ('90-MODEL) I T E M L I M I T STA N DA R D Cams haft j o u r n a l h o l d e r 2 2 . 0 1 2 - 2 2 . 0 2 5 0 .
  • Page 360 L T-4WDL A N D L T-F4WDL ('90-MODEL) 1 3 -4 I T E M STA N D A R D L I M IT Piston pi n bore 1 6 . 002 - 1 6 . 00 8 1 6 . 030 0 .
  • Page 361 1 3·5 LT-4WDL AND LT·F4WDL ('90-MODEL) TRAN S M I S S I O N U n i t : mm ( i n ) E x cept r a tio ITEM S TA N DA R D LI M IT Pri m a ry red ucti o n rati o 3 .
  • Page 362 L T-4WDL AND L T-F4WDL ('90-MODEL) 1 3-6 CA R B U R E T O R ITEM S P E C I F I CATION C a r b u retor type * M I K U N I BST3 1 SS Bore size * 3 1 m m I .
  • Page 363 1 3-7 LT-4WDL AND LT-F4WDL ('90-MO DEL) ITEM NOTE SPECIFICATION Type d e s i g n ation Batte ry For U . K . and C a p a c ity A h ) / 1 0 H R 1 2V 5 0 .
  • Page 364 LT-4WDL AND L T-F4WDL ('90-MODEL) 1 3-8 I T E M STA N DA R D L I M I T 3 8 ° ± 3 ° Ste e ring a n g l e I n s i d e 2 8 °...
  • Page 365 1 3-9 LT-4WDL AND L T-F4WDL ('90-MODE L) F U E L O I L IT EM S P E C I F I CA T I O N N O T E Fuel type U s e o n l y u n l e a d e d t y p e g a s o l i n e of at least 8 7 p u m p octane o r 9 1 octa n e o r h ig h e r rated by t h e research method .
  • Page 366 LT-4WDL AND LT-F4WDL ('90-MODEL) 1 3 -1 0 T I G HTE N I N G TO R Q U E E N G I N E I T E M N · m kg-m l b-ft Cy l i n der head cover bo lt 8 - 1 0 0.8 - 1 .0 6 .0 - 7 .
  • Page 367 LT-4WDL AND LT-F4WDL ('90-MODEL) 1 3- 1 1 C H AS S I S l b-ft ITEM N · m kg-m F ra me b ridge bolt 43.5 - 50 . 5 60 - 7 0 6.0 - 7 . 0 D ifferentia l case fi l le r cap 20 - 25 2 .
  • Page 368 LT-4WDL AND LT-F4WDL ('90-MODEL) 1 3 - 1 2 N · m I T E M kg-m l b-ft Rear b ra ke d ru m cover bolt 1 8 - 28 1 . 8 - 2 . 8 1 3. 0 - 20.0 Rear sh ock absorber m o u n t i n g bolt 40 - 60 4.
  • Page 369 1 3-1 3 LT-4WDL A N D LT-F4WDL ('90-MODEL) E N G I N E M O U N T I N G Engine mounting bolt I T E M Diam . Length 1 2 m m 3 0 0 m m 1 0 m m 240 m m S pacer...
  • Page 370 Ll4WDL A N D LT-F4WDL ('90-MODEL) 1 3- 1 4 G EA RS H I FT A R M L E V E R • I n sta l l the g e a r s h ift a r m l e v e r t o t h e g e a r s h ift s h aft verti c a l l y a s s h o w n in the i l l u strat i o n .
  • Page 371 1 3· 1 5 LT·4WDL AND LT-F4WD L ('90-MOD EL) C RAN KCAS E A p p l y S U Z U K I BO N D N o . 1 2 1 6 A p p l y S U Z U K I B O N D N o . 1 20 7 B / 1 2 1 5 •...
  • Page 372 LT-4WD L AND LT-F4WDL ('90-MODEL) 1 3- 1 6 C A R B U R E T O R S PE C I F I CATI O N ITEM S P E C I F I CATI O N I T E M S P E C I F I CATI O N C a r b u retor type M I K U N I B S T 3 1 SS...
  • Page 373 1 3-1 7 L T-4WDL AND L T-F4WDL ('90-MODEL) I G N IT I O N S YS T E M M A G N ETO • Rem ove t h e s e a t . • D i scon nect t h e p i c k - u p c o i l l e a d w i re s . M e a s u re the resista n c e betwee n t h e l e a d w i re s w i t h t h e p o c ket teste r .
  • Page 374 L T·4WDL A N D L T-F4WDL ('90-MODEL) 1 3-1 8 C D I U N IT • D i s c o n nect t h e l e a d w i re s at t h e C D I u n i t .
  • Page 375 1 3· 1 9 LT·4WD L A N D LT·F4WDL ('90-MODEL) A C G E N E RA T O R N O - L O A D P E R F O R MA N C E • R e move t h e s e a t . •...
  • Page 376 L T-4WDL AND L T-F4WDL ('90-MO D E L) 1 3 -20 T I R E S T I R E R E PlAC E M E N T • R e m ove t h e f r o n t o r r e a r w h e e l . •...
  • Page 377 1 3-21 LT-4WDL AND LT-F4WDL ('90-MODEL) • I nf l ate the t i re to s e a t t h e b e a d . & M a x . B E A D S EAT P R E S S U R E ( F R O N T R E A R ) 2 5 0 kPa F o r S w e d e n...
  • Page 383 1 3·27 LT·4WDL AND LT·F4WDL ('90-MODEL) Sweden E m e r g ency s w itch Cool i n g f a n s w i t c h C o o l i ng fan M a n u a l switch Horn E m e r g ency switch W i r i n g h a rness...
  • Page 384 1 4- 1 SPEC/FICA TIONS .............
  • Page 385 1 4- 1 LT-4WDM AND LT-F4WDM ('91 -MODEL) S PE C I F I CATI O N S E L EC T R I CA L D I M E N S I O N S A N D D RY M A S S I g n ition type S U Z U K I "...
  • Page 386 LT-4WD M AND LT-F4WDM ('9 1 -MODEL) 1 4-2 S E RV I C E DATA VALVE + G U I D E U n it : mm ( i n ) ITEM S TA N DARD l i M I T V a l v e d i a m .
  • Page 387 1 4-3 LT-4WDM AND LT·F4WD M ('91 -MODEL) I T E M STA N DA R D L I M IT Ca m s h aft journal h o l d e r 1 . 0 . 2 2 . 0 1 2 - 2 2 . 0 2 5 0 .
  • Page 388 LT-4WD M AND LT-F4WDM ('9 1 -MODEL) 1 4-4 STA N DA R D L I M I T I T E M 1 6 . 002 - 1 6 . 008 1 6 . 030 Pi ston pin bore 0 .
  • Page 389 1 4-5 LT-4WDM AND LT-F4WDM ('91 -MODEL) T RA N S M I S S I O N U n it : mm ( i n ) Except ratio I T E M STAN DARD l i M I T Pri m a ry reducti o n rat i o 3 .
  • Page 390 LT-4WD M AND LT-F4WDM ('91 -MODEL) 1 4-6 CA R BU R ET O R I T E M S P E C I FICATION C a r b u retor type M I K U N I BST3 1 SS B o re size 3 1 m m 1 .
  • Page 391 1 4-7 LT-4WDM AND LT-F4WDM ('91 -MODEL) ITEM SPECIFICATION N OTE Battery Type d e s i g n at i o n F B 1 4A-A 2 1 2V 5 0 . 4 kC ( 1 4 A h ) / 1 0 H R For U .
  • Page 392 LT-4WD M AND LT-F4WDM ('91 -MODEL) 1 4-8 ITEM STA N DARD liMIT ± J O 3 8 0 I n s i d e Steeri ng a n g l e ± 2 8 ° 3 ° Outs i de 2 .
  • Page 393 1 4·9 LT·4WDM AND LT-F4WDM ('91 -MODEL) F U E L O I L ITEM N O T E S P E C I F I CA T I O N � Fuel type U s e o n l y u n l e a d e d t pe gasoline of at least ( �M ) 8 7 p u m p oct a n e...
  • Page 394 LT-4WDM AND LT-F4WDM ('9 1 -MODEL) 1 4- 1 0 T I G H T E N I N G T O RQU E C H A S S I S N ·m kg-m l b-ft I T E M F ra m e b ridge b o l t 60 - 7 0 6.0 - 7 .0...
  • Page 395 1 4-1 1 LT-4WDM AND LT-F4WDM ('91 -MODEL) l b-ft I T E M N ·m kg-m Rear b rake d ru m cover bolt 1 . 8 - 2.8 1 3. 0 - 20.0 1 8 - 28 R ear sh ock a bsorber mou nti ng bolt 40 - 60 4.
  • Page 399 1 4- 1 5 LT-4WDM A N D LT-F4WDM ('91 -MODEL) CABLE ROUTI N G Forwar d Clam p Pass the speedometer c a b l e outside of frame Rear b r a k e cable h o s e Pass t h e c a b l e u n d e r t h e s h i ft lever Pa r k i n g b r a k e c a b l e Pass the p a r k i n g ca b l e ,...
  • Page 402 FOREWORD This section describes up -to -da te service p rocedures which differ from those o f the L T-4 WDL!L T-F4 WDL ( '90-model) . NO TE: • A n y differences b e t ween L T-4 WDL!L T-F4 WDL ( '90-mo del) and L T-F4 WDXM ('9 1 -model) in spe cifica tions a n d service da ta are clearly indica ted with the as terisk marks •...
  • Page 403 1 5· 1 LT-F4WDXM ('91 -MOD EL) S PE C I F I CATI O N S D I M E N S I O N S A N D D R Y M A S S E LE C T R I C A L S U Z U K I "...
  • Page 404 LT-F4WDXM ('9 1 -MODEL) 1 5-2 S E RVICE DATA VA LVE + G U I D E U n i t : m m ( i n ) S TA N DA R D L I M I T I T E M V a l ve d i a m .
  • Page 405 1 5-3 L T-F4WDXM ('91 -MODEL) CAM S H A FT + C Y LI N D E R H EA D U n it : m m ( i n ) L I M I T I T E M S TA N DA R D * 3 4 .
  • Page 406 L T-F4WDXM ('91 -MODEL) 1 5-4 I T E M STAN D A R D L I M I T * 1 . 0 1 - 1 . 0 4 Piston ri n g g ro ov e w i d t h 1 st ( 0 .
  • Page 407 1 5-5 LT-F4WDXM ('91 -MODEL) ITEM STAN DARD LIMIT C l ut c h s p r i n g free l e n gt h 2 7 . 5 (1 . 0 8 ) � 8· 1 5 C l u t c h w h e e l Scuffi n g o r 1 1 6 + 0 .
  • Page 408 LT-F4WDXM ('91 -MODEL) 1 5-6 S H AFT D R I V E U n i t : m m ( i n ) I T E M STAN D A R D L I M I T F i n a l d r i v e b e v e l g e a r b a c k l a s h 0 .
  • Page 409 1 5·7 LT-F4WDXM ('91 -MODEL) E L EC T R I C A L U n it : m m ( i n ) I T E M S P E C I F I CATI O N N O T E I g n it i o n t i m i n g 5 °...
  • Page 410 LT-F4WDXM ('91 -MODEL) 1 5-8 B R A K E + W H E E L U n it : m m ( i n ) STA N DA R D l i M I T I T E M R e a r brake c a b l e p l a y 3 - 7 ( 0 .
  • Page 411 1 5-9 LT-F4WDXM ('91 -MODEL) F U E L + O I L N OTE ITEM SPECIFICATI O N Fuel type U s e o n l y u n l e a d e d g a s o l i n e of a t l e a st 8 7 p u m p o c t a n e o c t a n e...
  • Page 412 LT-F4WDXM ('91 -MODEL) 1 5- 1 0 T I G H T E N I N G T O R Q U E E N G I N E I T E M N · m kg-m l b-ft C y l i n de r h ead cove r bo l t * 9 - 1 1 * 0 .
  • Page 413 1 5-1 1 L T-F4WDXM ('91 -MODEL) C H AS S I S I T E M N ·m kg-m l b-ft 60 - 70 6 . 0 - 7 .0 43 .5 - 50. 5 F rame b r i d ge b o l t 2 0 - 25 2 .
  • Page 414 LT-F4WDXM ('91 -MODE L) 1 5- 1 2 kg-m l b-ft N · m I T E M 32 . 5 - 47 .0 45 - 65 4.5 - 6 .5 R ea r whee l set n u t 0.8 - 1 .
  • Page 416 LT-F4WDXM ('91 -MODEL) 1 5- 1 4 • Fit a r i n g to e a c h v a l ve g u id e . Be s u re to u s e n e w r i n g s a n d valve g u ides .
  • Page 417 1 5- 1 5 L T-F4WDXM ('91 -MODEL) VALVE A N D S EA T C O N D I T I O N VALVE S EAT W I D T H C o a t t h e v a l ve s e a t w i t h p r u ss i a n b l u e u n if o r m l y . Fit t h e v a l ve a n d t a p t h e c o ated s e a t w i t h t h e v a l ve f a c e i n a rotat i n g m a n n e r , i n o r d e r t o o bt a i n a c l e a r i m p r e s s i o n o f t h e s e at i n g c o n t a c t .
  • Page 418 LT-F4WDXM ('91 -MODE L) 1 5- 1 6 C A U T I O N : Cut t h e minimum a m o u n t necessary from t h e seat to prevent the p o s s i b ility o f the valve stem becom i n g too close to t h e rocker a rm f o r correct v a l v e contact a n g l e .
  • Page 419 1 5- 1 7 LT-F4W DXM ('91 -MODEL ) 7 . 1 - 9 . 2 kg V a lve s p r i n g t e n s i o n ( I N . & EX . ) �...
  • Page 420 LT-F4WDXM ('91 -MODEL) 1 5- 1 8 C A M S H A FT C A M W E A R W o r n -d o w n c a m s a re often t h e c a u s e of m isti m e d v a l ve o p e r­ ation res u lting i n red uced power o u t p u t .
  • Page 421 1 5- 1 9 LT·F4WDXM ('91 -MODEL) C A M S H A F T R U N O U T M e a s u re t h e r u n o u t w i t h a d i a l g a u g e . R e p l a c e t h e c a m s h aft if t h e r u n o u t e x c e e d s t h e l i m i t .
  • Page 422 L T·F4WDXM ('91 -MODEL) 1 5-20 P I S T O N - C Y L I N D E R C l E A RA N C E A s a r e s u lt o f t h e p r e v i o u s m e a s u re m e nt , i f t h e p i st o n to c y l i n d e r c l e a r a n c e exceeds the l i m it s h o w n b e l o w , o v e r h a u l t h e c y l i n d e r a n d u s e a n o v e r s i z e p i sto n , o r re p l a c e b o t h c y l i n d e r a n d p i sto n .
  • Page 423 1 5-21 LT-F4WDXM ('91 -MODEL) Piston ring e n d g a p Service Limit 1 st : 0 . 70 mm ( 0 . 028 i n ) 2 n d : 1 . 00 m m (0 . 039 i n ) O V E R S I Z E R I N G S Oversize piston rings T h e fo l l o w i n g two types of o v e rs i z e p i sto n r i n g s a re u s e d .
  • Page 424 LT·F4WDXM ('91 -MODEL) 1 5·22 C O N R O D S M A l l E N D I . D . M e a s u r e the c o n ra d s m a l l e n d i n s i d e d ia m et e r w it h a c a l i p e r g a u g e .
  • Page 425 1 5-23 L T-F4WDXM ('91 -MODEL) C L U T C H PC') R e l ea s e a d · J U St t n g b o l t Drive p l ate ( 8 e ease b a l l p l ate ressu re p l ate R e i "...
  • Page 426 L T-F4WDXM ('9 1 -MODEL) 1 5-24 S PE C I F I CATI O N I T E M S P E C I F I CATI O N I T E M S P E C I F I CA T I O N C a r b u retor t y p e M I K U N I B S T 3 1 S S T h rott l e v a l v e ( T h .
  • Page 428 LT·F4WDXM ('91 -MODEL) 1 5·26 O I L C O O L E R O i l c o o l e r 0 - r i n g O i l hose N o . O i l hose N o . Ti g hte n i n g t o r q u e I t e m N ·...
  • Page 429 1 5-27 LT-F4WDXM ('91 -MODEL) R E M OVAL • R e move t h e fro n t f e n d e r a n d re a r f e n d e r . • D r a i n e n g i n e o i l . •...
  • Page 430 L T-F4WDXM ('91 -MODEL) 1 5-28 O I L I N D I CATO R L I G H T T H E R M O -SW I T C H R E M O VAL • R e m ove t h e rear fe n d e r . •...
  • Page 432 LT·F4WDXM ('9 1 -MODEL) 1 5-30 T I G H T E N I N G T O R Q U E N O T E I T E M For other models N · m kg-m l b -ft For U .
  • Page 433 1 5-31 L T-F4WDXM ('91 -MOD E L) R EA R W H E E L A N D R EA R B R A K E...
  • Page 434 LT-F4WDXM ('91 -MODEL} 1 5-32 R E M OVAL A N D D I S AS S E M B lY • R e move t h e r e a r w h e e l by r e m o v i n g t h e m o u n t i n g n uts •...
  • Page 441 1 5·39 LT-F4WDXM ('91 ·MODEL) R e a r bra k e cable Wiring harness C l a m p VIEW A P a s s t h e r a n g e c a b l e a b o v e t h e r e v e r s e c a b l e c a b l e C h o k e R e a r b r a k e c a b l e...
  • Page 445 1 5-43 LT-F4WDXM ('91 -MODEL) F R O NT BRAKE H O S E R O U T I N G Master cy hose Front brake No co ntact between the front brake h ose a n d Harness steering plate. Pass the brake h ose in front of Parking brake cable...
  • Page 447 LT-F4WDXM ('91 -MODEL) 1 5-4 5 APPEN DIX (CYLI N D E R 0 - R I N G ) A l l L T-4W DX h ave b e e n fitted a n 0 - r i n g i n t h e i r cyl i n d e rs from t h e i r fi rst p r o d u ctio n . Before fitt i n g t h e d o w e l p i n into t h e c y l i n d e r , a p p l y S U Z U K I B O N D N o .
  • Page 448 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Sl'l: C /J=/ C�...
  • Page 449 1 6-1 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) S P ECI FICATIONS LT-4W D AN D LT-F4 WD D I M E N S I O N S A N D D RY M A S S E L E CT R I CA L I g n it i o n t y p e E l e c t ro n i c I g n i t i o n ( C D I ) O v e ra l l l e n g t h...
  • Page 450 LT-4WD, LT-F4WD AND LT-F4WDX N,P, R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-2 S P EC I FICATIO N S LT-4WDX D I M E N S I O N S A N D D RY M A S S E l E C T R I C A l I g n it i o n t y p e E l e c t ro n i c I g n it i o n ( C O l ) Overa l l l e n gth...
  • Page 451 1 6-3 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) S E RV I C E OAT A 4WDT AN D LT F4WDT VALVE + G U I D E U n it : m m ( i n ) L I M I T I T E M STA N DA R D...
  • Page 452 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-4 C A M S H A FT + C YL I N D E R H EA D U n it : m m ( i n ) STA N D A R D I T E M li M IT C a m h e i g ht...
  • Page 453 1 6-5 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) L I M I T I T E M STA N D A R D Piston ri n g g roove width 1 . 0 1 - 1 . 0 3 1 st ( 0 .
  • Page 454 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-6 STAN D A R D L I M IT I T E M 2 7 . 5 C l utch s p r i n g free l e n gt h ( 1 .
  • Page 455 16-7 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) S H A FT D RIVE U n it : m m ( i n ) LIMIT ITEM STAN DARD �- Fin a l d rive bevel gear b a c k l a s h 0 .
  • Page 456 L T -4WD, L T -F4WD AND L T -F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-8 E l E CT R I CA l U n i t : m m ( i n ) I T E M S P E C I F I CATIO N N O T E I g n it i o n t i m i n g 5 °...
  • Page 457 1 6-9 LT-4WD, LT-F4WD AND LT-F4WDX N,P, R,S,T ('92,'93,'94,'95 AND 96-MODELS) BRAKE + WH E E L U n i t : mm ( i n ) L I M I T ITEM STA N D A R D Rear b ra ke c a b l e p l a y 3 - 7 ( 0 .
  • Page 458 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-1 0 F U E l + O i l I T E M S P E C I F I CATI O N N O T E R � M U s e o n l y u n l e a d e d g a s ol i n e o f a t l e a st 8 7 F u e l ty p e p u m p octa n e (...
  • Page 459 1 6-11 LT-4WD, LT-F4WD AND LT-F4WDX N.P,R,S,T ('92.'93.'94.'95 AND 96-MODELS) S E RVICE DATA LT- F4WDXT VALVE + G U I D E U n i t : m m ( i n ) L I M I T ITEM STA N DARD V a l ve d i a m .
  • Page 460 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-12 CAM S H A FT + C Y L I N D E R H EA D U n it : m m ( i n ) I T E M STA N D A R D L I M IT Cam h e i g ht...
  • Page 461 1 6-13 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) U n i t : mm ( i n ) I T E M S TA N D A R D L I M I T Pisto n ri n g g roove width 1 .
  • Page 462 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-14 I T E M STA N D A R D L I M IT -� C l utch s p r i n g free l e n gt h 2 7 .
  • Page 464 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-16 E lE C T R I C A l I T E M SPEC I F I CATI O N N OTE I g n ition t i m i n g 5 °...
  • Page 465 1 6-17 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) B RA K E + W H E E L U n it : m m ( i n ) I T E M STA N DA R D li M I T 3 - 7 Rea r b r a ke c a b l e pl a y (0.1 - 0.3)
  • Page 466 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-18 F U EL + O I L I T E M S P E C I F I CAT I O N N O T E Fuel type Use o n l y u n leaded g a s o l i n e of at l east 8 7 p u m p o c t a n e ) o r 9 1 o c t a n e...
  • Page 467 1 6-19 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) '92-model) S E C O N DA R Y D R I V E A N D D R I V E N S H I M (O n and after R EA S S E M B LY I N F O R M AT I O N T i g h te n i n g t o rq u e App l y "...
  • Page 469 1 6-21 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) CDI U N IT INSP ECTIO N (On and after '95-m odel) LT-4WDS, LT- F4WDS AND LT- F4WDXS • D i sc o n n e ct t h e l e a d w i re c o u p l e r . U s i n g t h e p o c k e t t e s t e r kO r a n g e ) , m e a s u r e t h e r e s i st a n c e b e t w e e n t h e t e r ­...
  • Page 470 LT-4WD, LT-F4WD AND LT-F4WD X N,P,R,S,T ('92,'93,'9 4,'95 AND 96-MOD ELS) 1 6-22 REAR U N IVE RSAL J O I NT BOOT (On and after '94-model) Rea r u n ive rsal j o i nt boot a n d its re l ated pa rts h ave been c h a n g e d as s h own in t h e fo l l owi n g i l l ustrat i o n s .
  • Page 471 16-23 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) I n s t a l l a t i o n m a n n e r of t h e l at e t y p e b o ot i s a s s h o w n i n t h e f o l l o w i n g i l l u st r a t i o n . Boot R o t at i o n a l d i re ct i o n U n i v e rs a l j o i n t...
  • Page 479 1 6-31 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) SPEEDOM ETER CABLE ROUTING L T-4WDN AND L T-F4WDN I g n it i o n c o i l C l a m p G u i d e C l a m p S p e e d o m et e r c a l b e LT-F4WDXN...
  • Page 480 F U E L C O L T - 4 W D, L T -F C K V A C U 6 - M O D E L S) ..� >- CO ..Q .., C .!: � > ..
  • Page 485 1 6-37 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) A i r c l e a n e r i n l et m u d g u a rd F u e l ta n k ¢:J Forward Rear bra ke breather hose C a r b u retor...
  • Page 486 LT-4WD, LT-F4WD AND LT-F4WDX N,P,R,S,T ('92,'93,'94,'95 AND 96-MODELS) 1 6-38 R E A R B RAKE B R E ATH E R H OS E R O UTI N G ( LT- F4WDXS ) C l a m p C l a m p Front d i f f e r e n t i a l case breather hose h o s e...
  • Page 488 S P E C I F I C A T I ON S 1 7 - 1 e • • • e o e e e o o e o • • • 11 e • • • e • • e e o • • o • • o • e e o • s o • • o o e m o o • • e • • e e e o o s e o e e e o a o • e o o G L T -F 4 WD 1 7 .., 1 L T -F 4 W D X...
  • Page 489 17-1 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) S PE C I FI CATI O N S LTmF4WD D I M E N S I O N S A N D D RY M A S S E L E CT R I CA L E l e ctro n i c I g n it i o n ( C D I ) I g n it i o n t y p e O v e ra l l l e n gt h...
  • Page 491 17-3 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) S E RVICE DATA LT- F4WD VALVE + G U I D E U n it : m m ( i n ) I T E M STA N DARD L I M I T V a l v e d i a m .
  • Page 492 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) 17-4 CA M S H A F T + C Y L I N D E R H EA D U n i t : m m ( i n ) I T E M li M I T STA N D A R D Cam height...
  • Page 493 17-5 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) I T E M L I M I T STA N DA R D Piston ring g ro ove width 1 . 0 1 - 1 . 03 1 st ( 0 . 040 - 0 . 04 1 ) 1 .
  • Page 494 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) 1 7-6 L I M IT I T E M STAN D A R D 2 7 . 5 C l utch spring free l e n gth ( 1 . 08 ) C l utch w h e e l I . D . S c uffi n g o r 1 1 6 ±...
  • Page 495 17-7 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) S HA F T D R I V E U n it : m m ( i n ) L I M I T STAN DARD I T E M 0 . 0 5 - 0 . 3 2 Final d rive bevel gear b a c k l a s h ( 0 .
  • Page 496 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODEL S) 1 7-8 E L E C T R I C A L U n i t : m m ( i n ) N OT E I T E M S PEC I F I CATI O N I g n ition ti m i n g 5 °...
  • Page 498 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) 17-1 0 F U E L + O I L I T E M N OT E S P E C I F I CATI O N F u e l type U s e o n l y u n l e a d e d g a so l i n e o f a t l e a st 8 7 p u m p oct a n e ( R M ) o r 9 1 octa n e o r h i g h e r rated by t li e r e s e a r c h m e t h o d .
  • Page 499 17-11 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) LT-F4WDX VAlVE + G U I D E U n it : m m ( i n ) L I M I T I T E M STA N D A R D -�...
  • Page 500 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) 1 7-12 C A M S H A F T + C Y L I N D E R H EA D U n i t : m m ( i n ) L I M IT I T E M STAN D A R D C a m h e i g ht...
  • Page 501 1 7-13 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) U n i t : mm ( i n ) I T E M STA N D A R D L I M I T Pisto n r i n g g ro o v e w i d t h 1 .
  • Page 502 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) 17-14 I T E M L I M I T STA N DA R D C l utch s p r i n g f r e e l e n gt h 2 7 . 5 ( 1 .
  • Page 503 1 7-15 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) S HAFT D R I V E U n it : m m ( i n ) L I M I T I T E M STA N DA R D F i n a l d rive b e v e l g e a r b a c k l a s h 0 .
  • Page 504 LT-F4WDV/W AND LT-F4WDXV/W ('97 AND '98-MODELS) 17-16 E L ECTRICAL I T E M S P E C I F I CATI O N N O T E I g n it i o n t i m ing 5 ° B . T . D . C . B e l o w 1 8 0 0 r /m i n . a n d 3 0 °...
  • Page 507 Prepared by SUZUKI MOTOR CORPORAnON Overseas Service D epartment lO th Ed. July, 1 997 1 st Ed. March, 1 986 No.: Part 99500 - 4205 9 - 0 lE Printed in Japan 5 1 6...

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