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Suzuki LT-4WD 1990 Service Manual

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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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