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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.
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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...
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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)
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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.
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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...
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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 •...
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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...
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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.
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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 .
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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.
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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 .
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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)
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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...
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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...
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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...
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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 ®...
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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 ) •...
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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...
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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...
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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...
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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 .
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 .
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.
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.
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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.
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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) .
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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. ®...
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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 .
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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 ®...
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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 .
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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 .
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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 .
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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.
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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 @ .
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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 @ . •...
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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 ®...
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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...
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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 ®...
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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 .
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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. •...
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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. •...
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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.
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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��...
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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 •...
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...
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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.
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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 .
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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...
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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 .
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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 .
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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 .
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 .
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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...
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.
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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 .
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 .
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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.
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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 ®...
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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. •...
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.
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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 ®...
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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 "...
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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. •...
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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 .
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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. •...
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 .
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.
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...
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 .
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.
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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.
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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...
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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 .
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 .
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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 .
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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 .
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...
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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 .
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. •...
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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. •...
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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. ) •...
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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.
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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.
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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.
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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...
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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 ) •...
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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 ®...
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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.
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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 •...
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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 ®...
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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.
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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 •...
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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 •...
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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 .
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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 •...
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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 . •...
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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. •...
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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.
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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 .
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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 ®...
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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 .
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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 .
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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) •...
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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...
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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 .
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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 .
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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.
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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 .
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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.
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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 .
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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...
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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.
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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.
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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.
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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.
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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...
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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...
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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 •...
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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...
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· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · I GN I T I ON S Y S TE M ·...
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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.
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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.
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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 .
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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 •...
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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.
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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 .
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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.
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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.
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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 .
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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.
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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 .
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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...
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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 .
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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 .
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· · · · · · · · · · · · · · · · · · · · · · · · · · · · 7 - F RO NT C AR RI E R AND FRONT F E ND E R · · · · F RONT AND RE AR ..,fi EEL �...
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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...
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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>...
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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 .
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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. •...
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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 ®...
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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 .
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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...
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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.
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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 .
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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. •...
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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. ) •...
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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 ® . •...
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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.
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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.
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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.
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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...
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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.
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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 . ) •...
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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 . •...
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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 @ .
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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.
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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 .
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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. •...
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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. •...
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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:)
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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...
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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 ®...
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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.
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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 .
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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 . ) •...
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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 •...
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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 .
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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...
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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.
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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 .
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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 : •...
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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...
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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 @ .
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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.
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T ROUB LE S H OOT I N G · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8 - 1 W I R I N G D I A G R A M ·...
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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...
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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.
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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 .
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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 .
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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 .
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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 .
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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...
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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 .
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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...
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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...
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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...
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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...
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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 .
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S E R V I C I N G I N F O R M AT I O N 8-20 ® ® ® ® ® ® "' .
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8-2 1 S E R V I C I N G I N F O R M AT I O N ® ® ® ® ® ® �� ® ® ® ®...
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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 ·...
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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 .
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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.
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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...
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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 .
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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 .
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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...
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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...
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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 .
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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 °...
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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 ·...
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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 .
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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 " °...
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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...
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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...
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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 .
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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 .
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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 .
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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...
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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 .
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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 .
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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...
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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...
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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 .
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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 °...
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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...
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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 •...
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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...
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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 . •...
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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 ) .
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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...
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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...
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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 ·...
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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 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 .
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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 .
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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 .
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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...
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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...
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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 .
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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 .
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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 .
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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 .
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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 .
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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 °...
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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...
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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 .
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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 .
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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 . •...
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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 . •...
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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...
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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...
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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 .
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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...
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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 .
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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 "...
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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 .
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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 ·...
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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 . •...
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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 . •...
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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 .
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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...
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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...
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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 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 .
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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 .
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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 .
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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 (...
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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...
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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 .
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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 .
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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 °...
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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)
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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...
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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 ...
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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 .
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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 .!: � > ..
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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...
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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...
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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...
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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 .
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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 ±...
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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 .
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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 .
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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...
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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 .
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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 °...
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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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