Suzuki 2005 LT-A700XK5 ATV Manuals

Manuals and User Guides for Suzuki 2005 LT-A700XK5 ATV. We have 1 Suzuki 2005 LT-A700XK5 ATV manual available for free PDF download: Manual

Suzuki 2005 LT-A700XK5 Manual (478 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 58 MB

Group Index
1
Component Parts and Work to be Done
2
Symbol
3
Abbreviations
4
Wire Color
6
General Information
7
Warning/Caution/Note
8
General Precautions
8
Serial Number Location
10
Fuel
11
Engine Oil
11
Front Differential Gear Oil
11
Rear Drive (Final) Gear Oil
11
Engine Coolant
12
Water for Mixing
12
Anti-Freeze/Engine Coolant
12
Liquid Amount of Water/Engine Coolant
12
Break-In Procedures
13
Information Labels
14
Specifications
15
Dimensions and Dry Mass
15
Periodic Maintenance
17
Periodic Maintenance Schedule
18
Periodic Maintenance Chart
18
Maintenance and Tune-Up Procedures
19
Air Cleaner
19
Exhaust Pipe Nuts and Muffler Mounting Bolts
21
Valve Clearance
21
Valve Clearance Adjustment
23
Intake Side
24
Exhaust Side
25
Spark Plug
26
Carbon Deposits
26
Electrode
26
Spark Arrester
27
Fuel Line
27
Spark Plug Installation
27
Throttle Cable Play
28
Throttle Body
28
Engine Oil and Oil Filter
28
Engine Oil Replacement
28
Oil Filter Replacement
29
Differential Gear Oil Inspection
30
Differential Gear Oil Replacement
30
Final Gear Oil
31
Final Gear Oil Inspection
31
Final Gear Oil Replacement
31
Engine Coolant Level Check
32
Engine Coolant Replacement
32
Radiator
33
Radiator Hoses
33
Drive Belt Removal
34
Drive Belt Inspection
35
Drive Belt Remounting
36
Brakes
38
Front Brake Pad
38
Rear Brake Friction Plate Wear Limit
38
Rear Brake Pedal and Lever
38
Brake Fluid
39
Rear Brake Lever
39
Brake Fluid Level
39
Air Bleeding the Brake Fluid Circuit
40
Brake Hoses
41
Tires
41
Tire Tread Condition
41
Tire Pressure
41
Steering
42
Toe-Out
42
Suspensions
43
Chassis Nuts and Bolts
44
General Lubrication
46
Compression Pressure Check
47
Compression Test Procedure
47
Oil Pressure Check
48
Oil Pressure Test Procedure
48
Low Oil Pressure
48
High Oil Pressure
48
Initial Engagement and Clutch Lock-Up Inspection
49
Initial Engagement Inspection
49
Clutch Lock-Up Inspection
50
Engine
51
Engine Components Removable with Engine in Place
52
Engine Left Side
52
Engine Right Side
52
Engine Center
52
Engine Removal
53
Engine Installation
59
Engine Disassembly
62
Engine Top Side
62
Recoil Starter and Valve Timing Inspection Plug
63
Cam Chain Tensioner
64
Cylinder Head
64
Cylinder
65
Engine Bottom Side
66
Generator Cover
66
Starter Torque Limiter
67
Starter Idle Gear
67
Gearshift
67
Generator
68
Cam Chain and Cam Chain Tensioner
69
Oil Pump
69
Balancer Shaft Drive/Driven Gear
69
Movable Drive Face
71
Movable Driven Face
71
Fixed Drive Face
72
Gear Position Switch
72
Clutch Housing Case
72
Clutch Shoe
73
Crankcase
73
Rear Output Shaft
74
Transfer
75
Engine Components Inspection and Servicing
78
Camshaft
78
Automatic Decompression
78
Cam Wear
79
Camshaft Journal Wear
79
Camshaft Runout
80
Cylinder Head Distortion
82
Valve Stem Runout
82
Valve Head Radial Runout
82
Valve Face Wear
83
Valve Stem Deflection
83
Valve Stem Wear
83
Valve Guide Servicing
83
Valve Seat Width Inspection
85
Valve Seat Servicing
85
Initial Seat Cut
86
Valve Spring
88
Valve Reassembly
88
Water Bypass Union and Oil Gallery Plug
91
Thermostat
92
Cam Chain Guide
93
Cylinder Distortion
93
Cylinder Bore
94
Piston
95
Piston Diameter
95
Piston Ring to Groove Clearance
95
Piston Ring Free End Gap and Piston Ring End Gap
96
Piston Pin and Pin Bore
96
Conrod/Crankshaft
97
Conrod Small End I.D.
97
Conrod Deflection
97
Crankshaft Runout
97
PCV Hose
98
Clutch Wheel
99
Starter Clutch
99
Movable Drive Face and Driven Face
101
Movable Drive Face Disassembly
102
Roller and Sliding Surface
102
Oil Seal
102
Movable and Fixed Drive Face
103
Movable Driven Face Disassembly
104
O-Ring and Oil Seal
105
Movable Driven Face Spring
106
Movable and Fixed Driven Face
106
Transfer Disassembly
109
Transfer Reassembly
109
Gearshift Fork
112
Gearshift Fork-To-Groove Clearance
112
Gearshift Fork Groove Width
112
Gearshift Fork Thickness
112
Gearshift Cam Disassembly
113
Drive Train (Front and Rear Output Shaft) Construction
116
Front Output Shaft Removal
117
Front Output Shaft Installation
117
Rear Output Shaft Disassembly
117
Rear Output Shaft Reassembly
118
Shim Adjustment
120
Backlash
120
Tooth Contact
121
Final Assembly
122
Drive Bevel Gear Removal
123
Drive Bevel Gear Installation
124
Crankcase Bearing Inspection
125
Left Crankcase Bearing Removal
125
Left Crankcase Bearing Installation
125
Right Crankcase Bearing Removal
126
Right Crankcase Bearing Installation
127
General Cover Disassembly
128
General Cover Reassembly
129
Recoil Starter Disassembly
130
Recoil Starter Reassembly
131
Engine Reassembly
133
Oil Sump Filter
135
Movable Drive/Driven Face and Drive Belt
139
Clutch Cover
141
Cylinder Head Cover
153
Valve Timing Inspection Plug
153
Water Union
154
Starter Motor
154
Drive Train
155
Front Drive Train (Differential) Construction
156
Front Drive Train (Differential) Gear Case Oil Seal
161
Drive Bevel Gear Bearing
161
2WD/4WD Shifting Cam Bearing
161
Drive Bevel Gear Pilot Bearing
161
Front Drive Train (Differential) Gear Bering
162
Breather Rubber Case
162
Remounting
168
Left Side Shim Selection
170
Rear Drive Train Construction
176
Rear Drive Train Disassembly
177
Rear Drive Train Inspection
181
Gear Case Cover/Final Gear Case Cover Oil Seal
181
Gear Case Cover/Final Gear Case Cover Bearing
181
Pinion Gear/Pinion Gear Bearing
181
Gear Case Bearing
182
Gear Case Oil Seal
183
Pinion Gear Shaft Bearing and Locknut
183
FI System Diagnosis
194
Precautions in Servicing
196
Electrical Parts
196
Connector/Coupler
196
Fuse
197
Ecm/Various Sensors
197
Electrical Circuit Inspection Procedure
199
Open Circuit Check
199
Voltage Check
200
Continuity Check
200
Short Circuit Check (Wire Harness to Ground)
201
Using the Multi-Circuit Tester
202
Using the Tester
202
FI System Technical Features
203
Injection Time (Injection Volume)
203
Compensation of Injection Time (Volume)
204
Injection Stop Control
204
FI System Parts Location
205
FI System Wiring Diagram
207
User Mode
208
Dealer Mode
209
TPS Adjustment
211
Fail-Safe Function
212
FI System Troubleshooting
213
Customer Complain Analysis
213
Visual Inspection
214
Self-Diagnosis Reset Procedure
216
Use of SDS Diagnostic Procedures
216
Use of SDS Diagnosis Reset Procedure
217
Show Data When Trouble
218
ECM Terminal
220
Malfunction Code and Defective Condition
221
C12 CKP Sensor Circuit Malfunction
223
C13 IAP Sensor Circuit Malfunction
226
C14 TP Sensor Circuit Malfunction
230
C15 ECT Sensor Circuit Malfunction
235
C20 Diff-Lock Relay Circuit Malfunction
239
C21 IAT Sensor Circuit Malfunction
242
C23 to Sensor Circuit Malfunction
246
C24 Ignition Coil Circuit Malfunction
250
C32 Fuel Injector Circuit Malfunction
252
C40 ISC Valve Circuit Malfunction
254
Active Control Inspection (ISC RPM Control)
256
C41 FP Relay Circuit Malfunction
259
Sensors
260
To Sensor Inspection
261
To Sensor Removal and Installation
261
Fuel System and Throttle Body
262
Fuel Tank and Fuel Pump
263
Fuel Line Inspection
263
Fuel Tank Removal
263
Fuel Tank Inspection
264
Fuel Tank Installation
264
Fuel Pressure Inspection
265
Fuel Pump Inspection
266
Fuel Discharge Amount Inspection
266
Fuel Pump Relay Inspection
267
Fuel Pump Removal
267
Fuel Filter Cleaning and Fuel Filter Inspection
268
Fuel Pump Installation
268
Fuel Tank Pressure Control (FTPC) Valve Inspection
268
Throttle Body Contruction
269
Air Cleaner Box Removal
270
Throttle Body Removal
271
Throttle Body Disassembly
272
Throttle Body Cleaning
274
Throttle Body Selection
274
ICS Valve Inspection
274
Fuel Injector Inspection
275
Throttle Body Reassembly
275
Throttle Body Installation
276
Air Cleaner Box Installation
277
TP Sensor Adjustment
277
Fuel Injector Removal
277
Fuel Injector Installation
277
Throttle Position Sensor (TPS) Setting
278
Cooling and Lubrication System
279
Cooling Circuit
281
Cooling Circuit Inspection
281
Radiator and Hoses
282
Radiator Removal
282
Radiator Inspection and Cleaning
282
Radiator Remounting
283
Radiator Reservoir Tank Removal/Installation
283
Radiator Cap Inspection
283
Radiator Hose Inspection
284
Cooling Fan Inspection
285
Cooling Fan Removal
285
Cooling Fan Remounting
285
Cooling Fan Thermo-Switch Removal
286
Cooling Fan Thermo-Switch Inspection
286
Cooling Fan Thermo-Switch Installation
286
ECT Sensor Removal
287
ECT Sensor Inspection
287
ECT Sensor Installation
287
Thermostat Removal
288
Thermostat Inspection
288
Thermostat Installation
289
Water Pump Removal and Disassembly
290
Mechanical Seal
291
Mechanical Case
292
Impeller
292
Engine Lubrication System Chart
296
Engine Lubrication System
297
Chassis
299
Exterior Parts Construction
301
Seat Removal
303
Front Carrier
303
Front Grip Bar
304
Front Fender
304
Front Box
306
Side Cover
307
Mud Guard
307
Rear Box
307
Rear Carrier
308
Fuel Tank Cover
309
Rear Fender
309
Exhaust Pipe Removal
311
Exhaust Pipe Remounting
311
Front and Rear Wheels Construction
312
Tire Replacement
313
Front Drive Shaft Construction
315
Front Drive Shaft Removal and Disassembly
315
Front Brake Construction
320
Brake Pad Replacement
322
Brake Fluid Replacement
323
Brake Caliper Removal and Disassembly
323
Brake Caliper Inspection
325
Brake Caliper Piston
325
Brake Caliper Reassembly and Remounting
326
Brake Caliper Holder
327
Brake Disc Removal and Disassembly
328
Brake Disc Inspection
329
Brake Disc Reassembly and Remounting
329
Master Cylinder Removal and Disassembly
330
Master Cylinder Inspection
332
Master Cylinder Reassembly and Remounting
332
Front Suspension Construction
334
Front Suspension Removal and Disassembly
335
Dust Seal
339
Hub Bearing
339
Spring Pre-Load Adjustment
342
Steering Construction
343
Steering Removal and Disassembly
344
Steering Shaft
349
Handlebars
350
Toe-Out Adjustment
351
Handlebar Switch
351
Rear Drive Shaft Construction
353
Rear Drive Shaft Inspection and Reassembly
354
Rear Brake Construction
357
Rear Brake Removal and Disassembly
358
Rear Brake Cam Lever
361
Rear Brake Cam Shaft
362
Rear Brake Plate
362
Brake Plate Return Spring
363
Rear Brake Pressure Plate
363
Rear Final Drive Gear Shaft
363
Rear Suspension Construction
367
Rear Suspension Removal
368
Rear Suspension Inspection and Disassembly
369
Rear Shock Absorber
369
Bushing
369
Dust Seal Inspection
369
Transfer Gear Shift Lever Construction
377
Transfer Gear Shift Lever Removal
378
Transfer Gear Shift Lever Remounting
379
Shift Rod Installation
380
Gear Selection Rod
380
Shift Rod Adjustment
381
Electrical System
382
Cautions in Servicing
384
Connector
384
Coupler
384
Clamp
384
Semi-Conductor Equipped Part
385
Battery
385
Connecting the Battery
385
Wiring Procedure
385
Location of Electrical Components
387
Charging System Troubleshooting
389
Battery Runs down Quickly
389
Battery Current Leakage
390
Regulated Voltage
391
Generator Coil Resistance
391
Generator No-Load Performance
392
Regulator/Rectifier
392
Starter System Troubleshooting
393
Starter Motor will Not Run
393
Starter Motor Removal
394
Starter Motor Runs but Does Not Crank the Engine
394
Starter Motor Disassembly
395
Starter Motor Inspection
396
Carbon Brush
396
Commutator
396
Armature Coil Inspection
396
Starter Motor Installation
397
Starter Relay Inspection
397
Neutral Relay Inspection
398
Ignition/Starter Control Relay Inspection
398
Ignition System Troubleshooting
399
Ignition Coil Primary Peak Voltage
401
Ignition Coil Resistance
402
CKP Sensor Peak Voltage
402
CKP Sensor Resistance
403
Transfer Selecting System
404
Actuator
404
Drive Relay
404
Diff-Lock Relay
405
Combination Meter Description
406
Combination Meter Operating Procedure
407
Initial Display
407
Change the Display Mode
407
Tripmeter
407
Clock
408
Setting the Time
408
Led
410
Engine Coolant Temperature Meter and Indicator
410
Fuel Meter
411
Fuel Gauge
411
Speedometer
412
Speed Sensor
412
Lamps
413
Headlight and Auxiliary Headlight
413
Headlight Installation
415
Brake Light/Taillight
416
Auxiliary Headlight Bulb Replacement
416
Diode
418
Backup Light Relay
418
Switches
419
Initial Charging
420
Filling Electrolyte
420
Recharging Operation
422
Servicing Information
423
Engine will Not Start or Is Hard to Start
426
Engine Idles Poorly
427
Engine Stalls Often
427
Noisy Engine
428
Engine Runs Poorly in High Speed Range
429
Engine Lacks Power
430
Dirty or Heavy Exhaust Smoke
431
Transfer will Not Shift Back
431
Transfer Jumps out of Gear
431
Engine Overheats
432
Engine Overcools
432
Heavy Steering
433
Wobbly Handlebar
433
Steering Pulls to One Side
433
Shocks Felt in the Steering
433
Front Suspension too Soft
434
Front Suspension too Stiff
434
Noisy Front Suspension
434
Rear Suspension too Soft
434
Insufficient Brake Power
435
Brake Squeaking
435
Excessive Brake Lever Stroke
435
Leakage of Brake Fluid
435
Electrical
436
No Sparking or Poor Sparking
436
Spark Plug Soon Become Fouled with Carbon
436
Spark Plug Become Fouled too Soon
436
Unstable Charging
437
Start Button Is Not Effective
437
2Wd/4Wd Button Does Not Work
437
Diff-Lock Button Does Not Work
437
Battery "Sulfation"
438
Wiring Harness Routing
439
Cable Routing
441
Fuel Hose Routing
443
Fuel Tank Breather Hose Routing
444
Cooling System Hose Routing
445
Rear Drive Breather Hose Routing
446
Front Brake Hose and Pipe Routing
447
Fender Installation
448
Rear Fender Heat Shield Installation
450
Belt Cooling Duct Installation
451
Rear Brake Pedal
452
Trailer Towing Installation
453
Engine Mounting
454
Radiator Guard Installation
455
Special Tools
456
Tightening Torque
460
Tightening Torque Chart
463
Service Data
464

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Suzuki 2005 LT-A700XK5 ATV Manuals

Suzuki 2005 LT-A700XK5 Manual (478 pages)

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