Suzuki LT-A700X 2004 Manuals

Manuals and User Guides for Suzuki LT-A700X 2004. We have 1 Suzuki LT-A700X 2004 manual available for free PDF download: Service Manual

Suzuki LT-A700X 2004 Service Manual

Suzuki LT-A700X 2004 Service Manual (481 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 88.78 MB

Table of Contents

General Information 1

8
- Table of Contents
  8
- Warning/Caution/Note
  9
- General Precautions
  9
- Serial Number Location
  11
- Suzuki Lt-A700Xk5 ('05-Model)
  11
- Engine Oil (for Other Countries)
  12
- Rear Drive (Final) Gear Oil
  12
- Front Differential Gear Oil
  12
- Brake Fluid
  12
- Engine Oil (for Usa)
  12
- Fuel (for Other Countries)
  12
- Fuel (for Usa and Canada)
  12
- Fuel, Oil and Engine Coolant Recommendation
  12
- Water for Mixing
  13
- Anti-Freeze/Engine Coolant
  13
- Liquid Amount of Water/Engine Coolant
  13
- Engine Coolant
  13
- Break-In Procedures
  14
- Information Labels
  15
- Specifications
  16
- Dimensions and Dry Mass
  16
- Engine
  16
- Drive Train
  16
Chassis

17
- Capacities
  17
- Electrical
  17
- Periodic Maintenance Chart
  19
- Periodic Maintenance Schedule
  19
- Air Cleaner
  20
- Maintenance and Tune-Up Procedures
  20
- Exhaust Pipe Nuts and Muffler Mounting Bolts
  22
- Valve Clearance
  22
- Spark Plug
  27
- Fuel Line
  28
- Spark Arrester
  28
- Engine Oil and Oil Filter
  29
- Throttle Body
  29
- Throttle Cable Play
  29
- Differential Gear Oil Inspection
  31
- Differential Gear Oil Replacement
  31
- Final Gear Oil
  32
- Engine Coolant
  33
- Radiator
  34
- Radiator Hoses
  34
- Drive Belt
  35
- Brakes
  39
- Brake Fluid
  40
- Brake Hoses
  42
- Tires
  42
- Steering
  43
- Suspensions
  44
- Chassis Nuts and Bolts
  45
- General Lubrication
  47
- Compression Pressure Check
  48
- Compression Test Procedure
  48
- Oil Pressure Check
  49
- Oil Pressure Test Procedure
  49
- Initial Engagement and Clutch Lock-Up Inspection
  50
- Initial Engagement Inspection
  50
- Clutch Lock-Up Inspection
  51
Engine

52
- Engine Center
  53
- Engine Components Removable with Engine in Place
  53
- Engine Left Side
  53
- Engine Right Side
  53
- Engine Removal
  54
- Engine Removal and Installation
  54
- Engine Installation
  60
- Engine Disassembly
  63
- Engine Top Side
  63
- Engine Bottom Side
  67
- Camshaft and Cylinder Head
  79
- Engine Components Inspection and Servicing
  79
- Cam Chain Guide
  94
- Cam Chain Tensioner
  94
- Cylinder
  94
- Piston
  96
- Conrod/Crankshaft
  98
- Pcv Hose
  99
- Starter Torque Limiter
  99
- Clutch
  100
- Movable Drive Face and Driven Face
  102
- Drive Belt
  109
- Oil Pump
  109
- Transfer
  110
- Gearshift Fork
  113
- Gearshift Cam
  114
- Crankshaft
  115
- Drive Train (Front and Rear Output Shaft)
  117
- Shim Adjustment
  121
- Crankcase
  124
- Generator Cover
  129
- Recoil Starter
  131
- Engine Bottom Side
  134
- Engine Reassembly
  134
- Engine Top Side
  147
Drive Train

156
- Construction
  157
- Front Drive Train (Differential)
  157
- Removal
  158
- Disassembly
  159
- Inspection
  162
- Reassembly
  164
- Remounting
  169
- Shim Adjustment
  170
- Reassembly Information
  173
- Front Propeller Shaft
  174
- Inspection
  174
- Removal
  174
- Reassembly
  175
- Construction
  177
- Rear Drive Train
  177
- Disassembly
  178
- Inspection
  182
- Reassembly
  183
- Shim Adjustment
  186
- Reassembly Information
  189
- Rear Propeller Shaft
  190
- Removal and Disassembly
  190
- Inspection
  192
- Reassembly and Remounting
  193
Fi System Diagnosis

195
- Electrical Parts
  197
- Precautions in Servicing
  197
- Ecm/Various Sensors
  198
- Fuse
  198
- Electrical Circuit Inspection Procedure
  200
- Using the Multi-Circuit Tester
  203
- Fi System Technical Features
  204
- Injection Time (Injection Volume)
  204
- Compensation of Injection Time (Volume)
  205
- Injection Stop Control
  205
- Fi System Parts Location
  206
- Fi System Wiring Diagram
  208
- Self-Diagnosis Function
  209
- User Mode
  209
- Dealer Mode
  210
- Tps Adjustment
  212
- Fail-Safe Function
  213
- Customer Complaint Analysis
  214
- Fi System Troubleshooting
  214
- Visual Inspection
  215
- Self-Diagnostic Procedures
  216
- Self-Diagnosis Reset Procedure
  217
- Use of Sds Diagnostic Procedures
  217
- Use of Sds Diagnosis Reset Procedure
  218
- Show Data When Trouble (Displaying Data at the Time of Dtc)
  219
- Ecm Terminal
  221
- Malfunction Code and Defective Condition
  222
- C12" (P0335) Ckp Sensor Circuit Malfunction
  224
- C13" (P0105) Iap Sensor Circuit Malfunction
  227
- C14" (P0120) Tp Sensor Circuit Malfunction
  231
- C15" (P0115) Ect Sensor Circuit Malfunction
  236
- C20" (P1752) Diff-Lock Relay Circuit Malfunction
  240
- C21" (P0110) Iat Sensor Circuit Malfunction
  243
- C23" (P1651) to Sensor Circuit Malfunction
  247
- C24" (P0351) Ignition Coil Circuit Malfunction
  251
- C32" (P0201) Fuel Injector Circuit Malfunction
  253
- C40" (P0505) Isc Valve Circuit Malfunction
  255
- C41" (P0230) Fp Relay Circuit Malfunction
  260
Fuel System and Throttle Body

264
- Fuel Line Inspection
  265
- Fuel Tank and Fuel Pump
  265
- Fuel Tank Removal
  265
- Fuel Tank Inspection
  266
- Fuel Tank Installation
  266
- Fuel Pressure Inspection
  267
- Fuel Pump Inspection
  268
- Fuel Pump Relay Inspection
  269
- Fuel Pump Removal
  269
- Fuel Filter Cleaning and Fuel Pump Inspection
  270
- Fuel Pump Installation
  270
- Construction
  271
- Throttle Body
  271
- Air Cleaner Box Removal
  272
- Throttle Body Removal
  273
- Throttle Body Disassembly
  274
- Isc Valve Inspection
  276
- Throttle Body Cleaning
  276
- Throttle Body Inspection
  276
- Fuel Injector Inspection
  277
- Throttle Body Reassembly
  277
- Throttle Body Installation
  278
- Air Cleaner Box Installation
  279
- Fuel Injector Installation
  279
- Fuel Injector Removal
  279
- Tp Sensor Adjustment
  279
- Fast Idle
  280
- Fast Idle Adjustment
  280
- Throttle Position Sensor (Tps) Setting
  281
Cooling and Lubrication System

282
- Engine Coolant
  283
- Cooling Circuit
  284
- Cooling Circuit Inspection
  284
- Radiator and Hoses
  285
- Radiator Inspection and Cleaning
  285
- Radiator Removal
  285
- Radiator Cap Inspection
  286
- Radiator Remounting
  286
- Radiator Reservoir Tank
  286
- Radiator Hose Inspection
  287
- Cooling Fan
  288
- Inspection
  288
- Remounting
  288
- Removal
  288
- Cooling Fan Thermo-Switch
  289
- Inspection
  289
- Installation
  289
- Removal
  289
- Ect Sensor
  290
- Inspection
  290
- Installation
  290
- Removal
  290
- Inspection
  291
- Removal
  291
- Thermostat
  291
- Installation
  292
- Removal and Disassembly
  293
- Water Pump
  293
- Reassembly and Installation
  295
- Lubrication System
  298
- Oil Filter
  298
- Oil Pressure
  298
- Oil Pump
  298
- Oil Sump Filter
  298
- Engine Lubrication System Chart
  299
- Engine Lubrication System
  300
Chassis

303
- Construction
  305
- Exterior Parts
  305
- Removal
  307
- Exhaust Pipe
  315
- Remounting
  315
- Removal
  315
- Construction
  316
- Front and Rear Wheels
  316
- Remounting
  316
- Removal
  316
- Tire Replacement
  317
- Tires
  317
- Construction
  319
- Front Drive Shaft
  319
- Removal and Disassembly
  319
- Inspection and Reassembly
  321
- Remounting
  323
- Construction
  324
- Front Brake
  324
- Brake Pad Replacement
  326
- Brake Caliper Removal and Disassembly
  327
- Brake Fluid Replacement
  327
- Brake Caliper Inspection
  329
- Brake Caliper Reassembly and Remounting
  330
- Brake Disc Removal and Disassembly
  332
- Brake Disc Inspection
  333
- Brake Disc Reassembly and Remounting
  333
- Master Cylinder Removal and Disassembly
  334
- Master Cylinder Inspection
  336
- Master Cylinder Reassembly and Remounting
  336
- Construction
  338
- Front Suspension
  338
- Removal and Disassembly
  339
- Inspection
  341
- Reassembly and Remounting
  344
- Construction
  347
- Steering
  347
- Removal and Disassembly
  348
- Reassembly and Remounting
  353
- Toe-Out Adjustment
  355
- Front Wheel, Front Brake, Front Suspension and Steering Reassembling Information
  356
- Construction
  357
- Rear Drive Shaft
  357
- Removal
  357
- Inspection and Reassembly
  358
- Remounting
  360
- Construction
  361
- Rear Brake
  361
- Removal and Disassembly
  362
- Disassmbly
  363
- Inspection
  365
- Reassembly and Remount
  368
- Construction
  371
- Rear Suspension
  371
- Removal
  372
- Inspection and Disassembly
  373
- Reassembly and Remounting
  375
- Rear Stabilizer Removal
  378
- Rear Stabilizer Installation
  379
- Rear Wheel, Rear Brake, Rear Suspension and Rear Axle Shaft Reassembling Information
  380
- Construction
  381
- Transfer Gear Shift Lever
  381
- Inspection
  382
- Removal
  382
- Remounting
  383
- Installation
  384
- Shift Rod
  384
- Shift Rod Adjustment
  385
Electrical System

387
- Cautions in Servicing
  389
- Clamp
  389
- Connector
  389
- Coupler
  389
- Fuse
  389
- Battery
  390
- Connecting the Battery
  390
- Semi-Conductor Equipped Part
  390
- Wiring Procedure
  390
- Using the Multi-Circuit Tester
  391
- Location of Electrical Components
  392
- Main Fuse
  392
- Charging System
  394
- Fuse
  394
- Troubleshooting
  394
- Inspection
  395
- Starter System
  398
- Troubleshooting
  398
- Starter Motor Removal
  399
- Starter Motor Disassembly
  400
- Starter Motor Inspection
  401
- Starter Motor Reassembly
  401
- Starter Motor Installation
  402
- Starter Relay Inspection
  402
- Ignition/Starter Control Relay Inspection
  403
- Neutral Relay Inspection
  403
- Parking Brake Switch
  403
- Ignition System
  404
- Troubleshooting
  404
- Inspection
  406
- Inspection
  409
- Transfer Selecting System
  409
- Combination Meter
  411
- Description
  411
- Operating Procedure
  412
- Removal and Disassembly
  414
- Inspection
  415
- Headlight and Auxiliary Headlight
  418
- Lamps
  418
- Headlight Installation
  420
- Brake Light/Taillight
  421
- Backup Light Relay (for E-17)
  423
- Diode
  423
- Switches
  424
- Battery
  425
- Initial Charging
  425
- Specifications
  425
- Recharging Operation
  427
- Servicing
  427
Servicing Information

428
- Fi System Malfunction Code and Defective Condition
  429
- Troubleshooting
  429
- Engine
  431
- Radiator (Cooling System)
  437
- Chassis
  438
- Brakes
  440
- Electrical
  441
- Battery
  443
- Wiring Harness Routing
  444
- Wiring Harness, Cable and Hose Routing
  444
- Cable Routing
  446
- Fuel Hose Routing
  448
- Cooling System Hose Routing
  449
- Rear Drive Breather Hose Routing
  450
- Front Brake Hose and Pipe Routing
  451
- Fender Installation
  452
- Rear Fender Heat Shield Installation
  454
- Belt Cooling Duct Installation
  455
- Rear Brake Pedal
  456
- Trailer Towing Installation (Option)
  457
- Engine Mounting
  458
- Special Tools
  459
- Engine
  463
- Tightening Torque
  463
- Cooling System
  464
- Drive Train
  464
- Fi System and Intake Air System
  464
- Chassis
  465
- Tightening Torque Chart
  466
- Service Data
  467
- Backup Light
  474
- High Beam Indicator Light
  474
- Neutral Indicator Light
  474
- Reverse Indicator Light
  474
- Speedometer Light
  474

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