Suzuki LT-A400 User manual

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FOREWORD
This manual contains an introductory description on
the SUZUKI LT-A400/400F and procedures for its
inspection/seNiee and overhaul of its main compo-
nents. Other information considered as generally
known is nol included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections.
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.
"This manual has been prepared on the basis of the
latest specifications al the time 01publication. If
modificatioos have been made since then, differ-
ences mayexist between the content of this manual
and the actual motorcycle.
"Illustrations in this manual are used to show the
basic principles of operation and work procedures.
They may not represent the actual motorcycle ex·
actiy in detail.
"This manual
is written for persons who have enough
knowledge, skills and tools, including special tools,
fo r servicing SUZUKI motorcycles. If you do nol
have the proper knowledge and tools, ask your
authorized SUZUKI mo torcycle dealerto help you.
WARNING
Inexperienced mechanics or mechanicswith-
out the proper tools and equipment may not
be able to properly perform the services de-
scribed in this manual. Improper repair may
result In Injury to the mechanic and may ren-
der the motorcycle unsafe for the rIder and
passenger.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
DRIVE TRAIN
FUEL SYSTEM
OIL COOLING
AND
LUBRICATION SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATlON

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SUPPLEMENTS
LT-A400K3/FK3 ('03-MODEL)
LT-A400K4/FK4 ('04-MODEL)
LT-A400KS/FKS ('OS-MODEL)
ILT-A400K6/FK6 ('06-MODEL) II
ILT-A400K7/FK7 ('07-MODEL) III

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HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the
GROUP INDEX .
3. Holding the manual as shown altha right will allow you to find
the first page of the section eas it y.
4. The contents are listed on the first page of ea ch sec ti on to
help you fi nd the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Underthe name of each system or unit there is an exploded view which provides work instructions and other
service information (e.g.; tightening torque, lubricating points, and locking agent poinls).
Example: Rear suspension
(J) Ra;or shod< absorber
1%1 S,...;ng a rm
(JlBoshing
® Rea, &hock a~r mounting upper nut
IBI Rev 5hoci. abso<tler Jl\OU'l t ing ~ .....
C SII/ino a rm pivoI nut
I!l
, ....
"
"
C
,..
'''~
,~ "
" "
'"
.,
" 43.5
'" 10.2 74
.0

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the lable.
SYMBOL DEFINITION SYMBOL DEFINITION
~
T orque contro l required.
=Apply THREAD LOCK SUPER "1322",
Data beside it indicates specified
99000-32110 (Except USA)
torque.
Indicates service data.
Apply THREAD LO CK "1342",
-=99000-32050
~
Apply oil. Use engine oil unless
1= Apply THREAD LOCK SUPER "1360",
otherwise specified.
99000-32130
Jill
Apply hypoid gear oi l.
a
Apply or use br ake fluid .
1rr
Apply molybdenum oil solution.
~
Measure in voltage rang e.
(mixture of engine oil and SUZUKI
MOLY PASTE ina ratio of 1 ; 1)
~
Apply SUZUKI SU PER GREASE "A",
~
Measure in r esis tan ce range.
99000-25030 (USA)
99000-25010 (Others)
J0i
Apply SUZUKI SILICONE GREASE,
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Measure in current range.
99000-25100
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Apply SUZUKI MOLY PAS TE,
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Mea su re in diode test range.
99000-25140
J0i
Apply WATER RE SISTANCE GREASE,
~
Measure in co ntinuit y t est r ange.
99000-25160
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Apply SUZUKI BOND "1207B"
.foot!
Use special to ol.
99104-3 11 40 (USA)
99000-31 1
40 (Others)
-cmJ
Apply SUZUKI BOND "1215",
99000-31110 (Except USA)
e Apply SUZU
KI BOND "12 16B ",
99000-31230
=Apply THREAD LOCK SUPER "1303",
99000-32030

GENERALINFORMATION 1-1
GENERAL INFORMATION
,-------------------- CONTENTS
WARNING/CAUTION/NOTE .................
.. ........................................... 1- 2
GENERAL PRECAUTIONS ........._.. .... ........._...................................... 1- 2
SUZUKI LT-A400K2I400FK2 (2002-MODELj .................................... 1- 4
SERIAL NUMBER LOCATION ...................._...................................... 1- 4
FUEL AND OIL RECOMMENDATlON ............................................... 1- 4
FUEL .........................._. .. ............................................... .. .............. 1- 4
ENGINE OIL........
.... ...................................................................... 1- 5
FRONT AND REAR DRIVE GEAR OIL ....................................... 1- 5
BRAKE FLUID ............................................................................. 1- 5
BREAK-IN PROCEDURES ................................................................ 1- 5
INFORMATION LABELS ....................................................... .. ... .. ...... 1- 6
SPECIFICATIONS .............................................................................. 1- 7
COUNTRY AND AREA CODES ....................... .. ........................... .. ... 1- 9

1 ·2 GENERALINFORMAnON
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information. the symbol
and the words WARNING, CAU TI ON and NO TE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
A WARNING
Indicates a potential hazard that could result In death or Injury.
I CAUTION I
Indicates a potential hazard that could result In vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please no t e, however, th at the warnings an d cau tions contained in th is m an u al cannot possibly cover all
potential hazards relati ng to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS
and CA UTI ONS slaled, you must use good judgemenl and basic mechanical safety principles. If you are
unsure about
how to perform a pa rt icular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
A WARNING
• Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the vehicle.
• When two or more persons work together, pay aHentlon to the safety of each other .
• When it Is necessary to run the engine indoors , make sure that exhaust gas is forced out·
doors.
• When working with toxic or flammable materials, make sure that the area you work in is well
ventilated and that you follow all of the manufacturer's Instructions.
• Never use gasoline as a cleaning solvent.
• To avoid geHlng burned, do not touch the engine, engine 011. radiator, and exhaust system
until they have cooled.
• After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fiHings
related to the system for leaks.

GENERAllNFORMATlON I·J
I CAUTION I
* If parts replacement Is necessary , replace the part s with SUZUKI Genuine Parts or their equiv-
alent.
• When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the
proper order .
• Be sure to use special tools when instructed .
• Make sure that all parts used in reassembly are clean. Lubricate them when specified.
• Use the specified lubricants, bonds , or sealants.
• When removing the battery , disconnect the e ba ttery lead wire first , then the <B battery lead
wire.
• When reconnecting the battery , connect the ® battery lead wire first , th en the e battery lead
wire. Finally, cover the ® battery terminal with the terminal cover.
• When performing service to electrical parts , disconnect the e battery lead wire , unless th e
service
procedure requires the battery power .
• When tightening cylinder head and crankcase nuts and bolts , tighten the larger sizes first.
Always tighten th e nuts and bolts from the inside working out , diagnoally and to the specified
torque.
• Whenever you remove all seals, gaskets , packing , O-rings , self-locking nuts , locking wash-
ers , cotter pi ns , circlips , snap rings and other specified parts , be sure to replace them with
new ones . Also , before Installing these new parts , be sure to remove any left over material
from the mating surfaces.
• Never reuse a circlip and snap ring . When Installing a new snap ring , take care not to expand
the end gap larger than required to slip the s nap ring over the s haft . After I nstalling a snap
ring , always ensure It is completely seated in Its groove and securely fitted .
• Use a torque wrench to tighten fasteners to the specified torque . Wip e off grease and oil it a
thread Is smeared with them.
• After reassembling , check parts for tightness and proper operation.
*To protect the environment, do not unlawfully dispose of used motor oil , all other fluids , bat-
teries, and tires .
• To protect th e earth's natural resources , properly dispose of used vehicles and parts.

1-4 GENERALINFORMAnON
SUZUKI LT-A400K2I400FK2 (2002-MODEL)
RIGHT SIDE
LEFT SIDE
• Difference betWeen photographs and actual vehicles depends on lila marKelS.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) CD is stamped on the left side altha rear
frame pipe. The engine serial number (1) is located on the teft side of the crankcase. These numbers are
required especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATION
FUEL (For CANADA and USA)
• Use only unleaded gasolineof al Jeast 87 pump octane ( A ~ M ) method or 91 octane or higher raled by
the Research Method.
• SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible.
• Use of blended gasoline containing MTBE (Methyl Teniary Butyl Ether) is permitted.
• Use of blended gasoline/alcohol fuel is permined, provided that the fuel contains not more than 10% elha·
nol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolve nl s and corrosion Inhibi·
tors are present in it.
• If the performance of t he vehicle is unsatisfactory while using blended gasoline/alcohol fuel. you should
switch to alcohol·free unleaded gasoline.
• Failure to follow these guidelines could possibly void applicable warranty coverage.
Check with your fuel
supplier to make sure that Ihe fuel you intend 10 use meets the requirements listed above.

GENERAL INFORMATION 1·5 ~
FUEL (For the other countries)
Use unleaded gasoline thaI is graded 91 octane or higher by the Research Method.
ENGINE OIL (For USA)
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or oils that meet AP I service classifications SF or
SG and that have a viscosity rating of SAE 10W/40. II engine oil
wi th a rating of SAE 10W/ 40 is not available, select an alter-
native according to the chart.
ENGINE OIL (For the other countries)
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your vehic le. Use only oils thai meet AP I service clas-
sifications SF or SG and thaI have a viscosity rating of SAE
10W/
40. If engine oil with a rating of SAE 10W/40 is nol avail-
able, select an alternative accor ding to the chart.
FRONT AND REAR DRIVE GEAR OIL
MULT IGRAD£
5W 30
·c 30 -20 - 10 0 10 20 30 _0
TEMP . ' f
22 . a 32 &0 68 86 10.
Use hypoid gear oil that meets the AP I service classification GL·5 and is rated SAE #90. Use a hypoid gear
oil with a rating of SAE #80 if the vehicle is operated where the ambient temperat ure is below oce (32CF).
BRAKE FLUID
~ Specification and classification : DOT 4
A WARNING
This vehicle uses a glycol-based brake fluid . Do not use or mi x different types of brake fluid
such as silicone - based and petroleum-based fluids for refilling the system , otherwise serious
damage will result to the brake system .
Never use any brake fluid taken from old , used , or unsealed containers .
Never reuse brake fluid left over from the last servicing or which has been stored for a long
period of time.
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a very
high standard. It is still necessary
to allow the moving parts to ~BR E A K -IN~ before subjecting the engine to
maximum stresses. T
he future performance and reliability of the engine depends on the ca re and restraint
exercised during its early life. Refer
to the following break-in engine speed recommendations.
• Keep to these breake·in engine sp eed limits.
Break- In engine speeds
Initial 500 km (300 miles) : Less than 1h throttl e
• Upon reaching an odomete r reading of 500 km (300 miles) you can subject the vehicle to full throttle oper-
ation, for short periods of time.

1-0 GENERALINFORMATI ON
INFORMATION LABELS
NO
LABEL or PLATE NAME
APPliED SPECIFICATION
E-03
E-17 E-24
E·28 E·33
CD
Certificat ion plate IS 0 -0 -0
<2J
Information label it)
-- - - 0
ill Tire air
prBSSUre label e 0 0 0 0 0
® Tire air
p!"essure label and warning no-passeoger labelS 0 0
I5l
GenlHBl warning label if)
0 0 0 0 0
I5l
G&nefal warning label IE>
-0 -0 -
(j)
Warning no-passengerlabel ifl 0 0 0 0 0
I5l
Age. 16 label ifl 0 0 0 0 0
I5l
Age, 16 label and gearshift label it)
-0 -0 -
S Manual notice label
IE! 0 0
®
Mal( AMP caution label!£> 0 0 0
~ Max AMP caution label
e, I[>
0 0
@ Fuel caution label
IS 0
® Gearshift label
if)
0 0 0 0 0
S Frool carner warning
Label if)
0 -0 -0
I5l
Front carrier warning label e, €l -0 -0 -
I5l
Rear carrier warning label e 0 -0 -0
I5l
Rear carrier warning label e. I[) -0 -0 -
@
Traile r 10 warning la bel IS
0 0 0 0 0
<»
Traile r 10 warning label it)
0 0
® ICESCanada label
it)
0
@
~iance label It)
- - 0 -
@
lDpialeS -0 - - -

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................... 2 225 mm (87.6 in) ....... E-17
GEN E RAL IN FORMAn ON 1·'
2 155 mm (84.4 in) ....... E- 03, 24, 28, 33
Overall width ....................................................... 1 130 mm (44.5 in)
Overall height...................................................... , 180 mm (46.5 in)
Wheelbase ........................................ ... .. ... .......... , 270 mm (50.0 in)
Fronllrack ...........................,... ... ........................ 895 mm (35.2 in)
Rear track............................................................ 900 mm (35.4 in)
Ground clearance................................................ 235 mm ( 9.3 in)
Seat height.......................................................... 830
mm (32.7 in)
Dry mass............................................................. 252 kg (555Ibs)......... LT-A400
269 kg (593 Ibs) ......... LT -A400F E-17
268 kg (590
Ibs) ......... LT-A4 00F E-03. 24. 28. 33
ENGINE
Type .................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................ 1
Bore..................................................................... 82.0 mm (3.22B in)
Stroke.................................................................. 71.2 mm (2.B03 i
n)
Piston displacement............................................ 376 cm3 (22.9 cu.in)
Compression ratio ............................................... 9.0 : 1
Carburetor........................................................... KEIHIN CVK32SS
Aircleaner ...........................................
... ............. Polyurethane foam element
Starter system ..................................................... Electric and recoil starter
Lubrication system .......
... .................................... Wet su mp
DRIVE TRAIN
Clutch .................................................................. Wet shoe, automatic, centrifugal type
Transmission....................................................... Automatic variable ratio (V-velt)
Transfer............................................... .. .............. 2-speed forward with reverse
Gearshift pattern, Transmission.......................... Automatic
Transfer.................................. L-H-N-R (Hand operated)
Automatic transmission ratio ............................... Variable change (2.938 -0.813)
Secondary reduction ratio ................................... 2.210
(421 19)
Final reduction ratio (Front & Rear) ................... 3.600 (36/10)
Transfer gear ratio, Low .................................... 2.500 (40/16)
High ................................... 1.375 (33124)
Reverse............................. 2.000 (32116)
Drive sys1em ....................................................... Shaft drive

1-8 GENERALINFORM A noN
CHASSIS
Front suspension ....... .. ........................................lndependen!, double wishbone, coil spring, oil damped
Rear suspension...........................................
.. .....Swingarm type, coil spring, oil damped
Steering angle......................................................In si de 39.5°
Outside 26.5°
Caster ................................................... .. ............. 3°
Trail ...... .............................................................. .. 14 mm (0.55 in)
Turning radius ......................................................3.1 m (10.2 It)
Front brake...........................................................Disc brake, tw in
Rear brake ...........................................................Drum brake
Front tire size .......................................................AT2S x 8·12 ,
'Cl'Cl tubeless
Aeartire size........................................................AT2S x 10-12 , 'Cl'Cl tubeless
Front wheel travel ............................................... 170
mm (6.7 in)
Aearwheel trave!.......... ......................................170 mm (6.7 in)
ELECTRICAL
Ignition type ..........................................................Electronic ignition (COl)
Ignition timing............
.. .. ....................................... 100 B.T.D.C. atl 500 r/min
Spark plug............................................................NGK: CR7E
DENSO: U22ESR-N
BatlelY..................................................................12 V 43.2 kC (12 Ah)/IO HR
Generator.............................................................Three·phase A.C. generator
Main fuse .......................
.. ....................................30 A
Fuse.....................................................................1
0/1 01 10/1 0/1 OI SA
Headlight.............................................................. 12 V 30/30 W
Brake lighVTaillight...............................................12 V
21 /5 W
Back-up light........................................................12 V
21 W .....................E-17
Speedometer light................................................12 V 1.7 W
Reverse indicator light .............
.. .... .. ....................12 V 3.4 W
Neutral indicator light ...........................................12 V 3.4 W
High beam indicator light .....................................12 V 1.7 W ....................E
·17
Oil temperature indicator light.............................. 12 V 3.4 W
CAPACITIES
Fuel tank,including reselVe .................................15.0 L (4.013.3 US/Imp gal)
reselVe .................................
.. .. ........... 3.3 L (0.9/0.7 US/Imp gal)
Engine oi l,o il change...........................................2 900 ml (3.112.6 US/Imp qt)
oil and filter change .......... .. ................ 3100 ml (3 .31 2.7 US/Imp qt)
engine overhaul..................................3 400 ml (3.613.0 US/Imp qt)
Front drive (differential)
gear oil........................... 300 ml (10.1/10.6 US/lmp ozl
Rear drive gear oil................................................ 250 -350 ml (8.518.8 - 11 .8/12.3 USllmp oz)
NOTE:
• These specifications are subject to c hange without notice.

GENERAL INFORMATION 1·9 -
COUNTRY AND AREA CODES
The following codes stand for the applicable cou ntries and areas.
CODE COUNTRY
OR AREA
E-03 USA
E-17
Sweden
E-24 Australia
E-28 Canada
E- 33
California ( USA)

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PERIOD IC MAINTENANC E 2 ·1
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE ........•..................•................2- 2
PERIODIC MAINTENANCE CHART ............................ .. .............2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ................ .. ............. 2- 3
AIR CLEANER ................ .. ......... .. ...... .. ....... .. ............................... 2- 3
EXHAUSTPIPE NUTS AND MUFFLER BOLTS ......... .. ............. 2- 4
VALVE CLEARANCE .. ..... .. .................. ... ................ .. ... .. . .. ..........2- 5
SPARK PLUG ................... .. . .. ...................................................... 2- 8
FUEL HOSE ............ .. .................. .. ................ .. .............................2- 9
THROTTLE CABLE PLAY ................ .. . .... ............•................•...... 2- 9
ENGINE IDLE SPEED .. .........................................................•.... .. 2- 9
ENGINE OIL AND OIL FILTER .............................................•...... 2-10
DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL ......•......2-12
INITIAL ENGAGEMENTAND CLUTCH LOCK- UP INSPECTION ...2-13
INITIAL ENGAGEMENTINSPECTION ................................•......2-13
CLUTCH LOCK-UP INSPECTION .....................•.........................2-14
DRIVE
BELT .............. .. . .. ............... .. ............................................ 2-14
SPARK ARRESTER .................................................. ..• ............... 2-17
BRAKES .....•...........................•.......... .. ... .. ....................•........•...... 2-18
BRAKE FLUID ........... .. ..................... .... . .. ........... .. .......•........•......2-20
BRAKE HOSES ......... .. .•.......... .. ..................................•........•...... 2-22
TIRES .........•.... .. ................................. .. ........................•........•......2- 22
STEERING .. .. ............. .. ..........•.....................................•............... 2-23
SUSPENSIONS .......... .. ..........•......................................... .. ..... .. . .. 2- 24
CHASSIS NUTS AND BOLTS .....................................•........•...... 2-25
GENERAL LUBRICATION ..........................................•........••..... 2-28
COMPRESSION PRESSURE CHECK ..................... .. ..........•........•......2-29
COMPRESSION TEST PROCEDURE ................................... .. ....2-29
OIL PRESSURE CHECK ......................................................•...............2-30
OIL PRESSURE TESTPROCEDURE .. . .. ....................•...............2-30

2·2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommen ded intervals forall the required pe riodic service work necessary to keep
the vehicle operating al peak performance and economy. Maintenance intervals are expressed in terms of
kilometers, miles and months, and are dependent on whichever comes first.
NOTE:
More frequent servicing may be performed on vehicles that are use undersevere conditions.
PERIODIC MAINTENANCE CHART
~al
km I ni li al200 Every 1 000 E very 2 000
miles Initial 100 Every 600 Every 1 200
It em
months 1 3 6
Air cleaner -C C
Exhaust pipe nu ts and muffter bolts T T T
Valve clearance I -I
I
Spark plug Replace every 6 000 km (4 000 mites).
F uel li ne
Throttle cable play I
Engine idle speed I
Engine oil an d oil filter R
-
Front differential gear oil/Final gear oi l
D rive belt -
Cl u tch
Spark arrester -
Brakes I
-
Br ake fluid
Bra ke hose
Tires
Steering system I
Suspensions
Chassis nuts and bolls T
Gener al l ub ricat io ns
I =Inspect and adjust, clean, lubricat e, or replace as necessary.
R=Repface
T=Tighten
C = Clean
L =Lubricate
I I I I
Repl ac e every four year s.
I I
I I
-R
-I
Replace every two year s.
I R
-I
-C
I I
I I
Replace every two year s.
I I
Replace every four ye ar s.
I I
I I
I
T T
L L
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