Suzuki LT-A700X 2004 User manual

Printed in U.S.A
K5
99500-46060-01E LT-A700X_01E SERVICE MANUAL 2004. 9. 15 for PS printing
99500-46060-01E
TOP
BOTTOM

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
DRIVE TRAIN 4
FI SYSTEM DIAGNOSIS 5
FUEL SYSTEM AND THROTTLE
BODY 6
COOLING AND LUBRICATION
SYSTEM 7
CHASSIS 8
ELECTRICAL SYSTEM 9
SERVICING INFORMATION 10
WIRING DIAGRAM 11
FOREWORD
This manual contains an introductory description on
the SUZUKI LT-A700X and procedures for its
inspection/service and overhaul of its main compo-
nents.
Other information considered as generally known is
not 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 vehicle better so
that you can assure your customers of fast and reli-
able service.
!
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual vehicle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcy-
cle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.

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 at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example:

1TP sensor

2ISC valve

3IAP sensor

4Fuel delivery pipe

5O-ring

6Fuel injector

7Cushion seal

8Vacuum hose

9Throttle linkage cover

0IAP sensor cover

ATP sensor mounting
screw

BISC valve mounting
screw

CFuel delivery pipe
mounting screw
"
ITEM N·m
kgf-m lb-ft

A2.0 0.2 1.5

B2.0 0.2 1.5

C50.53.5

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 table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1305”.
99000-32100
Indicates service data. Apply THREAD LOCK SUPER “1322”.
99000-32110 (Except USA)
Apply oil. Use engine oil unless other-
wise specified.
Apply THREAD LOCK “1342”.
99000-32050
Apply hypoid gear oil. Apply THREAD LOCK SUPER “1360”.
99000-32130
Apply molybdenum oil solution.
(mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Apply or use brake fluid.
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA)
99000-25010 (Others)
Measure in voltage range.
Apply SUZUKI SILICONE GREASE.
99000-25100
Measure in resistance range.
Apply SUZUKI MOLY PASTE.
99000-25140
Measure in current range.
Apply WATER RESISTANCE GREASE.
99000-25160
Measure in diode test range.
Apply SUZUKI BOND “1207B”
99104-31140 (USA)
Measure in continuity test range.
Apply SUZUKI BOND “1215”.
99000-31110 (Except USA)
Use special tool.
Apply SUZUKI BOND “1216B”.
99100-31230
Use engine coolant.
99000-99032-11X (Except USA)
Apply THREAD LOCK SUPER “1303”.
99000-32030
H/O
W
1216B

ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC : After Bottom Dead Center
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
ATM Pressure : Atmospheric Pressure
: Atmospheric Pressure sensor
(APS, AP Sensor)
A/F : Air Fuel Mixture
B
BBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CO : Carbon Monoxide
CPU : Central Processing Unit
D
DC : Direct Current
DIFF-LOCK Relay : Differential Lock Relay
DMC : Dealer Mode Coupler
DOHC : Double Over Head Camshaft
DRL : Daytime Running Light
E
ECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp.
Sensor (WTS)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
G
GEN : Generator
GND : Ground
GP Switch : Gear Position Switch
H
HC : Hydrocarbons
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
ISC Valve : Idle Speed Control Valve (ISCV)
L
LCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand

M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
N
NOX : Nitrogen Oxides
O
OHC : Over Head Camshaft
OPS : Oil Pressure Switch
P
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
REC : Rectifier
REG : Regulator
RH : Right Hand
ROM : Read Only Memory
S
SAE : Society of Automotive Engineers
SDS : Suzuki Diagnosis System
T
TO Sensor : Tip-Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR
B : Black Gr : Gray R : Red
Bl : Blue W : White Br : Brown
Lg : Light green Y : Yellow Dg : Dark green
O : Orange G : Green
P:Pink
B/Bl : Black with Blue tracer B/Br : Black with Brown tracer
B/G : Black with Green tracer B/Lg : Black with Light green tracer
B/R : Black with Red tracer B/W : Black with White tracer
B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer
Bl/G : Blue with Green tracer Bl/R : Blue with Red tracer
Bl/W : Blue with White tracer Bl/Y : Blue with Yellow tracer
G/B : Green with Black tracer G/Bl : Green with Blue tracer
G/W : Green with White tracer G/Y : Green with Yellow tracer
Gr/B : Gray with Black tracer Gr/R : Gray with Red tracer
Gr/W : Gray with White tracer Gr/Y : Gray with Yellow tracer
O/B : Orange with Black tracer O/Bl : Orange with Blue tracer
O/G : Orange with Green tracer O/R : Orange with Red tracer
O/W : Orange with White tracer O/Y : Orange with Yellow tracer
P/B : Pink with Black tracer P/W : Pink with White tracer
R/B : Red with Black tracer R/Bl : Red with Blue tracer
R/G : Red with Green tracer R/W : Red with White tracer
W/B : White with Black tracer W/Bl : White with Blue tracer
W/G : White with Green tracer W/R : White with Red tracer
W/Y : White with Yellow tracer Y/B : Yellow with Black tracer
Y/Bl : Yellow with Blue tracer Y/G : Yellow with Green tracer
Y/R : Yellow with Red tracer Y/W : Yellow with White tracer

GENERAL INFORMATION 1-1
1
GENERAL INFORMATION
CONTENTS
COUNTRY AND AREA CODES
The following codes stand for the applicable country (-ies) and area (-s).
MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO.
LT-A700X K5
E-17
E-24
E-28
E-33
Sweden
Australia
Canada
U.S.A.
JSAAP41A 52100001-
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS...........................................................................1- 2
SUZUKI LT-A700XK5 (’05-MODEL) .............................................................1- 4
SERIAL NUMBER LOCATION......................................................................1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION........................1- 5
FUEL (FOR USA AND CANADA)...........................................................1- 5
FUEL (FOR OTHER COUNTRIES).........................................................1- 5
ENGINE OIL (FOR USA).........................................................................1- 5
ENGINE OIL (FOR OTHER COUNTRIES) .............................................1- 5
FRONT DIFFERENTIAL GEAR OIL .......................................................1- 5
REAR DRIVE (FINAL) GEAR OIL ..........................................................1- 5
BRAKE FLUID.........................................................................................1- 5
ENGINE COOLANT ................................................................................1- 6
WATER FOR MIXING .............................................................................1- 6
ANTI-FREEZE/ENGINE COOLANT........................................................1- 6
LIQUID AMOUNT OF WATER/ENGINE COOLANT ..............................1- 6
BREAK-IN PROCEDURES ...........................................................................1- 7
INFORMATION LABELS...............................................................................1- 8
SPECIFICATIONS .........................................................................................1- 9
DIMENSIONS AND DRY MASS .............................................................1- 9
ENGINE ...................................................................................................1- 9
DRIVE TRAIN ..........................................................................................1- 9
CHASSIS .................................................................................................1-10
ELECTRICAL ..........................................................................................1-10
CAPACITIES ...........................................................................................1-10

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
#
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS
and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the vehicle.
* When 2 or more persons work together, pay attention 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 material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.
* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings
related to the system for leaks.

GENERAL INFORMATION 1-3
#
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lents.
* 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 and orientation.
* 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 lubricant, bond, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negative cable from the battery.
* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, 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 snap ring. When installing a new snap ring, take care not to expand the end gap
larger than required to slip the snap ring over the shaft. After installing a snap ring, always
ensure that it is completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if 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, engine coolant and
other fluids: batteries, and tires.
* To protect Earth’s natural resources, properly dispose of used vehicle and parts.

1-4 GENERAL INFORMATION
SUZUKI LT-A700XK5 (’05-MODEL)
• Difference between photograph and actual vehicle may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number)

1
is stamped, on the left side of the front
frame pipe. The engine serial number

2
is located on the right side of the crankcase. These numbers are
required especially for registering the machine and ordering spare parts.
RIGHT SIDE
LEFT SIDE

GENERAL INFORMATION 1-5
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the
Research Method.
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10 % ethanol, or less than 5 % methanol
with appropriate cosolvents and corrosion inhibitor is permissible.
FUEL (FOR OTHER COUNTRIES)
Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline is recom-
mended.
ENGINE OIL (FOR USA)
SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG
under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE
10W-40. If SAE 10W-40 oil is not available, select an alternative according to the following chart.
ENGINE OIL (FOR OTHER COUNTRIES)
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your vehicle. Use only oils which are rated SF or SG
under the API service classification. The recommended viscosity
is SAE 10W-40. If SAE 10W-40 motor oil is not available, select
an alternative according to the right chart.
FRONT DIFFERENTIAL GEAR OIL
Use hypoid gear oil that meets the API service classification GL-5 and is rated SAE #90. Use a hypoid gear
oil with a rattng of SAE #80 if the vehicle is operated where the ambient temperature is below 0 °C (32 °F).
REAR DRIVE (FINAL) GEAR OIL
Use mobil fluid 424 or equivalent oil.
BRAKE FLUID
Specification and classification: DOT 4
!
5W-30
10W-40. 10W-50
15W-40. 15W-50
20W-50
5W-30
Since the brake system of this vehicle is filled with a glycol-based brake fluid by the manufac-
turer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

1-6 GENERAL INFORMATION
ENGINE COOLANT
Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.
WATER FOR MIXING
Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.
ANTI-FREEZE/ENGINE COOLANT
The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the atmospheric temperature in your area does not go down
to freezing point.
Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use
an equivalent which is compatible with an aluminum radiator.
LIQUID AMOUNT OF WATER/ENGINE COOLANT
Solution capacity (total): Approx. 2 450 ml (2.59/2.16 US/Imp qt)
For engine coolant mixture information, refer to cooling system section in page 7-2.
#
Mixing of anti-freeze/engine coolant should be limited to 60 %. Mixing beyond it would reduce
its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50 %, rust inhabiting perfor-
mance is greatly reduced. Be sure to mix it above 50 % even though the atmospheric tempera-
ture does not go down to the freezing point.

GENERAL INFORMATION 1-7
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine
to maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.
• Keep to these break-in engine speed limits:
Brake-in engine speeds
Initial 500 km (300 miles): Less than 1/2 throttle
• Upon reaching an odometer reading of 500 km (300 miles) you can subject the vehicle to full throttle oper-
ation, for short periods of time.

1-8 GENERAL INFORMATION
INFORMATION LABELS
A: Attached
*1: Except for E-28 *2: For E-28 *3: For E-33 *4: For E-24 *5: For E-17
*6: This label is attached on the seat. *5: This label is attached on the left side of frame.

1
Certification plate A (For E-24, 33)

2
Information label A (For E-33)

3
Gearshift label A

4
Gearshift label A (For E-28)

5
Tire air pressure label A

6
Tire air pressure label and warning no-passenger label A (For E-28)

7
General warning & AGE, 16 label A

8
General warning label A (For E-28)

9
Warning no-passenger label A

0
AGE, 16 label A (For E-28)

A
Manual notice label A (For E-33)

B
Max AMP caution label A (Except for E-28)

C
Max AMP caution label A (For E-28)

D
Fuel caution label A (For E-24)

E
Front carrier warning label A (For E-24, 33)

F
Front carrier warning label A (For E-17, 28)

G
Rear carrier warning label A (For E-24, 33)

H
Rear carrier warning label A (For E-17, 28)

I
Trailer to warning label A

J
Trailer to warning label A (For E-17 (CH), 28)

K
ICES Canada label A (For E-28)

L
Compliance label A (For E-28)

M
ID plate A (For E-17)

N
Cooling fan label A
*2*2 *2
*2
*4 *3
*2
*2
*5
*1 *2
Left side of frame
Frame
*3

GENERAL INFORMATION 1-9
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length .......................................................................... 2 115 mm (83.3 in) ..........E-28, 33
2 135 mm (84.1 in) ..........E-17, 24
Overall width ........................................................................... 1 210 mm (47.6 in) ..........E-28, 33
1 250 mm (49.2 in) ..........E-17, 24
Overall height .......................................................................... 1 220 mm (48.0 in)
Wheelbase .............................................................................. 1 280 mm (50.4 in)
Ground clearance.................................................................... 260 mm (10.2 in)
Seat height .............................................................................. 860 mm (33.9 in)
Dry mass ................................................................................. 273 kg (601 lbs)..........E-28, 33
275 kg (606 lbs)..........E-17, 24
Front track ............................................................................... 930 mm (36.6 in)
Rear track................................................................................ 940 mm (37.0 in)
ENGINE
Type ........................................................................................ 4 stroke, liquid-cooled, DOHC
Number of cylinders ................................................................ 1
Bore......................................................................................... 102.0 mm (4.016 in)
Stroke...................................................................................... 85.0 mm (3.346 in)
Displacement .......................................................................... 695 cm³ (42.4 cu.in)
Compression ratio ................................................................... 10.0:1
Fuel system............................................................................. Fuel injection
Air cleaner ............................................................................... Nonwoven fabric element
Starter system ......................................................................... Electric and recoil starter
Lubrication system .................................................................. Wet sump
Idle speed................................................................................ 1 300 ± 100 r/min
DRIVE TRAIN
Clutch ...................................................................................... Wet shoe, automatic, centrifugal type
Transmission ........................................................................... Automatic variable ratio (V-belt)
Transfer ................................................................................... 2-speed forward with reverse
Gearshift pattern, Transmission .............................................. Automatic
Transfer ...................................................... L-H-N-R (Hand operated)
Automatic transmission ratio ................................................... Variable change (2.763 – 0.78)
Secondary reduction ratio ....................................................... 2.158 (40/21 × 17/15)
Final reduction ratio (Front & Rear)......................................... 3.600 (36/10)
Transfer gear ratio, Low .......................................................... 2.563 (41/16)
High ......................................................... 1.240 (31/25)
Reverse ................................................... 1.882 (32/17)
Drive system ........................................................................... Shaft drive

1-10 GENERAL INFORMATION
CHASSIS
Front suspension .................................................................... Independent, double wishbone, coil spring,
oil damped
Rear suspension ..................................................................... Independent, double wishbone, coil spring,
oil damped
Front wheel travel ................................................................... 180 mm (7.1 in)
Rear wheel travel .................................................................... 200 mm (7.9 in)
Caster ..................................................................................... 1.6 °
Trail......................................................................................... 3.4 mm (0.13 in)
Toe-out.................................................................................... 10 mm (0.39 in)
Camber ................................................................................... 0.64 °
Steering angle......................................................................... 46 ° (right & left)
Turning radius ......................................................................... 3.1 m (10.2 ft)
Front brake.............................................................................. Dual hydraulic disc
Rear brake .............................................................................. Sealed oil-bathed multi-disc
Front tire size .......................................................................... AT25 × 8 – 12
✩✩
, tubeless
Rear tire size........................................................................... AT25 × 10 – 12
✩✩
, tubeless
ELECTRICAL
Ignition type............................................................................. Electronic ignition (CDI)
Ignition timing.......................................................................... 7 ° B.T.D.C.at 1 300 r/min
Spark plug............................................................................... NGK CR6E or DENSO U20ESR-N
Battery..................................................................................... 12 V 64.8 kC (18 Ah)/10 HR
Generator................................................................................ Three-phase A.C. generator
Main fuse ................................................................................ 30 A
Fuse ........................................................................................ 10/10/10/10/15/15 A
Headlight................................................................................. 12 V 30/30 W × 2
Auxiliary light........................................................................... 12 V 40 W
Brake light/Taillight.................................................................. 12 V 21/5 W
Backup light ............................................................................ 12 V 21 W ... E-17
Speedometer light................................................................... LED
Neutral indicator light .............................................................. LED
High beam indicator light ........................................................ LED ............. E-17
Coolant temperature/FI warning light ......................................... LED
Reverse indicator light ............................................................ LED
Diff-lock indicator light............................................................. LED
CAPACITIES
Fuel tank ................................................................................. 17.5 L (4.6/3.8 US/lmp gal)
Engine oil,oil change............................................................... 2 300 ml (2.4/2.0 US/Imp qt)
with filter change .................................................... 2 500 ml (2.6/2.2 US/lmp qt)
overhaul ................................................................. 3 000 ml (3.2/2.6 US/lmp qt)
Differential gear oil .................................................................. 500 ml (16.9/17.6 US/lmp oz)
Final gear oil ........................................................................... 770 ml (26.0/27.1 US/lmp oz)
Coolant ............................................................................... 2.45 L (2.6/2.2 US/lmp qt)
These specifications are subject to change without notice.

2
6
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE .....................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ........................................2- 3
AIR CLEANER .......................................................................................2- 3
EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS ..............2- 5
VALVE CLEARANCE ............................................................................2- 5
SPARK PLUG ........................................................................................2-10
SPARK ARRESTER ...............................................................................2-11
FUEL LINE .............................................................................................2-11
THROTTLE CABLE PLAY .....................................................................2-12
THROTTLE BODY .................................................................................2-12
ENGINE OIL AND OIL FILTER ..............................................................2-12
DIFFERENTIAL GEAR OIL INSPECTION .............................................2-14
DIFFERENTIAL GEAR OIL REPLACEMENT .......................................2-14
FINAL GEAR OIL ...................................................................................2-15
ENGINE COOLANT ...............................................................................2-16
RADIATOR .............................................................................................2-17
RADIATOR HOSES ...............................................................................2-17
DRIVE BELT ...........................................................................................2-18
BRAKES .................................................................................................2-22
BRAKE FLUID ........................................................................................2-23
BRAKE HOSES ......................................................................................2-25
TIRES .....................................................................................................2-25
STEERING ..............................................................................................2-26
SUSPENSIONS ......................................................................................2-27
CHASSIS NUTS AND BOLTS ...............................................................2-28
GENERAL LUBRICATION .....................................................................2-30
COMPRESSION PRESSURE CHECK .........................................................2-31
COMPRESSION TEST PROCEDURE ...................................................2-31
OIL PRESSURE CHECK ..............................................................................2-32
OIL PRESSURE TEST PROCEDURE ...................................................2-32
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION ........2-33
INITIAL ENGAGEMENT INSPECTION ..................................................2-33
CLUTCH LOCK-UP INSPECTION .........................................................2-34

2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the vehicle operating at 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 used under severe conditions.
PERIODIC MAINTENANCE CHART
I = Inspect and adjust, clean, lubricate, or replace if necessary.
R = Replace
T = Tighten
C = Clean
L = Lubricate
Interval
Item
km Initial 200 Every 1 000 Every 2 000
miles Initial 100 Every 600 Every 1 200
months 1 3 6
Air cleaner — C C
Exhaust pipe nuts and muffler mounting bolts T T T
Valve clearance I — I
Spark plug —— I
Replace every 6 000 km (4 000 miles).
Spark arrester — — C
Fuel line —I I
Replace every four years.
Throttle cable play I I I
Throttle body — I I
Engine oil and oil filter R — R
Differential gear oil —— I
Replace every two years.
Final gear oil —— I
Replace every year.
Engine coolant Replace every two years.
Radiator — I I
Radiator hose — — I
Drive belt — I R
Brakes III
Rear brake plates Replace every 10 000 km (6 000 miles).
Brake fluid —I I
Replace every two years.
Brake hose —— I
Replace every four years.
Tires — I I
Steering I I I
Suspensions — — I
Chassis nuts and bolts T T T
General lubrication — L L

PERIODIC MAINTENANCE 2-3
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item
mentioned in the periodic maintenance chart.
Before performing the servicing procedures mentioned in the
periodic maintenance chart, remove following parts to ease ser-
vicing work;
• Seat. (
$
8-4)
• Front carrier. (
$
8-4)
• Front grip bar. (
$
8-5)
• Front fender. (
$
8-5)
• Left inner fender. (
$
8-6)
• Right inner fender. (
$
8-6)
• Left side cover. (
$
8-8)
• Right side cover. (
$
8-8)
• Left mud guard. (
$
8-8)
• Right mud guard. (
$
8-8)
• Rear carrier. (
$
8-9)
• Fuel tank cover. (
$
8-10)
• Rear fender. (
$
8-10)
AIR CLEANER
If the air cleaner element is clogged with dust, intake resistance
will be increased, which results decrease in power output and
increase in fuel consumption. Check and clean the air cleaner
element in the following manner.
• Remove the seat. (
$
8-4)
• Remove the air cleaner box cover

1
.
• Remove the air cleaner box cap

2
.
• Remove the air cleaner element.
Clean every 1 000 km (600 miles, 3 months).