i FOREWORD Thismanualcontainsanintroductory descriptionon theSUZUKI LT-A400/400Fandproceduresforits inspection/seNiee and overhaul of itsmaincompo-nents.Otherinformation consideredas generally knownisnolincluded. Read theGENERAL INFORMATIONsectionto familiarize yourselfwiththe motorcycle and itsmain-tenance.Use thissectionas wellas other sections. touseas aguideforproper inspectionandservice. This manual willhelp youknow themotorcyclebet-ter so that you canassureyour customersof fast andreliableservice. "This manual has been prepared on the basis of the latestspecificationsalthetime01 publication.If modificatiooshavebeenmadesincethen, differ-ences may exist between the content of this manual andthe actualmotorcycle. "Illustrations inthismanualareused toshow the basic principles ofoperation and work procedures. Theymay not represent the actual motorcycle ex actiy indetail. "This manual is written for persons who have enough knowledge,skills and tools, including special tools, forservicingSUZUKImotorcycles.If youdonol havetheproperknowledgeandtools,askyour authorized SUZUKI motorcycle dealer to help you. WARNING Inexperienced mechanics or mechanics with-out the proper tools and equipment may not be able to properly perform the services de-scribedin this manual. Improper repairmay result InInjury to the mechanic and may ren-der themotorcycle unsafe for therIder and passenger. GROUP INDEX GENERAL INFORMA TION PERIODIC MAINTENANCE ENGINE DRIVE TRAIN FUEL SYSTEM OILCOOLING AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMA TlON I r SUPPLEMENTS L T-A400K3/FK3 ('03-MODEL) L T-A400K4/FK4 ('04-MODEL) L T-A400KS/FKS ('OS-MODEL) ILT-A400K6/FK6 ('06-MODEL)II IL T-A400K7/FK7 ('07-MODEL)III HOW TOUSE THISMANUAL TOLOCATE WHAT YOUARELOOKINGFOR: 1.Thetext of thismanualisdivided intosections. 2.Thesection titles are listed in theGROUP INDEX. 3.Holding the manual as shownaltha right willallow you to find the first page of the section easity. 4.Thecontentsarelistedonthefirstpageofeachsecti onto help you fi nd theitem and page you need. COMPONENT PARTS AND WORK TOBE DONE Under the name of each system or unit there is an exploded view which provides work instructions and other service information(e.g.; tighteningtorque,lubricating points, and locking agent poinls). Example:Rear suspension (J) Ra;or shod< absorber 1%1 S,...;ngarm (JlBoshing Rea, &hocka ~ rmountingupper nut IBIRev 5hoci. abso. Remove the rear carrier @ and rear fender @. Turn thefuel valve to the "ON- position. Disconnect the fuelhose and vacuum hose. ENGINE3-5 Remove the fuellank. Fuel tank removal t:753 Remove the inner fender (j), (L&R) Removethe carburetor. Carburetorremoval c:rS8 Remove the engine under cover (2). Disconnect the oilhoses. UENGINE Remove the speedometer cable CD. Remove the gearshift arm. NOTE: Flattenthe locked parts with a long nose pliers. Disconnecllhe neutral switchlead wirecoupler t%>. Disconnect the signalgenerator lead wire coupler ~and gen erator lead wirecoupler @. Remove the spark plug cap @. Disconnect thebreather hose (1). Disconnecttheengine groundleadwire~andstarter motor lead wire @. Disconnect theoilcooler fanswitchlead wire coupler @and oil temp.switchleadwire coupler@. Remove theright footrest @. Remove the brake pedal (j). Remove themuffler. ENGINE3-7 l-8ENGINE Remove the exhaust pipe, Remove the cooting ducts CD. (Front& Rear) Remove thepropeller shaft flange couplimgbolts. Remove the enginemounting bolts and nuts. Remove theenginemounting bracket . ,.,51 ,. ~ ~ !,,-p.~i 1fiI'" 'i'" I, ~~ ~ - , \ ~ . .1=- .. .",' '\.I,.,- Of' , i I~ ~ \~ ... ENGINE3-9 Remove theenginemounting bolts andnuts. Removethe engine from theright si de. 3-10ENGINE ENGINE INSTALLATION Remount the engine in thereverse order of engine removaL Pay anenlion to the followingpoints: NOTE: The engine mounting nuts are self-locking. Once the nut has been removed,it isno longer of any USB.Be suretousenew nuts,and thentightenthemtothespecified torque. ...... / ITEMNmkgf-mI... 404.029.0 555.540.0 C555.540.0 Drivebe $Shim .... elgear

< (4.5kgf-rn325 /" . lbM) ;@o

ENGINE359

@ 100N.m .,@ Check the gear case bearings for wear or damage. Ifanywear ordamageisfound,replacethebearingwithanew one. BEARINGREMOVAL c:74-5, 6. Checkthebreatherrubbercaseforwearordamage.Also, check that thejoint of therubber case fitstightly. DIFFERENTIAL BEARING/BEVEL RINGGEAR Check theouter race play and smoothrotationof the bearing by handwhileit is on the di fferential. Inspect theringgear for wear or damage. If the ringgear is damaged,inspect the pinion gear also. Ifany defects are found,replace the bearings and ringgear with thenew ones. BEARINGREMOVAL c:74-4. DRIVE TRAI N4-9 .. /). 4-1 0DRIVETRAIN FRONT DRIVE (DIFFERENTIAL) REASSEMBLY Reassemblethe front driveinthereverseorder of disassembly. Pay anention to the followingpoints; NOTE: Beforereassembly,thoroughlycleanallpartsincleaningso/-vent. DIFFERENTIAL BEARING Drive the bearings to the differential with thespecial tool. ng, 0991370210:Bearing Installer set FRONT DRIVEGEARCASE OIL SEAL Inslallthenewoilsealsintothegearcaseandcasecover with thespecial tool. Apply grease to the new oilseallips. diJ 09913-70210:Bearing Instatler set ,@99000-25030: SUZUKI SUPER GREASE " A"(USA) 99000-25010:SUZUKI SUPER GREASE " A"(Others) BEVEL PINION GEARBEARING Drive the bearing onto the shaft with the special tool. mil 09913-7021 0:Bearing Installer set BEVEL P1NIONGEARPILOT BEARING Drive thebearinginto thegear case withthe specialtool. diJ 0991370210:Bearing installer set BEVEL PINIONGEAR Instal l thepi niongear assembly andfixthebearingrace with thesnap ring. SHIFTING SLEEVE/UNIVERSAL JOINT YOKE Installtheshiftingsleeve to thepiniongear shaft. Drivethenew beari ng intothegear casewiththespecial tool and fixitwith the snap ring. IT'iR! 09913-70210:Bearing installer set insl ali the oil seal into thegear casewith thespecial 1001. I,Q i 09913-70210: Bearing installer set Apply grease to the seal lip groove. ,@99000-25030: SUZUKI SUPER GREASE" A"(USA) 99000-25010: SUZUKI SUPER GREASE" A"(01hers) Apply4 - 5 gram of water resistancegrease tothe outside of seall ip groove. ,.@181.8 C181.8 6232.3 CD232.3 il. WARNING Ib-ft 7.0 18.5 11.5 ' .7 19.0 13.0 13.0 16,5 16.5 MaSler cylinder mounting bott (JlBrake hOseunion bolt ~Brake pipe nut o Air bleeder valve ~Brake caliper mounting bolt Clip 7-70CHASSIS REMOVAL Remove the fueltankcover andfront fender sidecover (AH). (c:77-5 and7-S) Disconnect the gear selection cable (D. Remove the gearshift[ever assy ~ . INSPECTION GEARSHIFT LEVER ASSEMBLY Inspect thegearshiftlever assemblyfor wear or damage.Ifany damage are found, replace the gearshift lever assembly. NOTE: Do not disassemblethe gearshift lever assembly. REMOUNTING Reassembleandremountthegearshift[everinthereverse order ofremoval and disassembly. Pay attention tothe following points: ApplySUZUKISUPERGREASE~ Ntotheeachpivotand Slidingarea. ~99000-25030: SUZUKI SUPERGREASE " A"(USA) 99000-25010: SUZUKI SUPERGREASE "A"(Olhers) ,----,I CABLES REMOVAL AND INSTALLATION GEAR SELECTIONCABLE Remove the fuel tank cover.(c:::r7-S) Remove the front fender side cover (RH). (c:::77-S) Disconnect the gear selection cable 0). Flattenthetongues onthe clip ~ . Remove the gear selection cable withclip. Removetheclipfromthegear selectioncablewithflattening the tongue @ on theclip. Removethegearselectioncable@fromtheenginebyfol-lowing thesame procedure explained above. I CAUTION I Donot applya loadto theendof the eyerodwiththe cable andthe metalfi xture. Applying sucha load may causethesleevet obrakeor comeoffthepivotsus-pension. CHASSIS771 7-72CHASSIS Release thecable adjuster lock.(c::7Below) Install the clips to the gear selectioncable. Installthe gear selectioncable if> -------* 0.4-0.70.3-0.60.3-0.60.3-0.6 .n e @ * -------**** c. " ** -------** ~ * @ ** 0.3-0.6 -------** t--CD ** 0.3-0.6 ** ------- * More than1.4 V (tester's battery voltage) NOTE: If thetester readsunder1.4Vwhenthetester probes arenot connected, replace the battery of multi circuit tester. STARTER SYSTEM AJW ELECTRICAL SYSTEM8-1 1 EngineEmergency stop switchswitCh(El7) Fuse Neutralrelay Starter mOlor , fi-t---i-YIB Starter relay TROUBLESHOOTING (Starter motor witl not run.) I -0 The transmission isinneutral. Turnon the ignition switch with theengine stopswitch in the &AUN- position and emergency switch in the &SEr position (E17 model). Listen for a click from the starter rel ay whenthe starter bulton ispushed. I No click ..:': ON YIG tnillon!I control realy BIB' , Neutral indicator light Toreverse indicatorlight Neutral switch Parking brake switch

llii ,= '''' 1 Check iftheslarter motor runs when its terminal is connected f-- Clickstothe battery terminal (00 not use athin wirebecause a large amount of current flows.) I Runs Does notrun Faulty starter molor Faulty starter relay Measure thestarter relay voltageatthestart er relay connectors (between Y/B()and 81W 8) f--- No voltage------.. whenthe starter button ispushed. Loose or disconnected starter motor lead wire Faulty ignition switch Faulty engine stop switch Faulty neutral relay Faulty neutral switch Faulty emergency switch (E17) Faulty starter button Improper connector contact I Voltage + Continued onnext page Open circuit in wire harness -8-12ELECTRICAL SYSTEM Check the starter relay.1----(C7S-15) Incorrect----...... Faulty starter relay Correct ll _______________....... Improper starter relay contact The starter motor runs whenthe transmission isinneutral , but does nol runwhenthetransmission isin any position other thanneutral,with the parking brake lever grasp firmly.

Incorrect - --i..... Faulty parking brake switch 1 Correct Check the ignition/starter control relay.Incorrect - --i..... Faulty ignilionlstarter controlrelay Correct IL----------------1...... Open circuitin wire harness Poor contact of connector (O1hers) Engine does not turnthough the starter motor runs. Faulty starter clutch STARTERMOTORREMOVAL AND DISASSEMBLY Remove the front fender side covers.(c:::::/7-B) Disconnect thestarter motorleadwi reCDandengineground lead wire (2). Loosenthecarburetor clamp screws. Remove the starter motor. Disassembly the starter motor, as shown. STARTERMOTOR INSPECTION CARBONBRUSHES Inspectthecarbonbrushesforabnormalwear,cracks,or smoothness in thebrush holder. Ifanydamagesarefound,replacet hebrushassemblywitha new one. COMMUTATOR Inspectthecommutatorfordiscoloration,abnormalwearor undercut . If abnormal wear is found, replace the armature with a new one. If the commutator surface is discolored, polish it with#400 sand-paper and wipeitusing a clean,dry cloth. Ifthereisnoundercut,scrapeoultheinsulatorCDwithasaw blade. ARMATURE COIL INSPECTION Check for continuity between each segmentandbetweeneach segment and the armature shaft using the multi ci rcuit tester. Ifthere is no continuity between thesegments or thereisconti-nuitybetweenthesegmentsandshaft,replacethearmature withanew one. .,2 .09900-25008:Multi circuit tester set ~Tester knob indication: Continuity lest (-III) ELECTRICAL SYSTEM~13 (])Housing end(outside) !%lBrush holder i3lBruSh spring O-ring (5)Brush terminal set Z C'l '"' o z ! Inside SECT EE Outside Rear brake breather hose Clamp Rear swingarm ,\\It_Rear brake breather hose Clamp L-----.r- Rear swlngarm SECT FF c'" E Fuel lank cover plate VIEWA Pass the rear brake breather hose outside the rear brake cable. Clamp Rear brake cable Rear brake breathElf hose Pass the rear brake breather hose outside the frame. VIEWB Rear brake breaher hose Clip o Rear brake breather hose Inside Keep the clearance between rear brake breather hose and rear brake cable. Rear brake cableOot_ Clip n Clip Rear brake breather hose Install Iherear brake breather hose SECT DO union fully. VIEWC :xl 'f' m 0 :xl 0 m til :s :xl " % C> ;>; z m 0 til '" :xl ,. =! m 0 % -i :J: m :xl :J: 0 en m :xl 0 c: -i Z G) SPECIAL TOOLS 09900-0041009900-06106 Hexagon wrench setSnap ring pliers 09900-20101 Vernier calipers 09900-20602 Dialgauge (111000mm) 09900-20805 Tire depth gauge 09900-25008 Multi circuit t ester sot 09900-20202 Micrometer (11100mm, 25-50 mm) 09900-20605 Dial calipers (1/100mm, 10-34 mm) 09900-21203 Surface plate 09900-26006 Tachometer 09900-06107 Snap ring pliers 0990020204 Micrometer (1 /100 mm, 75-100 mm) 09900-20607 Dialgauge (11100mm) 0990021304 V-block set (100 mm) 09910-32812 Crankshaft installer SERVICINGINFORMATION9-21 09900-061 08 Snap ring pliers 1J99OO.20205 Micrometer (1 /1000 mm, 0-25 mm) 09900-20701 Magnetic stand 0990022302 Plastigauge 09913-50121 Oil sealremover 09900-09004 Impact driver set 09900-20508 Cylinder gauge set (1 /100 mm, 40-80 mm) 099QO.20803 TIckness gauge 09900-22403 Small bore gauge (18-35 mm) ~ @ 09913-70210 Bearing install er set ~ 2 2SERVICINGINFORMATION 09915.-64510 Compression gauge set 09915-406100991506331009915-74511099161091109916-14510 Valve lifterOil filter wrench(Adaptor)Oilpressure gaugeValve lapper set ,\ , \" .....- , 099161491009916211110991624311 Valvelifter attach- 09916-24900Solid pilot mentValve seat cutter set(N-100-5.0) 09916-34570 Valve guide reamer (5.0mm) 09917-23711 Ring nut socket wrench 0991634580 Valve guide reamer (10.8mm) 09917-50410 Bearing remover 09922-31430 09916-4431 0 Valve guide removerlinstaller 09920-13120 Crankcase separat-ing tool 09916-22410 Solidpilot (N14o-S.0) 09916-84511 Tweezers 09916-34542 Reamer handle 09917-14920 Valve adjuster driver 09924-41830 09921-20240Bearing locknut Bearing remover setwernch 09924-21950 09921-21910 Bearing holder Movable driven face09924-21930Front axle coupling09924-21940 spring compressorDrive shaft removerpuller attachmentWheelhub remover 09924-8451009930-30104 09924 54520 Fixed driven face holderBearing installer setSl iding hammer 09930-30190 Rotor remover attachment 09930-30721 Rotor remover 09940-52861 09930-73190Front fork oil seal Output shaft holderinstal1er NOTE: 09930-31921 Rotor remover 09944-66020 Bearing remover SERVICING INFORMATION9- 23 09930-10121 Spark plug wrench09930-30141 setAHachment 09930-40113 Rotor holder 0993044540 Rotor holder When ordering a special tool,please confirm whether it is available or not. 9-24SERVI CINGINFORMATION TIGHTENING TORQUE ENGINE ITEM Cylinderheadcoverbolt Camchainsprocket bolt Cylinder headbolt Cylinder headnut Cylinder basenut Camchaintensioner bolt Camchaintensionadjuster mountingbolt 6mm 8mm Camchaintensionadjusterspringholder bolt Spark plug Valveclearanceadjuster locknut Rocker armshaft bolt 6mm Crankcasebolt 8mm Neutral switchbolt T. O.C. plug Clutchshoenut Movable drivefacenut Movable drivenfacenut Movabledrivenfaceringnut Generator rotornut Starter clutchbolt Starter cupnut Oilpumpdrivegearbolt Gearshift camstopper Exhaust pipenul Muffler mountingbolt Muffler connectingbolt Engine oildrain plug Oilcoolingfanthermo-swi tch Oiltemp.switch Oilpressureregulator Drive/drivenbevelgear nut Enginemountingnut 8mm 10mm Enginemountingbracketbolt Frontdrive(differential)gear casemountingbolt Front/rear outputshaftnul Nmkgf-mIb-H 101.07.0 151.511.0 383.827.5 101.07.0 252.518.0 101.07.0 131.39.5 101.07.0 80.86.0 111 .18.0 101.07.0 282.820.0 111 .18.0 262.619.0 6.50.654.5 232.316.5 12012.087.0 11511.583.0 11511.583.0 10010.072.5 16016.0115.5 262.619.0 333.324.5 505.036.0 232.316.5 232.316.5 232.316.5 232.316.5 232.316.5 202.014.5 303.021.5 232.316.5 10010.072.5 404.029.0 555.540.0 262.619.0 454.532.5 10010.072.5 SERVICING INFORMATION~ 2 5_ DIFFERENTIAL ITEMNmkgf-mIb-It Front drive(differential) gear oildrain plug323.223.0 Frontdrive(differential) gear oilfillerplug353.525.5 Frontdrive(differential) gear casemountingnut454.532.5 Frontdrive(differential)gear casebolt232.316.5 Front propeller shaftflangecouplingbolt454.532.5 Rear driveshafthousingnut232.316.5 Rear propeller shaftflangecouplingbolt303.021.5 Rear drivegear casebolt232.316.5 Rear drivegear oil fillerplug333.324.0 Rear drivegear oildrainplug333.324.0 CHASSIS ITEMNmkgf mIb-It Handlebar clamp bolt232.316.5 Steeringshaftholder boll232.316.5 Steeringshaftnul494.935.5 Steeringknuckle pinchbott505.036.0 Ti e rodendnut353.525.5 Tie rodlocknut292.921.0 Frontshockabsorbermountingbolt(Upper)555.540.0 Frontshock absorbermountingnut(Lower)606.043.5 Wishbone arm pivotnul656.547.0 Hubnul(FrontandRear)10010.072.5 Wheelset nul(Front andRear)505.036.0 Brakemaster cylinder mountingbolt101.07.0 Brakehoseunionbolt232.316.5 Frontbrake pipe nut161.611.5 Brake air bleeder valve7.50.755.5 Brake discbolt232.316.5 Brake caliper mountingbolt262.619.0 Brakepadmounting bolt181.813.0 8mm262.619.0 Footrestbolt 10mm555.540.0 Rear brake pedalnut121.28.5 Rear brake cam lever nut121.28.5 Rear brake panelbolt232.316.5 Rear axle housingbolt555.540.0 Rear axel housingmountingnut606.043.5 Rear shockabsorber mountingnut(Upper)353.525.5 nut(Lower)606.043.5 Rear swingarmpivotnut10210.274.0 H6SERVICI NG INFORMATlON TIGHTENING TORQUECHART For other nutsand bolts notlistedintheprecedingpage,refer tothischart: Bolt DiameterConventional or"4" markedbolt"7"markedbolt (mm)Nmkgf-mIb-ItNmkgf-mIb-It 41.50.151.02.30.231.5 530.32.04.50.453.0 65.50.554.0101.07.0 8131.39.5232.316.5 10292.921.0505.036.0 12454.532.5858.561 .5 14656.547.013513.597.5 1610510.576.021021.0152.0 1816016.0115.524024.0173.5 @RIIIIIIR(j Conventionalbolt"4" marked bolt or markedbolt SERVICEDATA VALVE+GUIDE ITEM Valvediam. Valveclearance(whencold) Valveguidetovalvestem clearance Valveguidel.O. Valvestem0.0. Valvestemdeflection Valvestemrunout Valveheadthickness Valveslemendlength Valveseatwidth Valveheadradialrunout Valvespringfreelength Valvespringtension IN. EX. IN. EX. IN. EX. IN.& EX. IN. EX. IN. & EX. IN. & EX. IN.&EX. IN.& EX. IN. &EX. IN.&EX. IN.& EX. IN. &EX. SERVICINGINFORMATION!l-27 Unit:mm(i n) STANDARDLIMIT 30.6 (1.20) --27.0 --(1.06) 0.05- 0.10 --(0.002- 0.004) 0.22- 0.27 --(0.009- 0.011) 0.010- 0.037 --(0.0004- 0.0015) 0.030- 0.057 --(0.0012- 0.0024) 5.000- 5.012 (0. 1969- 0.1973) --4.975- 4.990 --(0.1959- 0.1965) 4.955- 4.970 --(0. 1951- 0.1957) 0.35 --(0.014) 0.05 --(0.002) 0.5 --(0.02) 2.3 --(0.09) 0.9-1.1 --(0.035- 0.043) 0.03 --(0.001) -- 3 8 . ~ ) ( 1.53 182-210N (18.6- 21.4kg!,41.0 - 47.2Ibs)--atlength31 .5mm(1.24in) !l-28SERVICING INFORMATION CAMSHAFT+CYLINDERHEADUnitmm(in) ITEMSTANDARDLIMIT Camheight IN. 33.130- 33.19032.830 (1.3043- 1.3067)(1.2925) EX. 33.130- 33.19032.830 (1.3043- 1.3067)(1.2925) Camshaftjournaloilclearance 22 0.0320.0660.150 (0.0013- 0.0026)(0.0059) 17.5 0.028 - 0.0590.150 (0.0011- 0.0023)(0.0059) Camshaftjournalholder1.0. 22 22.Q1222.025 (0.8666- 0.8671) --17.5 1,17.512- 0.6894- 0.6900 --Camshaftjournal0.0. 21.959- 21.980 (0.8645- 0.8654) --17.5 17.466 - 17.484 (0.6876- 0.6883) --Camshaftrunout --0.10 (0.004) Rockerarm1. 0. IN.& EX. 12.000- 12.018 (0.4724- 0.4731) --Rockerarmshaft0.0. IN.& EX. 11.97311.984 (0.4714- 0.4718) --Cylinderheaddistortion --0.052) (0.002 Cylinderheadcoverdistortion --0.05 (0.002) CYLINDER+PISTON+ PISTONRINGUnitmm(in) ITEMSTANDARDLIMIT Compressionpressure1 000 kPa (Automatic-decamp.actuated)Approx.( 10.0 kgf/Cm2) --142psi Pistontocylinderclearance0.060 - 0.Q750.120 (0.0023- 0.0030)(0.0047) Cylinderbore82.000- 82.01582.070 (3.2283- 3.2289)(3.2311 ) Pistondiam.81.930- 81.945 81 .880 (3.2256- 3.2262) (3.2236) Measureal15mm(0.6in)fromtheskirtend. Cylinderdistortion0.05 --(0.002) Pistonring freeendgap 1 slRApprox. 11.28.9 (0.44)(0.35) 2ndRApprox. 10.48.3 (0.41 )(0.33) Pistonringend gap 1s l 0.15 - 0.270.50 (0.006- 0.011)(0. 020) 2nd 0. 15- 0.270.50 (0.006- 0.011)(0.020) SERVICINGINFORMATION9-29 ITEMSTANDARDLI MIT Pistonringtogrooveclearance 1 sl --0.180 (0.0071) 2nd 0.150 --(0.0059) Pistonringgroovewidth 1sl 1.01 - 1.036) (0.0398- 0.0406 --2nd 1.01-1.03 (0.0398- 0.0406) --Oil 2.01- 2.03 (0.0791- 0.0799) --Pistonringthickness 1s l 0.970 - 0.990 (0.0382- 0.0390) --2nd 0.970- 0.990 (0.0382- 0.0390) --Pistonpinbore20.002- 20.00820.030 (0.7875- 0.78n)(0.7866) Pistonpin0.0.19.992- 20.00019.980 (0.7870- 0.7874)(0.7866) CONROD+CRANKSHAFTUnit:mm(in) ITEMSTANDARDLIMIT Conradsmallend1.0.20.006- 20.01420.040 (0.7876- 0.7879)(0.7890) Conraddeflection3.0 --(0.12) Conrodbigendsideclearance0.100.551.0 (0.004- 0.022)(0.04) Conrodbigendwidth21.95 - 22.00 --(0.864- 0.866) Crankwebtowebwidth60.00.1 --(2.3620.004) Crankshaftrunoul0.080 --(0.0031) OILPUMP ITEMSTANDARDLIMIT Oilpressure(al60C.140F)Above110 kPa(1.1kgf/cm2,16psi) Below150kPa(1.5kgf/cm2,21psi )--al3 000r/min. CLUTCHUnit'mm(in) ITEMSTANDARDLI MIT Clutchwheel1.0. ( ~ 1 4 0 . 0- 1 4 0 . ~ ) 140.5 5.512- 5.520(5.53) Clutchshoe --Nogrooveal anypart Clutchenaaaemenir/min.1 900 - 2300r/min. Clutchlock-upr/min.3700 - 4300r/min.--9-30SERVICING INFORMATION DRIVETRAINUnit- mm(in)Exceptratio ITEMSTANDARDLIMIT AutomatictransmissionratioVariablechange(2.938- 0.813)--Secondaryreductionratio2.210(42119)--FinalreductionratioFront3.600(36110) --Rear3.600(36110)--TransfergearratioLow2.500(40/ 16) High1.375(33124)--Reverse2.000(32116)--Drivebellwidth30.329.3 (1.19)(1.15) Movabledrivenfacespring215.0204.3 freelength(8.46)(80.4) Shihforktogrooveclearance0.100.300.50 (0.004- 0.012)(0.020) Shiftforkgroove Highllow 5.505.60 width(0.217- 0.220) --Reverse 5.50 - 5.60 (0.217- 0.220) --Shiftforkthickness High/low 5.30 - 5.40 (0.209- 0.213) --Reverse 5.30 - 5.40 (0.209- 0.213) --FronVrearoutputshaftbevelgear0.03 - 0.15 backlash(0.001- 0.006) --Frontdrive(differential)gear0.050.10 backlash(0.002- 0.004) --Reardrive(final)gearbacklash0.080.013 (0.0031- 0.0051) --ENGINEOIL TEMP.SWITCH+COOLINGFAN THERMO-SWITCH ITEMSTANDARD/SPECIFICATIONLIMIT Engine oil temp.indicatorOFF.., ON160C light. -: 140C Iifanthermo-switch 120C ..,C110' C SERVICI NGINFORMATION9-31~ CARBURETOR SPECIFICATION ITEM E-03,24,28E-17E-33 CaburelortypeKEIHINCVK32

;I: " 0 0 m m .!: ::I: 0 en m II 0 c: ::! z G')