Suzuki LTA-700 - Fixed Drive Face; Gear Position Switch; Clutch Housing Case

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Group Index1
Component Parts and Work to be Done2
Symbol3
Abbreviations4
Wire Color6
General Information7
Warning/Caution/Note8
General Precautions8
Serial Number Location10
Fuel11
Engine Oil11
Front Differential Gear Oil11
Rear Drive (Final) Gear Oil11
Engine Coolant12
Water for Mixing12
Anti-Freeze/Engine Coolant12
Liquid Amount of Water/Engine Coolant12
Break-In Procedures13
Information Labels14
Specifications15
Dimensions and Dry Mass15
Periodic Maintenance17
Periodic Maintenance Schedule18
Periodic Maintenance Chart18
Maintenance and Tune-Up Procedures19
Air Cleaner19
Exhaust Pipe Nuts and Muffler Mounting Bolts21
Valve Clearance21
Valve Clearance Adjustment23
Intake Side24
Exhaust Side25
Spark Plug26
Carbon Deposits26
Electrode26
Spark Arrester27
Fuel Line27
Spark Plug Installation27
Throttle Cable Play28
Throttle Body28
Engine Oil and Oil Filter28
Engine Oil Replacement28
Oil Filter Replacement29
Differential Gear Oil Inspection30
Differential Gear Oil Replacement30
Final Gear Oil31
Final Gear Oil Inspection31
Final Gear Oil Replacement31
Engine Coolant Level Check32
Engine Coolant Replacement32
Radiator33
Radiator Hoses33
Drive Belt Removal34
Drive Belt Inspection35
Drive Belt Remounting36
Brakes38
Front Brake Pad38
Rear Brake Friction Plate Wear Limit38
Rear Brake Pedal and Lever38
Brake Fluid39
Rear Brake Lever39
Brake Fluid Level39
Air Bleeding the Brake Fluid Circuit40
Brake Hoses41
Tires41
Tire Tread Condition41
Tire Pressure41
Steering42
Toe-Out42
Suspensions43
Chassis Nuts and Bolts44
General Lubrication46
Compression Pressure Check47
Compression Test Procedure47
Oil Pressure Check48
Oil Pressure Test Procedure48
Low Oil Pressure48
High Oil Pressure48
Initial Engagement and Clutch Lock-Up Inspection49
Initial Engagement Inspection49
Clutch Lock-Up Inspection50
Engine51
Engine Components Removable with Engine in Place52
Engine Left Side52
Engine Right Side52
Engine Center52
Engine Removal53
Engine Installation59
Engine Disassembly62
Engine Top Side62
Recoil Starter and Valve Timing Inspection Plug63
Cam Chain Tensioner64
Cylinder Head64
Cylinder65
Engine Bottom Side66
Generator Cover66
Starter Torque Limiter67
Starter Idle Gear67
Gearshift67
Generator68
Cam Chain and Cam Chain Tensioner69
Oil Pump69
Balancer Shaft Drive/Driven Gear69
Movable Drive Face71
Movable Driven Face71
Fixed Drive Face72
Gear Position Switch72
Clutch Housing Case72
Clutch Shoe73
Crankcase73
Rear Output Shaft74
Transfer75
Engine Components Inspection and Servicing78
Camshaft78
Automatic Decompression78
Cam Wear79
Camshaft Journal Wear79
Camshaft Runout80
Cylinder Head Distortion82
Valve Stem Runout82
Valve Head Radial Runout82
Valve Face Wear83
Valve Stem Deflection83
Valve Stem Wear83
Valve Guide Servicing83
Valve Seat Width Inspection85
Valve Seat Servicing85
Initial Seat Cut86
Valve Spring88
Valve Reassembly88
Water Bypass Union and Oil Gallery Plug91
Thermostat92
Cam Chain Guide93
Cylinder Distortion93
Cylinder Bore94
Piston95
Piston Diameter95
Piston Ring to Groove Clearance95
Piston Ring Free End Gap and Piston Ring End Gap96
Piston Pin and Pin Bore96
Conrod/Crankshaft97
Conrod Small End I.D.97
Conrod Deflection97
Crankshaft Runout97
PCV Hose98
Clutch Wheel99
Starter Clutch99
Movable Drive Face and Driven Face101
Movable Drive Face Disassembly102
Roller and Sliding Surface102
Oil Seal102
Movable and Fixed Drive Face103
Movable Driven Face Disassembly104
O-Ring and Oil Seal105
Movable Driven Face Spring106
Movable and Fixed Driven Face106
Transfer Disassembly109
Transfer Reassembly109
Gearshift Fork112
Gearshift Fork-To-Groove Clearance112
Gearshift Fork Groove Width112
Gearshift Fork Thickness112
Gearshift Cam Disassembly113
Drive Train (Front and Rear Output Shaft) Construction116
Front Output Shaft Removal117
Front Output Shaft Installation117
Rear Output Shaft Disassembly117
Rear Output Shaft Reassembly118
Shim Adjustment120
Backlash120
Tooth Contact121
Final Assembly122
Drive Bevel Gear Removal123
Drive Bevel Gear Installation124
Crankcase Bearing Inspection125
Left Crankcase Bearing Removal125
Left Crankcase Bearing Installation125
Right Crankcase Bearing Removal126
Right Crankcase Bearing Installation127
General Cover Disassembly128
General Cover Reassembly129
Recoil Starter Disassembly130
Recoil Starter Reassembly131
Engine Reassembly133
Oil Sump Filter135
Movable Drive/Driven Face and Drive Belt139
Clutch Cover141
Cylinder Head Cover153
Valve Timing Inspection Plug153
Water Union154
Starter Motor154
Drive Train155
Front Drive Train (Differential) Construction156
Front Drive Train (Differential) Gear Case Oil Seal161
Drive Bevel Gear Bearing161
2WD/4WD Shifting Cam Bearing161
Drive Bevel Gear Pilot Bearing161
Front Drive Train (Differential) Gear Bering162
Breather Rubber Case162
Remounting168
Left Side Shim Selection170
Rear Drive Train Construction176
Rear Drive Train Disassembly177
Rear Drive Train Inspection181
Gear Case Cover/Final Gear Case Cover Oil Seal181
Gear Case Cover/Final Gear Case Cover Bearing181
Pinion Gear/Pinion Gear Bearing181
Gear Case Bearing182
Gear Case Oil Seal183
Pinion Gear Shaft Bearing and Locknut183
FI System Diagnosis194
Precautions in Servicing196
Electrical Parts196
Connector/Coupler196
Fuse197
Ecm/Various Sensors197
Electrical Circuit Inspection Procedure199
Open Circuit Check199
Voltage Check200
Continuity Check200
Short Circuit Check (Wire Harness to Ground)201
Using the Multi-Circuit Tester202
Using the Tester202
FI System Technical Features203
Injection Time (Injection Volume)203
Compensation of Injection Time (Volume)204
Injection Stop Control204
FI System Parts Location205
FI System Wiring Diagram207
User Mode208
Dealer Mode209
TPS Adjustment211
Fail-Safe Function212
FI System Troubleshooting213
Customer Complain Analysis213
Visual Inspection214
Self-Diagnosis Reset Procedure216
Use of SDS Diagnostic Procedures216
Use of SDS Diagnosis Reset Procedure217
Show Data When Trouble218
ECM Terminal220
Malfunction Code and Defective Condition221
C12 CKP Sensor Circuit Malfunction223
C13 IAP Sensor Circuit Malfunction226
C14 TP Sensor Circuit Malfunction230
C15 ECT Sensor Circuit Malfunction235
C20 Diff-Lock Relay Circuit Malfunction239
C21 IAT Sensor Circuit Malfunction242
C23 to Sensor Circuit Malfunction246
C24 Ignition Coil Circuit Malfunction250
C32 Fuel Injector Circuit Malfunction252
C40 ISC Valve Circuit Malfunction254
Active Control Inspection (ISC RPM Control)256
C41 FP Relay Circuit Malfunction259
Sensors260
To Sensor Inspection261
To Sensor Removal and Installation261
Fuel System and Throttle Body262
Fuel Tank and Fuel Pump263
Fuel Line Inspection263
Fuel Tank Removal263
Fuel Tank Inspection264
Fuel Tank Installation264
Fuel Pressure Inspection265
Fuel Pump Inspection266
Fuel Discharge Amount Inspection266
Fuel Pump Relay Inspection267
Fuel Pump Removal267
Fuel Filter Cleaning and Fuel Filter Inspection268
Fuel Pump Installation268
Fuel Tank Pressure Control (FTPC) Valve Inspection268
Throttle Body Contruction269
Air Cleaner Box Removal270
Throttle Body Removal271
Throttle Body Disassembly272
Throttle Body Cleaning274
Throttle Body Selection274
ICS Valve Inspection274
Fuel Injector Inspection275
Throttle Body Reassembly275
Throttle Body Installation276
Air Cleaner Box Installation277
TP Sensor Adjustment277
Fuel Injector Removal277
Fuel Injector Installation277
Throttle Position Sensor (TPS) Setting278
Cooling and Lubrication System279
Cooling Circuit281
Cooling Circuit Inspection281
Radiator and Hoses282
Radiator Removal282
Radiator Inspection and Cleaning282
Radiator Remounting283
Radiator Reservoir Tank Removal/Installation283
Radiator Cap Inspection283
Radiator Hose Inspection284
Cooling Fan Inspection285
Cooling Fan Removal285
Cooling Fan Remounting285
Cooling Fan Thermo-Switch Removal286
Cooling Fan Thermo-Switch Inspection286
Cooling Fan Thermo-Switch Installation286
ECT Sensor Removal287
ECT Sensor Inspection287
ECT Sensor Installation287
Thermostat Removal288
Thermostat Inspection288
Thermostat Installation289
Water Pump Removal and Disassembly290
Mechanical Seal291
Mechanical Case292
Impeller292
Engine Lubrication System Chart296
Engine Lubrication System297
Chassis299
Exterior Parts Construction301
Seat Removal303
Front Carrier303
Front Grip Bar304
Front Fender304
Front Box306
Side Cover307
Mud Guard307
Rear Box307
Rear Carrier308
Fuel Tank Cover309
Rear Fender309
Exhaust Pipe Removal311
Exhaust Pipe Remounting311
Front and Rear Wheels Construction312
Tire Replacement313
Front Drive Shaft Construction315
Front Drive Shaft Removal and Disassembly315
Front Brake Construction320
Brake Pad Replacement322
Brake Fluid Replacement323
Brake Caliper Removal and Disassembly323
Brake Caliper Inspection325
Brake Caliper Piston325
Brake Caliper Reassembly and Remounting326
Brake Caliper Holder327
Brake Disc Removal and Disassembly328
Brake Disc Inspection329
Brake Disc Reassembly and Remounting329
Master Cylinder Removal and Disassembly330
Master Cylinder Inspection332
Master Cylinder Reassembly and Remounting332
Front Suspension Construction334
Front Suspension Removal and Disassembly335
Dust Seal339
Hub Bearing339
Spring Pre-Load Adjustment342
Steering Construction343
Steering Removal and Disassembly344
Steering Shaft349
Handlebars350
Toe-Out Adjustment351
Handlebar Switch351
Rear Drive Shaft Construction353
Rear Drive Shaft Inspection and Reassembly354
Rear Brake Construction357
Rear Brake Removal and Disassembly358
Rear Brake Cam Lever361
Rear Brake Cam Shaft362
Rear Brake Plate362
Brake Plate Return Spring363
Rear Brake Pressure Plate363
Rear Final Drive Gear Shaft363
Rear Suspension Construction367
Rear Suspension Removal368
Rear Suspension Inspection and Disassembly369
Rear Shock Absorber369
Bushing369
Dust Seal Inspection369
Transfer Gear Shift Lever Construction377
Transfer Gear Shift Lever Removal378
Transfer Gear Shift Lever Remounting379
Shift Rod Installation380
Gear Selection Rod380
Shift Rod Adjustment381
Electrical System382
Cautions in Servicing384
Connector384
Coupler384
Clamp384
Semi-Conductor Equipped Part385
Battery385
Connecting the Battery385
Wiring Procedure385
Location of Electrical Components387
Charging System Troubleshooting389
Battery Runs down Quickly389
Battery Current Leakage390
Regulated Voltage391
Generator Coil Resistance391
Generator No-Load Performance392
Regulator/Rectifier392
Starter System Troubleshooting393
Starter Motor will Not Run393
Starter Motor Removal394
Starter Motor Runs but Does Not Crank the Engine394
Starter Motor Disassembly395
Starter Motor Inspection396
Carbon Brush396
Commutator396
Armature Coil Inspection396
Starter Motor Installation397
Starter Relay Inspection397
Neutral Relay Inspection398
Ignition/Starter Control Relay Inspection398
Ignition System Troubleshooting399
Ignition Coil Primary Peak Voltage401
Ignition Coil Resistance402
CKP Sensor Peak Voltage402
CKP Sensor Resistance403
Transfer Selecting System404
Actuator404
Drive Relay404
Diff-Lock Relay405
Combination Meter Description406
Combination Meter Operating Procedure407
Initial Display407
Change the Display Mode407
Tripmeter407
Clock408
Setting the Time408
Led410
Engine Coolant Temperature Meter and Indicator410
Fuel Meter411
Fuel Gauge411
Speedometer412
Speed Sensor412
Lamps413
Headlight and Auxiliary Headlight413
Headlight Installation415
Brake Light/Taillight416
Auxiliary Headlight Bulb Replacement416
Diode418
Backup Light Relay418
Switches419
Initial Charging420
Filling Electrolyte420
Recharging Operation422
Servicing Information423
Engine will Not Start or Is Hard to Start426
Engine Idles Poorly427
Engine Stalls Often427
Noisy Engine428
Engine Runs Poorly in High Speed Range429
Engine Lacks Power430
Dirty or Heavy Exhaust Smoke431
Transfer will Not Shift Back431
Transfer Jumps out of Gear431
Engine Overheats432
Engine Overcools432
Heavy Steering433
Wobbly Handlebar433
Steering Pulls to One Side433
Shocks Felt in the Steering433
Front Suspension too Soft434
Front Suspension too Stiff434
Noisy Front Suspension434
Rear Suspension too Soft434
Insufficient Brake Power435
Brake Squeaking435
Excessive Brake Lever Stroke435
Leakage of Brake Fluid435
Electrical436
No Sparking or Poor Sparking436
Spark Plug Soon Become Fouled with Carbon436
Spark Plug Become Fouled too Soon436
Unstable Charging437
Start Button Is Not Effective437
2Wd/4Wd Button Does Not Work437
Diff-Lock Button Does Not Work437
Battery "Sulfation"438
Wiring Harness Routing439
Cable Routing441
Fuel Hose Routing443
Fuel Tank Breather Hose Routing444
Cooling System Hose Routing445
Rear Drive Breather Hose Routing446
Front Brake Hose and Pipe Routing447
Fender Installation448
Rear Fender Heat Shield Installation450
Belt Cooling Duct Installation451
Rear Brake Pedal452
Trailer Towing Installation453
Engine Mounting454
Radiator Guard Installation455
Special Tools456
Tightening Torque460
Tightening Torque Chart463
Service Data464

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Suzuki LTA-700 - Fixed Drive Face; Gear Position Switch; Clutch Housing Case

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