1985 1990 Suzuki Lt F230ge Lt F230g Lt230s Lt250s 4x4 Atv service Manual Download Pdf

SUZUKI LT230 & LT250 • 1985-1990

Chapter One General Information Chapter Two • Troubleshooting Chapter Three Lubrication , Maintenance and Tune-up

II

Chapter Four .

Engine Chapter Five Clutch and Transmission Chapter Six Fuel and Exhaust Systems Chapter Seven Electrical System Chapter Eight Front Suspension and Steering Chapter Nine Rear Axle, Suspension and Final Drive Chapter Ten Brakes Chapter Eleven Body Supplement 1987 and Later Service Information Index

Wiring Diagrams

CONTENTS

OUICK REFERENCE DATA ................................................................................................... IX CHAPTER ONE GENERAL INFORMATION ..................................................................................................... 1 Manual organizalion

Service hints Torque specifications Safety firsl

Spcrlal lipS Expendable suppl ies Parts replacement

Serial numbers

Basic hand tools Tunc-up and troubleshooling l00ls MechaniC'S lips -Off the road" rules

Safel)

CHAPTER TWO TROUBLESHOOTING ........................................................................................................... 15 Operating requirements Emergency troubleshooting

Engme starting Engine pcrfonnance

Engine noises Excessive vibration

Front suspension and steering Brake problems

CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP ................................................................. 19 Pre-checks Service intervals

Tires and wheels Ballery (models so equippc<i)

Periodic lubrication PeriodiC maintenance Engine tunc· up

CHAPTER FOUR ENGINE .................................................................. ,....................................... ....................... 51 Engme pnnciples Engine cooling Scrvicing engine in frame Engine Cylinder head cover and rocker arm assembly C) linder head and camshaft Valves and vah'e seats Cylinder Piston. piston pin and pIston rmgs

011 pump Cam chain tenSloner Kickstarter (chain.driven models) Recoil starter (shaft·driven models) Starter gears (shaft·drivcn models) Secondary bevel gear and drive gear set (shaft·driven models) Crankcase and crankshaft Brcak·m procedure

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CHAPTER FIVE CLUTCH AND TRANSMISSION ........................................................................................... 94 Clutch operation Centri rugal dutch Manual clutch (shaft-driven models) Manual clutch (chain-driven models) Manual dutch inspection (all models) Clutch lifting mechanism (shaft-driven models)

Clutch release mechanism (chain-driven models) Clutch cable (chain-driven models) External shift mechanism (a ll models) Dri ve sprocket (chai n-dri ven) Transmission and internal shin mechanism Dual-range subtransmission (shaft-driven LT-F230)

CHAPTER SIX FUEL AND EXHAUST SYSTEMS Carburetor operntion Carburetor service Throllie cable Choke cable (shaft·dri ven models)

131 Fuel shutoff valve Fuel tank Fuel pump (shaft·driven models) Exhaust system

CHAPTER SEVEN ELECTRICAL SYSTEM Charging syste m (models so equipped) Voltage regula tor (shaft-driven models) Alternator (shaft-driven models) Magneto (chain-driven models) Capacitor discharge ign ition Igni tion coi l Staning system (models so equipped)

146 Starter Starter solenoid Light ing system Switches Odometer housing (sha ft -driven models)

F""

CHAPTER EIGHT FRONT SUSPENSION AND STEERING Front wheel Front hub

167 Siccring system Tires

CHAPTER NINE REAR AXLE , SUSPENSION AND FINAL DRIVE ............................................................... 185 Rear wheel Rear axle (shaft-driven models) Rear axle and d riven sprocket (Chain-dri ven models) Dri ven sprocket (chain.drive n models) Rear axle inspection (all models) Final drive un it (shaft-<lriven models)

Drive sprocket and chain (chain-driven models) Rear axle bearing and oil seal replacemen t (shaft-driven models) Rear axle bearing housing (chain-driven models) Shock absorber (chain-dri ven models) Swing arm (chain-driven models)

CHAPTER TEN BRAKES ..•........•.........•..........•.. ..........•.....•..........................................................•......•......•• 202 Drum brakes From drum brakes Rear drum brake Drum brake inspection (rron t hub and rear) Disc brakes Front brake pad replacement Rear brake pad replacemen t Front master cylinder (drum and disc brake models) Rear master cylinder (disc brake models)

From caliper Rear caliper Front brake disc Rear brake disc Front brake hose replacement (drum and disc brake models) Rear brake hose replacemem I1Iceding the system Rear disc brake pedal

CHAPTER ELEVEN BODy ..... ...... ............ ...•............... ............. .... .... ...... ... .......... .............. .. ...... . ......... 232 Front fender Rear fender Front hand grip

Rear hand grip From and rear carriers (shaft-driven models)

SUPPLEMENT 1987 AND LATER SERVICE INFORMATION ......•..•.... .. ......•.. .....•.................. ..•. ........ 239 Periodic maintenance Tunc-up Piston, piston pin and piston rings Transmission and internal shift mechanism Carburetor service Capacitor discharge ignition (LT250S models) SWItCheS

Rear axle and driven sprocket (chain-driven models)

Swing aml and shock absorbers (cham-driven models) Rear caJtper Front fender

Rear fender

INDEX .. .... ........ .. .. ......... ... .. ... ........... .... ...... ... ............ ........................ ..... .... .... .... . 256 WIRING DIAGRAMS ...••......••....•.. ........ .... .. ....••........••. .. .........•..............................• 260

QUICK REFERENCE DATA ATV INFORMATION

MOOEL:,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _YEAR :_ _ _ _ _ _ __ VIN NUMBER:_ _

_ _ __

_ _ _ _ _ _ _ _ __

_ _ _ __

_ _ _ __

_ __

ENGINE SERIAL NUMBER:,_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ CARBURETOR SERIAL NUMBER OR 1.0. MARK :

TUNE.UP SPECIFICATIONS Valve clearance Intake Exhaust Compre•• lon pressure (at sea level) Standard Service limit (min.)

Spark plug standard type* Hotter Standard heat range Coi,,", Spark plug resiltor type'

0.03-0.08 mm (O.OOHl.OO3 In.) 0.08-0.13 mm (0.003..(1.005 In.)

1,2()().1 ,600 kPa (171-228 pal) 1,000 kPa (1 " 2 pal) Champion A8Ve NGK 07EA, NO X22E5-U, Champion A8ye NGK D8EA, NO X24ES·U

Honer

Champion RABye NGK DR7ES, NO X22ESR-U, Champion RA6YC NGK DR8EA, NO X24ESR-U 0.6-0.7 mm (0.024-0.028 In.) 1,350-1 ,450 rpm

Standard heat range Colder Spark plug gap Idle speed Pilot aerew Initial opening Shaft drl ....

Chain drive

2318 lurna out 2 turn a out

'Higher spark plug number. Indicate colder heat range for bolh NGK and NO.

REPLACEMENT BULBI Volta,e/Watta,e Haadllght Tallllghl

12\1 45/45W 12\1 5W

TIAE INFLATION PREIIUAE (COLD)-

Load capacity Shaftodrlv.n models Up to 70 kg (155 lb.)

70-120 kg (155-265 lb.)

Chalnodrlven models Up to 105 kg (230 lb.)

105-170 kg (230-375 lb.)

.P.

TI ... p .....u ...

Front tire.

Aea, tire.

p.i

.P.

20 35

2.8 5.0

20 20

2.8 2.8

18 25

2.6 3.6

18 25

2.6 3.6

p.i

"TIre Inflation pressure fOf' faclory equipped Ilres. Aftermarket tlrea may require dlffetent Infletlon pressure.

iX

DRIVE CHAIN REPLACEMENT NUMBERS Olado 010 52DV TakllSago RK520SM

84 links 84 links

LUBRICANT CAPACITIES

Item Fuel tank Shaft-driven Chaln·drlven Engine oil (shaft·driven) Oil and filler Overhaul Engine 011 (chaln·driven) Oil and fllter Overhaul Subtransmission Final drive unit

10 Ute,.. (HI U.S. gal./2.11mp. gal.)

9.5 liters (2.4 U.S. gal. /2.0 Imp. gal.)

1,700 cc (1.8 U.S. qt./ 1.5 Imp. qt.)

1,900 cc (2.0 U.S. qt./1.7 Imp. qt.)

1,600 cc (1.7 U.S. qt./ 1.4 Imp. qt.)

1.700 cc 1'.8 U.S. ql. /l.5 Imp. qt.)

240·270 cc (8.1·9.1 U.S. oz. /6.7-7.6 Imp. oz.)

165·175 cc (5.6·5.9 U.S. 0%. /4.6·4.9 Imp. oz.)

RECOMMENDED FUEL AND LUBRICATION Unleeded or low-Ieacl; 85·95 octane SAE10Wf40; API SE or SF Hypoid gear oil SAE 90; API GL·5 Hypold gear oil SAE 90; API GL·s DOT 3. DOT 4 or SAE J1703 SAE 90 gear oil or chain lubricant recommended for O·rlng chains

Fuel Engine oil Subtranlmllslon 011 Final clrive unit 011 Brake fluid Drive chain lube

WIND CHILL FACTORS Actual Thermometer Read!n&: ( 0 F) Eltimsted Wind Speed in MPH

50

40

30

20

10

0

-10

-20

-30

--40

-50

~

--40 --47 -70 -85 -9.

-104 -109 -113

-50

-

Equivalent Temperature (O f)

calm 5 10 15 20 25 30 35 40

•

50 48 40 3.

32 30 28 27 2.

40 37 28 22 18 I.

13 11

10

30 27

"9 4 0 -2 -4 --6

Little Danler (for properly clothed person)

2.

"4 -5

-10

-15 -18 -20 -21

10

•

0 -5 -21

- 9 - 18 I -.36 25 -39 -29 -44 -33 -48 -35 -49 -37 -53

-10

-20

I -30

-15 1-26 33 -45

-53 -59 --63 --67 --69

Increasing Oanler

-3' -4. -58 -58 -72 --67 -82 -74 -88 -79 -94 -82 -98 -85 - 100 -116

-57 -aJ

• Danser from Ireezmg of u;poud flesh,

x

95

-99 -ll2 -110 -118 -125 -129 -132

Great Oanler

·Wind speeds greater than 40 mph have little addlhonel effect

- -'"

-124 - 133 -140 -145 -148

GENERAL TORQUI: 1"_C'PlCATIONI

'tom CyMncMf Mad cover bolt

Cyllndetn.ad 8 mm bolts 8 mm boltl Cylinder bale nut Ten,loner adjult bolt Alternator rotor nut Shaft·drlven Chaln·drlven Drive aprocket nut Front wheel hub nut Handlebar upper holder boItl Slearlnil ahaft Holder bolta Lower nut Shaft,drlven Chaln·driven St.. rlng knuckle Ann bolt Knuckle-te-wilhbone nut Knuckl..to-Iowar wllhbone clamping bolt Wlahbone-Ie-frlme boltl and nuta

"'"'

fl.·lb.

9·11

6.5·'

7-11 21·25 7·f1 a·a

5·8 5·a U-8

150·170 50-60

108·123 38-43.5

15·18

ao·loo

51·72

50-80 18·28

38·58 13·20

18·28

13·20

22·35 38·80

111·25 27·43

35·35 40-80

211·33 29·43

.....

32...

50·70

311·51

End locknut.

Locknuta Shaft·drlven Chaln·drlven Shock abaorber bolta

22-35

18·211

23·35 40-80 40·60

28·33 29-'"

Rear hub nut Wheel nut.

Axlll locknut Axle Inner nut Drive aprocket boltJi lind nuta 1985·1988 1987·t990 Rear axlll bearing houllng bolts 1985·1986 1987·1990 Reat brake dllc bolt.

Shock absorber bolta end nut.

Swing arm pivot boll and nut Subtranamlulon-to-final drive nuta

85-115 45-66 160·200 180.200

82,83 33-47 115·144 115-144

25·39 45·85

18-211 32-47

18·28 85·120 15·25 40-80 50-60

13·20 61.5·117 ,,.,8 29·44 36-58

24·31

17·23

TIe .... ,

2''''

1.110·1.130

DllCh~

1.140-1.180 1.170-1.190

1.200·1.220

Almaal dlactwlrv-d One-qua"M charged One·half charca-d

1.230·1.250 1.280·1.2110

Th,....quart.,. ctwlrged Fully ctwlrged

MAINTENANCE SCHEDULEPrior to .ach rid.

• In.pect tire. and rim. and check Inflallon pre•• ure • Check driva chain ten.lon, edJu.1 If nec....ry (model. to equipped) • Lubricate drive chain

of operation

• Lubricale conlrol cable.

Ev.ry I month. of Operation or 1,000 km or 100 mil••

• Ch.nge engln. oil and oil filter • Clean and oil air filter elem.nt (perlonn sooner if used In wet or dU.ty terr. In) • Check end adjust the carburetor • Cheek Ignition timing (COl Ignition) • Check cylinder head nut., cylinder nut. and exheu.t pip. nutl, tighten If nece.sary • Check e'eclrolyte 'evel in battery, add dl.tIIled waler if neces.ary (mode'. 10 .qulpped) • In.pect brake hOI.1 for cracked or .woll.n end., replace if nec•••• ry • Check brake fluid leva' In masle, cylinder(s), add fluid II necessary • In.pect fuel IInel for chafed, cr.ckad or .wollen end., replace If n.c.... ry • Check throttle operation, adJu.t If nec•••• ry • Clean and lubricate drlva chain (model. to .qulpped) • In'p.ct driva chain .lider (model ••0 equlpp.d) • AdJu.t drive chaIn t.n.lon • Check oil level in final drive unit, add 011 If nece.sary (model••0 aqulpped) • Check oil level In dual-ranga .ubtran.ml•• lon, add oil if necesaary (model••0 equipped) • Check and adJult clutch free play • Check and adju.t brake(l) • Check drum braka lining waar Indlcator(.)

• Check and adjust rea, braka pedal If" play • Lubricate r•• r brak. pedal and .hlft lever • Check Ure .nd wheel condition • In.pect front .ta.ring lor loo••ne•• • Check wheel bearing. for smooth operation • Check engine mounting bolt. for Ughlna ..

• Check chassl. bolt. for tlghtna •• • Check and adJu.t to.-In

Evary 12 month. of op.ration or 2,000 km or 1,200 mllas

• • • •

Inspect and clean .paril plug. regap II nece.aary In.pect valve cle.tance, adJu.t if nece ..ery Run a compresaion teat In.pect decompr.saion lavar Irea play, adJu.t If nece.sary (modals so equIpped) • inspecl cam chain len lion, adjust It n.ce ..ary • Change final driva 011 (moda'. 10 .qulpp.d) • Change dual-ranga lublranlmlilion oil (modal • • 0 equipped)

Ev.ry 5,000 Itm or 3,000 mil••

• Replace . paril plug

Evary 2 y ••,..

• R.place hydraulic brake lIuld • Replace fuel ho.e.

• Replace flexible brake ho.el

• Thi. Suzuki factory maintenance achedule ....ould be conllderad ea a guide to g.nera' maintenance end lubrication interv.i•. H.rder than nonnalule (tacing) and expolure to mud, weter, ..nd, high humidity, etc. will naturally dictate mora frequent att.nlion to mo.t malnlenance Items.

xu

CHAPTER ONE

GENERAL INFORMATION

This detailed, comprehensive manual covers the Suzuki LT230GE, LT-F23OG. LT230S and lT250S 4-whecl all-terrain vehicles. The expen text gives complete information on maintenance, rune-up. re-

pair and overhaul. Hundreds of photos and dmwings guide you through every step. The book includes all you need to know to keep your Suzuki running right.

A shop manual is a re ference. You want to be able to find information fast. As in all Clymer books, this one is designed with you in mind. All chapters 3rc thumb tabbed. Imponanl items are extensively indexed at the fcaT of the book. All the most frequent ly used specifications and capacities arc summarized on the Quick Reference Data pages al the front of the book.

Keep the book handy in your tool box. It will help you to better understand how the ATV runs, lower repair and maintenance costs and generally improve your satisfaclion with the bike.

Table I and Table 2 are at the end of this chapter.

MA NUA L ORGAN1ZATJON All dimensions and capacities are expressed in English units familiar to U.S. mechanics as wcll as in metric units. This chapler discusses equipment and tools useful both for preventive maintenance and troubleshooting.

Chapter Two provides methods and suggestions for quick and accurate diagnosis and repair of problems. Troubleshooting procedures discuss typical symptoms and logical methods to pinpoint the troublc.

Chapter Three explains all periodic lubrication and routine maintenance necessary to keep the ATV running well. Chapter Three also ineludes recommended tune-up procedures. eliminating the need to constantly consult chapters on the various assemblies.

Subsequent chapters describe specific systems such as the engine. clutch. transmission. fuel, exhaust, electrical. suspension and brakes. Each chapter provides disassembly. repair and assembly procedures in simple step-by-step fonn . If a repair is impractical for a home mechanic, it is so indicated.

It is usually faster and less expensive to take such repairs to a dealer or competent repair shop. Specifications concering a panicular system are included at the end of the appropriate chapter.

Some of the procedures in this manual specify special tools. In most cases, the tool is illustrated either in actual use or alone. Well equipped meehanics may find they can substitute similar tools already on hand or can fabricate their own.

The tenns NOTE. CAUT ION and WARNING have specific meanings in this manual. A NOTE provides additional infonnation to make a step or procedures easier or clearer. Disregarding a NOTE could cause inconvenience. but would not cause equipment damage or personal injury.

2

CHAPTER ONE A

CAUTION

emphasizes

areas

where

equi pment damage could occur. Disregarding a CAUTION CQuid cause permanent mechanical damage; however, personal injury is unlikely.

A WARNING emphasizes areas where personal injury or even death could result from negligence.

Mechanical damage may also occur. WARNINGS are /0 be taken seriously. In some cases, serious injury or death has resulted from disregarding sim ilar warnings.

Throughout this manual keep in mind 2

conventions. "Front" refers to the front of the ATV. The front of any component. such as the engine, is the end which faces toward the front of the bike. The "Ieft-" and "right-hand" sides refer to the position of the pans as viewed by a rider silting on the scat facing forward. For example, the throttle conlrol is on the right¡hand side and the clutch lever (models so equipped) is on the len-hand side. These rules arc simple. but even experienced mechanics occasionally become disoriented.

SERVICE HINTS Most of the service procedures covered are straightforward and can be performed by anyone reasona bly handy with tools. It is suggested, however. that you consider your own capabilities carefully before attempting any operation involving major disassembly of the engine.

Some operations. for example, require the use of a press. It would be wiser to have these performed by a shop equipped for such work, rather than trying to do the job yourself with makeshin equipment. Other procedures require precise measurements. Unless you have the skills and equipment required. it would be better to have a Qualified repai r shop make the measurements for you.

There are many items available thaI can be used on your hands before and after working on your ATV. A linle preparation prior to gelling Mall greased upM will help when cleaning up later.

Before starting out. work Vaseline. soap or a product such as Pro-Tek Invisible G love (Figure I) onto your forearm s, into your hands and under your fingernails and cuticles. This will make cleanup a lot easier.

For cleanup. use a waterless hand soap such as Sta-Lube and then finish up with powdered Boraxo and a fingernail brush.

Repairs go much faster and easier if the ATV is clean before you begin work. There are special cleaners, such as Gunk or Bel-Ray Degreaser (Figure 2), for washing the engine and related parts.

Just spray or brush on the cleaning solution, let it stand. then rinse it away wi th a garden hose. Avoid the use o f high pressure waler (coin-operated car washes) and do nOI poinl any water spray directly at the following parts or areas: a. Drive chain (models so equipped). b. Wheel hubs. c. Instrument cluster (models so equipped). d . Ignition switch and handlebar switches. e. Carburetor assembly. f. Master cylinders. g. Muffler outlet. h. Under the seat and the fuel tank.

Clean all oily or greasy parts with cleaning solvent as you remove them .

WARNING NCI'er use gasoline as a cleaning agell/.

It presems an eXlreme fire hazard. Be sure LO .... ,ork in a well-I'emilall'fi area .....hen IIsinge/eaning sob¡ent. Keep afire extinguisher. rated for gasoline fires, hand)' in any case.

Specia l tools are required for some repair procedures. These may be purchased from a dealer or motorcycle shop, re nted from a tool rental dealer or fabricated by a mechanic or machinist (often al a considerable savings).

Much of the labor charged for repairs made by mechanics is for the removal and disassembly of other parts to reach the defective unit. It is usually possible to perform the preliminary operations yourself and then take the defective unit in to the dealer for repair.

Once you have decided to tackle the job yo urself, read the entire section in this manual which penains to it, making sure you have identified the proper one. Study the illustrations and text until you have a good idea of what is involved in completing the job satisfactorily. If special tools or replacement pans are required, make

GENERAL INFORMATION

arrangements to get them before you start. It is frustrating and time-consuming to gct partly into a job and then be unable to complete it.

Simple wiring checks can be easily made al home, but knowledge of ele<:tronics is almost a necessi ty for performing teslS with complicated electronic testing gear.

During disassembly of parts keep a few general cautions In mind. Force is rarely needed 10 get things apart. If pans arc a tight fit, such as a bearing in a case, there is usually a tool designed to separate them. Never use a screwdriver to pry parts with machined surfaces such as crankcase halves.

Vou will mar the surfaces and end up with leaks.

Make diagrams (or take a Polaroid picture) wherever similar-appearing parts are found. For instance. crankcase bolts arc oOcn nOI the same length. You may think you can remember where everything came from, but mistakes are costly.

There is also the possibility you may be sidetracked and not return to work for days or even weeks. in which interval carefully 13id out parts may h3ve become disturbed.

Tag all similar internal parts for location and mark all mating partS for position. Record number and thickness of any shims as they are removed.

Small parts such as bolts can be idenlified by placing them in plastic sandwich bags. Seal and label them with masking tape.

Wiring should be tagged with masking tape and marked as each wire is removed. Even though most electrical connectors are color coded, mark them. Do not rely on memory alone.

PrOtect flOis hed surfaces from physical damage or cOrTosion. Keep gasoline and hydraulic brake fluid off painted surfaces.

Frozen or very tight bolts and screws can often be loosened by soaking with penetrating oil, such as WO-40 or Liquid Wrench, then sharply striking

3 the bolt head a few times with a hammer and punch (or screwdriver for screws). Avoid heat unless absolutely necessary, since it may melt, warp or remove the temper from many parts.

N<:, parts, except those assembled with a press fit , reqUIre unusual force during assembly. If a part is hard to remove or install, find out why before proceeding . . Cover all openings after removing parts to keep dirt. small tools, etc. from falling in.

When assembling 2 parts. start all fasteners then tighten evenly. .

Wiring connections and brake components should be kept clean and free of grease and oil.

When assembling partS, be sure all shims and washers are installed exactly as they came OUI. Whenever a rotating part butts against a stationary part. look for a shim or washer. Use new gaskets if there is any doubt about the condition of the old ones. A thin coat of oil on gaskets may help them seal effectively, but dan', use oil on gaskets if a service procedure specifies otherwise.

Heavy grease can be used to hold small partS in place if they tend to fall out during assemblv.

However, keep grease and oil away from electric~l and brake components.

High spots may be sanded off a piston with sandpaper, but fine emery cloth and oil will do a much more professional job.

Carbon can be removed from the heads, the piston crowns and the exhaust ports with a dull screwdriver. Do nOl scratch machined surfaces.

Wipe off the surface with a dean cloth when finished , The carburetor is best cleaned by disassembling it and soaking the parts in a commercial carburetor cleaner. Never soak gaskets and rubber parts in these cleaners. Never use wire to clean out jets and air passages; they are easily damaged. Use compressed air to blowout the carburetor after the float has been removed, A baby bottle makes a good measuring device for adding oil to the final drive case. Get one that is graduated in fluid ounces and cubic centimeters.

After it has been used for this purpose, do not let a small child drink out ofil as there will always be an oil residue in it.

Take your time and do the job right. Do not forget that a newly rebuilt engine must be broken in the same as a new one, Keep the rpm within the limits given in your Owner's manual when you get back on the road.

TO RQUE SPECIFICATIONS Torque specifications throughout this manual are given in Newton meters (N.m) and fOOl pounds

4

CHAPTER ONE

(ft.-lb.). Newlon mcters have been adopted in place of mClef kilograms (mkg) in accordance with the International Modernized Metric System. Tool manufacturers offer IOrque wrenches calibrated in Newlon meters and Sears has a Craftsman line calibrated in both values.

Existing torque wrenches calibrated in meier kilograms can be used by perfonning a simple conversion. All you have to do is move the decimal poin t one place to the right; for example, 4.7 mkg - 47 Nom. This conversion is accurate enough for mechanical work even though the exact mathematical conversion is ).5 mkg - 34,3 N-m.

Refer to Table 2 for standard torque specifications for various size scre~. bolts and nuts that ma y not be covered in the various chapters.

SAFET\' FIRST ProCessional mechanics can work for years and never sustain a serious injury. If you observe a few rules of common sense and safety. you can enjoy many hours servicing your own machine. If you ignore these rules you can hun yourself or damage the ATV. I. Never use gasoline as a cleaning solvent.

2. Never smoke or use a torch in the \'icinity of flammable liquids such as cleaning solvent in open containers.

J. If welding or brazing is required on the machine. remove the fuel tank to a safe distance, at least 50 feet away.

4. Use the proper sized wrenches to 3\'0Id damage to nuts and injuf} 10 }oursclf.

S. When loosening a tight or stuck nut, think about what would happen if the wrench should slip. Be careful; protect yourself accordmgly.

6. Keep your work area clean and uncluttered.

7. Wear safety goggles during all operations involving drilling, grinding or Ihc use of a cold chisel.

8. Never use .....orn tools.

9. Keep a fire extinguisher handy and be sure it is rated for gasoline and electrical fires.

SP[CIA L TI PS Because of Ihe extreme demands placed on an ATV several points should be kepI in mind when performing service and repair. The following items are general suggestions thai ma y improve the overall life of the machine and help avoid costly failures.

I. Use a locking compound such as Loctite Lock N' Seal No. 2 11 4 (blue Locti\c) on bolts and nuts (used in high-stress arcas) even if Ihey arc secured

with lockwashers. This type of Loctite does not harden completely and allows easy removal of the boll or nUl. A screw or bolt lost from an engine cover or bearing retainer could easily cause serious and expensive damage before its loss is noticed.

CAUTION Whell appl)"lng LoeWe, use a 511101/ omOllnt. If tOO much is used, it can work liS 11"0)' down the threads and stick I)arts together not meom to be stuck.

Keep a tube of Loctite in your tool box; when used properly it is cheap insurance.

2. Usc a hammer-driven impact tool to remove stubborn bolts. panicularly engine cover screws.

These tools help prevent the rounding off of bolt heads and ensure a light installation.

3. When replacing missing or broken fasteners (bolts. nuts and screws). espccially on the engine or frame components. always use Suzuki replacement pans. They are specially hardened for each application. The wrong fastener could easily cause serious and expensive damage, not to mention rider injury.

4. When installing gaskets in the engine, always use Suzuki re placement gaskets withollt sealer, un less designated. These gaskets are designed to

5

GENERAL INFORMATION

swell when they come in contact with oil. Some of the gaskets (head gasket) have a sticky surface on each side that ensures a good seal. Gasket scaler will prevent the gaskets from swelling or stick ing as intended. which can result in oil leaks. These Suzuki

gaskets arc cut from material of the precise thickness needed. Inst.1llation ora 100 thick or \00 thin gasket in a cntical area could cause engine damage.

EXPENDABLE SU PPLIES Certain expendable supplies arc required during maintenance and repair work. These include grease, oil. gasket cement, wipmg rags and cleaning solvent. Ask your dealer for the special locking compounds. silicone lubricants, drive chain lube and other products (Figure 3) which make vehicle maintenance simpler and easier. Cleaning solvent or kerosene is available at some service stations or hardware stores.

PA RTS

R[ P LACE~ I ENT

Suzuki makes frequent changes during a model year some minor. some relatively major. When you order parts from the dealer or other parts distributor. always order by cngine and frame number. Write the numbers down and eany them with you. Compare new parts to old beforc purchasing them. If they arc not alike. have the parts manager explam the dincrcnee to you.

SERIAL NUMBERS You must ha ... e the model serial number and VIN number for registration purposes and", hen ordering replacement pans. The various serial numbers are located as follows: a. The frame serial number (Figure 4) ;s stamped on the left-hand side of the horizonlal frame member jusl forward of the cngine. h. Thc vehicle identification number (VIN) is located on the left-hand side of the \cnieal frame member (Figure S). c. The cnginc serial number is located on the front Icft.h!tnd comer of the crankcase (Figure 6 ). d. The carburetor identification number !s located on the raised pad all thc left-hand side of the carburetor body above the float bowl (Figure 7).

BASIC TOOLS Most of the procedures in this manual can be car¡ ried out with simple hand tools and test equipment

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