Suzuki LT-4WD LT-F4WDX & LT-F250 Service Manual
YEARS 1987-1998
472 pages of information

Complete workshop manual with detailed pictures/diagrams & information. Step by step procedures for servicing, repairing, maintaining, diagnostic & troubleshooting. Plus gives you access to the same information that the Professional Technicians & Mechanics have. Covers all topics from changing a light bulb to a full engine rebuild!

CONTENTS

QUICK REFERENCE DATA
CHAPTER ONE
GENERAL INFORMATION
Manual organization
Notes. cautions and warnings
Safety first
Service hints
Washing the vehicle
Torque specifications
Fasteners
Lubricants
RTV gasket sealant
Threadlock
Gasket remover
Expendable supplies
Pans replacement
Basic hand tools
Test equipment
Precision measuring tools
Speciallools
Cleaning solvent
Mechanics tips
Ball bearing replacement
Oil seals
Riding safety
CHAPTER TWO
TROUBLESHOOTING
Expendable supplies
Parts replacement
Basic hand tools
Test equipment
Precision measuring tools
Special Tools
Cleaning solvent
Mechanics tips
Ball bearing replacement
Oil seals
Riding safety
Operating requirements EleclricallrOubleshoOling
Troubleshooting instruments Test equipment
Starting the engine Basic test procedures
Emergency troubleshooting Electrical problems
Engine sianing troubleshooting Charging system troubleshooting
Engine performance Ignition system troubleshooting
Engine noises Electric starter system troubleshooting
Engine lubrication Carburetor troubleshooting
Clutch Excessive vibration
Gearshift linkage Front suspension and steering
Transmission Brake problems
CHAPTER THREE
LUBRICATION, MAINTENANCE ANO TUNE-UP
Pre-checks
Service intervals
Tires and wheels
Battery
New battery installation
CHAPTER FOUR
Battery electrical cable connectors
Periodic lubrication
Periodic mainlenance
Engine tune-up
ENGINE TOP END
Engine principles
Engine cooling
Cleanliness
Servicing engine in frame
Cylinder head cover
CHAPTER FIVE
Cylinder head and camshaft
Valves and valve components
Cylinder
Piston, piston pin and pislon rings
Camshaft chain tensioner adjuster
ENGINE LOWER END
Servicing engine in frame
Engine
Right-hand crankcase cover
Left-hand crankcase cover
Recoil staner
Staner clutch and gears
Oil pump
Oil strainer
Oil cooler (LT-F4WDX 1280 wheel models)
Sub-transmission output shaft and rear final
driven gear
Secondary driven output shaft (4-wheel drive
models)
Crankcase and crankshaft
Break-in procedure
CHAPTER SIX
CLUTCH
Clutch operation
Centrifugal clutch
CHAPTER SEVEN
Manual clutch
Clutch lifting mechanism
TRANSMISSION AND SHIFT MECHANISM .
Main transmission external shift mechanism
Main transmission internal shift mechanism
Main transmission internal shift mechanism
inspection
CHAPTER EIGHT
Sub-transmission and shift mechanism
Gearshift lever cOnlroi mechanism
FUEL AND EXHAUST SYSTEMS
Carburetor operation
Carburetor service
Carburetor (1987- 1989 models)
Carburetor (l990-on models)
Cleaning and inspection (al l models)
Carburetor adjustmenls
Fuel system cleanliness inspection
Thronle cable
Choke cable (1990-on models)
Fuel shutoff valve
Fuel tank
Fuel pump
Air filter housing
Exhaust system
CHAPTER NINE
ELECTRICAL SYSTEM
El eclrical connectors
Battery negative tcnninal
Charging system
Vollage regulillor/reclifier
AC generator
Capacitor discharge ignition
Pickup coil
Ignition coil
Starting system
Electric starter
CHAPTER TEN
Starter relay
Neutral relay
Lighting system
Switches
Odometer housing (2 wheel drive models)
Speedometer housing ( 4 wheel drive models)
OUlpullcrminal
Fuses
Wiring diagrams
FRONT SUSPENSION AND STEERING
Front wheel
Tires and wheels
Shock absorber
CHAPTER ELEVEN
Front hub and brake drum
Steering system
Front suspension
FRONT DRIVE MECHANISM FOURWHEEL DRIVE
Front drive axles
Propeller shafl
CHAPTER TWELVE
Front differential
REAR SUSPENSION, REAR AXLE AND FINAL DRIVE
Rear wheel
Shock absorber
Rear hub and brake drum
CHAPTER THIRTEEN
Rear suspension ann
Rear drive axles
BRAKES
Front drum brakes
Rear drum brake
Drum brake inspection (front and rear)
Rear drum brake cable and foot pedal
CHAPTER FOURTEEN
Front master cylinder
Front brake hose replacement
Bleeding the system
BODY
Seat
Rear fender and rear rack
From fender, from rack and front grip
Footrest assembly
Trailer hitch plate
INDEX
WIRING DIAGRAMS

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