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400 eiger service manual

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400 eiger service manualOther information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. The seal rubber may end gap larger than required to slip the possibly come off the position during disconnecting circlip over the shaft. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc.Otherwise, damage to electronic unit prohibited. Such a wrong connection will damage the may result. If voltage drop in the circuit between terminals “A” and continuity is indicated, there is a short circuit to “B”. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply WATER RESISTANCE GREASE. These numbers are required. Gearshift label (French) For P-28 2. Information label (English) For P-33 17. Front carrier warning label (English) For P-24, 33 3. Neutral switch 4. Neutral relay 9. Neutral switch diode. Brake light switch 2. Main fuse 7. Parking brake switch 12. Starter motor 3. Starter relay 8. Burke light switch 13. Cooling fan thermo-switch 4. Neutral relay 9. Ignition switch 14. Reverse switch 23. Neutral switch. Clean element Every 1 000 km (600 miles, 3 months) If the air cleaner is clogged with dust, intake resistance “A”. Pull the recoil starter rope until the line specified range using the special tool. Refer to “Spark Plug Inspect spark plug Removal and Installation in Section 1H (Page 1H- Every 2 000 km (1 200 miles, 6 months) 3)”. Also, do not use a genuine suzuki automobile oil filter on this vehicle.A400F, LT-F400F) CAUTION B827H10206010 Replace front differential gear oil Replace the gasket washers with a new one.http://skibetjagtforening.damgruppen.dk/userfiles/bosch-mot-251-manual.xml

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Every 2 years Tightening torque Replace the oil filter differential gear oil in the following Front drive (differential) gear oil drain plug (a):. Refer to “Exterior Parts 4) Tighten the oil level plug (3) and oil filler plug (2) to Removal and Installation in Section 9D (Page 9D- the specified torque. 3)”. CAUTION Final Gear Oil Inspection Replace the gasket washers with new ones. If the Inspect brake system wear exceeds the grooved limit line, replace the pads Initially at 200 km (100 miles, 1 month) and every 1 with new ones. Inspect the wear of brake lining in the following procedures: 1) Make sure that the rear brake is properly adjusted. 2) While fully applying the rear brake, check that the extension line of index mark “A”. Initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter CAUTION Steering should be adjusted properly for smooth turning The lock-nuts (2) have left-hand threads. Special Tools and Equipment. Cylinder distortion — 0.05 (0.002) Approx. 8.9 (0.35) 7.1 (0.28) Piston ring free end gap Approx. Replace (Compression too low) Worn valve guide or improper valve. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability.Adjusting, interfering with, improper. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 1) Remove the right side cover. Clamp “H”: Pass the breather hose to outside of the cable.: Bind the rear brake cable with the clamp. Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 4) Keep the throttle lever in the fully-opened position. B827H11404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-1)”. Removal and Installation in Section 5A (Page 5A-7)”. Section 5A (Page 5A-7)”. Removal and Installation in Section 5A (Page 5A-7)”. Refer to “Exterior Parts Removal 1) Remove the rear fender. Refer to “Exterior Parts and Installation in Section 9D (Page 9D-3)”.http://xn----otbabpoogeff7mf.xn--p1ai/archive/image/bosch-nail-gun-manual.xml Removal and Installation in Section 9D (Page 9D- 3)”. I827H1140236-01 8) Disengage the gearshift link arm (5). I827H1140238-02 11) Disconnect the gear position switch lead wire I827H1140242-01 coupler (8), CKP sensor lead wire coupler (9) and 16) Remove the brake pedal (17). I827H1140245-01 I827H1140249-01 21) Remove the engine mounting bolts and nuts. WARNING Care should be taken not to drop the engine accidentally when the engine mounting bolts and nuts are removed. Reinstall the engine in the reverse order of removal. Pay Once the nut has been removed, it is no attention to the following points: longer any use. Be sure to use new nuts, and then tighten them to the specified torque. I827H1140005-01 2) Remove the cylinder head cover. I827H1140008-01 4) Drop the camshaft sprocket to the camshaft groove “A”. I827H1140011-01 I827H1140014-02 2) Remove the cylinder head bolts. 4) Remove the dowel pins and gasket (4). NOTE The cylinder head bolts must be loosened diagonally and evenly. If the diameter exceeds the Refer to “Engine Top Side Disassembly (Page 1D-10)”.Refer to “Engine Top Side Assembly (Page 1D-13)”. B827H11406042 7) Remove the valve spring seat. Disassembly 8) Remove other valves in the same manner. CAUTION NOTE Be sure to identify each removed part as to Remove of valves completes ordinary its location, and lay the parts out in groups disassembling work. If runout with the dial gauge. The valve must be replaced if any abnormal wear is found, replace the respective the runout exceeds the limit. A a micrometer. where the clearance is found to be in weakened spring results in reduced engine power output excess of the limit indicated replace the valve, if the stem and often accounts for the chattering noise coming from. If any leaks occur, inspect the valve 1) Visually check for valve seat width on each valve seat and face for burrs or other things that could face. Be sure to clean and oil the guides after reaming.https://www.becompta.be/emploi/3hm35f-service-manualReplace To properly measure the oil clearance with either the cylinder head set or camshaft if it the plastigauge, all gasket material must be clearance is incorrect. Refer to “Engine Top 1) Remove the cam chain tension adjuster. Piston and Piston Ring Inspection B827H11406032 Piston Diameter NOTE Using the micrometer, measure the piston outside 1st ring (4) and 2nd ring (3) differ in shape.If any of the clearances of each ring using vernier calipers. If the reading exceeds NOTE following limit, replace both piston and piston pin. Transfer Gearshift System Special tool Remove the transfer gearshift related parts.Refer to “V-belt Type Continuously Variable oil pump driven gear (1) using the special tool. Automatic Transmission Removal and Installation in 2) Remove the washer (2) and oil pump drive gear (3) Section 5A (Page 5A-7)”. Refer 1) Remove the balancershaft driven gear (1). Section 3C (Page 3C-7)”. I827H1140118-01 I827H1140257-01 3) Remove the balancershaft with the special tools. Remove the starter idle gear No.1, (1) and No.2 (2). I827H1140122-01 I827H1140126-01 Transfer shift cam stopper Transfer Gearshift System Remove the bolt, spring and transfer shift cam stopper Remove the transfer related parts. Gearshift Cam Remove the transfer reverse gearshift cam assembly (1), gearshift cam (2) and gearshift forks (3). I827H1140144-01 I827H1140147-01 Transmission 1) Remove the reverse idle gear assembly (1).Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-7)”.NOTE I827H1140208-01 Fit the clamp to the bolt “A”. Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”. 2) Remove the oil seal retainer. I827H1140290-03 6) Remove the oil seal. CAUTION Use the suitable size attachment for each bearing. I827H1140308-01 5) Remove the bearings with the special tools. CAUTION CAUTION Use the suitable size attachment for each Use the suitable size attachment for each bearing.http://efesup.com/images/400-amp-single-phase-manual-transfer-switch.pdf CAUTION CAUTION The removed bearings and oil seals must be replaced with new ones. Use the suitable size attachment for each bearing.Special Tools and Equipment. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. Inspect the oil cooler for oil leakage. If any defects are found, replace the oil cooler with a new one. If the fins are bent or dented, repair them by carefully straightening them with the blade of a small screwdriver. Removal 1) Remove the left inner fenders. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. 2) Disconnect the cooling fan motor lead wire coupler (1). Refer to 1) Remove the left side of the front inner fender. Refer “Cooling Fan Thermo-switch Removal and to “Exterior Parts Removal and Installation in Section Installation (Page 1E-13)”. Refer to 1) Remove the generator cover. Refer to “Generator “Engine Oil Temperature Switch Removal and Removal and Installation in Section 1J (Page 1J-5)”. If the piston does not operate, replace the oil pressure regulator with a new one.Special Tools and Equipment. Extreme care must be taken. Keep heat, sparks and flames away from gasoline. General Description I.D. No. Location B827H11701002 Each carburetor has an I.D. number “A” printed on its body. “A”. When there is negative pressure (vacuum) in the combustion chamber, the fuel is able to flow from the fuel tank, through the fuel valve and then to the carburetor assembly. When the engine has started, negative pressure (vacuum) “A” is generated in the combustion chamber and reaches the diaphragm through a passage in the carburetor’s main bore and the vacuum hose. The piston valve moves according to the negative pressure present on the downstream side of the venturi “A”. The fuel from the float chamber (2) is metered by the slow jet (3) where it mixes with air coming in through the slow air jet (4). This mixture, rich with fuel, then goes up through the passage to the pilot screw (5). This causes the piston valve (2) to move upward. The fuel in the float chamber (3) is metered by the main jet (4). The metered fuel enters the needle jet (5), mixes with the air admitted through the main air jet (6) and forms an emulsion. The starter jet (2) meters this fuel. The fuel then flows into the fuel pipe (3) and mixes with the air coming from the float chamber (1). As the float (1) moves up and down, so does the needle valve (2). When there is a high fuel level in the float chamber (3), the float (1) rises and the needle valve (2) pushes up against the valve seat. B827H11706009 7) Drain fuel completely.Pay Removal attention to the following points: WARNING WARNING Gasoline is very explosive. Extreme care Replace the gasket washers (1) and gasket must be taken. Refer to “Exterior Parts moves smoothly. Pilot screw 3. Jet needle 11. Cap 19. Main jet 26. O-ring 4. B827H11706028 WARNING Gasoline is highly flammable and explosive. Keep heat, spark and flame away. Removal 1) Turn the fuel valve ON position. 2) Remove the side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”. CAUTION Do not use compressed air on the carburetor body before removing the diaphragm; this may damage the diaphragm. I827H1170005-02 7) Remove the throttle stop screw (16). I827H1170002-02 4) Remove the spring (9), spring retainer (10), spacer (11), jet needle (12) and diaphragm (13). Refer to Carburetor Parts “Carburetor Assembly Removal and Installation Check the following items for any damage or clogging. Air Cleaner Element Inspection and Cleaning B827H11706036 Refer to “Air Cleaner Element Inspection and Cleaning in Section 0B (Page 0B-3)”.Special Tools and Equipment. Emergency switch Engine Ignition Fuse (E-17) stop switch switch Fuse CDI unit Wave form Ignition power arrangment source circuit circuit. Rebore or replace. Excessive valve-stem to valve-stem to Replace.Worn valve stem oil seals. Replace. Wait until the engine is cool enough to touch. 1) Turn the ignition switch OFF. 2) Remove the left side cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”. If the voltage is lower than standard range, inspect CAUTION the ignition coil and the CKP sensor. Before using the multi-circuit tester and peak Ignition coil primary peak voltage voltage adaptor, refer to the appropriate. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-13)”. Before using the multi-circuit tester and peak 2) Disconnect the spark plug cap. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. 2) Disconnect the CKP sensor coupler (1). I827H1180009-01 4) Inspect the engine stop switch for continuity with a tester. Troubleshooting Step Action 1) Shift the transfer to neutral. Go to step 2. Go to step 3. 2) Turn on the ignition switch with the engine stop switch in the “RUN”. Refer to “Battery Removal and GREASE A or equivalent) Installation in Section 1J (Page 1J-13)”. If either carbon brush is defective, replace the brush holder set with a new one. Measure the length “a” of the carbon brushes using a vernier calipers. If the I827H1190011-02 resistance is not within the specified value, replace Installation. If any abnormality is found, replace the gear position switch with a new one.NOTE The arrow mark “B” must face the engine side. Removal 1) Remove the starter driven gear. Refer to “Starter Starter Clutch Clutch Removal and Installation (Page 1I-9)”. 1) Install the starter driven gear onto the starter clutch. Removal 1) Remove the left side cover and left footrest Disassembly mudguard. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. GREASE A or equivalent) 7) Remove the reel (11). If any defects are found, replace the ratchet set with a new one. Special Tools and Equipment. Diagnostic Information and Procedures Charging System Symptom Diagnosis B827H11A04001 Condition. Refer to “Exterior Parts Removal and 1) Remove the left side cover and left footrest Installation in Section 9D (Page 9D-3)”. mudguard. Refer to “Battery Removal and Installation (Page 1J-13)”. 2) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-7)”. I827H11A0016-01 16) Remove the generator rotor (12) with the special tool. Fit the clamp to the bolt “C”.I718H11A0027-01 Correct I649G11A0042-03 NOTE If no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times. Refer to “Exterior Parts Removal Do not remove the caps on the battery top and Installation in Section 9D (Page 9D-3)”.Special Tools and Equipment Recommended Service Material B827H11A08001. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting. Refer to “Exterior falling. Parts Removal and Installation in Section 9D (Page 9D-3)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one. If any Inspect the drive shaft cover for damage. If any damages are found, replace the suspension arm with a damages are found, replace the drive shaft cover with a new one. Special Tools and Equipment Recommended Service Material. B827H12306005 Inspect the rear shock absorber for damage and oil CAUTION. Swingarm Inspection B827H12306018 Inspect the swingarm in the following procedures:. Special Tools and Equipment. Make sure that the vehicle is supported securely.WARNING Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train. I831G1310011-02 Assembly CAUTION. CAUTION CAUTION Replace the snap ring with a new one. F400F) B827H13106004 Inspect the front drive shaft in the following procedures: CAUTION 1) Remove the front drive shaft assembly. If any damages are found, replace the rear axle housing Tightening torque with a new one. Special Tools and Equipment Recommended Service Material. Use the special tool to remove the cover from NOTE housing if necessary. If there is no abnormal condition, the bearing Special tool removal is not necessary. NOTE Use the special tool if necessary.If excessive Inspect the pinion gear for wear or damage.Inspect the pinion gear bearing for abnormal noise and smooth rotation. If any defects are found, replace the breather rubber Tightening torque case with a new one. Repeat this procedure once more and compare the Refer to “Front Drive (Differential) Assembly difference of the three measurements. List of shims (for left side) NOTE Part No. Final gear coupling: Apply water resistant grease. Final Gear Oil Level Inspection 4) Remove the rear axle housing mounting bolts from B827H13206014 the swingarm. I827H1320086-01 15) Remove the spacer and bearing from the final drive gear shaft with a commercially available bearing puller or hydraulic press. If any defect Inspect the final drive gear for wear or damage. Inspect are found, replace the oil seal with a new one.Inspect the breather rubber case (1) for wear or damage.A400F, LT-F400F) 4) Turn in the adjuster (3) fully so that the cable obtains B827H13206021 enough play. Set the transfer selection lever to 4WD position and inspect that there is no play in the cable. If there is any play in the cable, adjust it in the following procedures. Lock washer 28. High driven gear 3. Bearing 16. Lock washer 29. Washer 4. Reverse idle gear shaft 17. Spacer 30. Transfer idle gear 2. Transfer low gear 8. Washer 14. Washer 3. Bushing 9. Transfer high gear 15. Transfer output shaft 4. Bearing 10. Washer 16. Transfer driven gear 5. B827H13306002 Removal 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D (Page 1D-6)”. 2) Remove the engine top side. Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-10)”. Installation Install the transfer in the reverse order of removal. Pay 13) Remove the shim (13).NOTE CAUTION Each gearshift fork has own embossed The removed drive bevel gear nut must be letters “A”. B827H13306018 Removal 1) Remove the generator cover. Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”. 2) Remove the washer and transfer idle gear (1) with bearings. Refer to “Generator crankcase side. Removal and Installation in Section 1J (Page 1J-5)”.Fit it to the side where the thrust is as B827H13306007 shown in the figure.Fit it to the side where the thrust is as B827H13306021 shown in the figure.Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-. B827H13306014 Removal 1) Drain engine oil. The removed oil seal must be replaced with Gearshift Shaft new one. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 3)”. Special Tools and Equipment. Refer to “Engine Assembly Removal in Section 1D (Page 1D-6)”. 2) Remove the engine top side. Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-10)”. 3) Separate the crankcase. Refer to “Engine Bottom Side Assembly in Section 1D (Page 1D-43)” and “Engine Top Side Assembly in Section 1D (Page 1D-13)”.I827H1340020-01 5) Remove the bearings by tapping them with the I827H1340024-01 special tool and hammer. Assembly Special tool Assemble the rear output shaft in the reverse order of. I827H1340038-02 I827H1340042-01 4) Remove the C-rings (3) from the universal joint (4). 9) Remove the washer, joint yoke (5), oil seal (6), bearing (7) and shim (8). Rear Output Shaft Inspect the rear output shaft for wear or damage.If excessive Inspect the front output shaft bearing for abnormal noise play is noted, replace the bearing with a new one.I827H1340063-01 6) Remove the washer (1) and drive bevel gear (2). 7) Remove the shim (3).Adjust the tooth contact and backlash until they are both within specification. If the correct tooth contact cannot be maintained when adjusting the backlash, replace the rear output shaft drive Incorrect (Contact at tooth top) Refer to “Rear Output Combined (0.0256 in) Special Tools and Equipment. Do not use or mix different types of fluid, such as silicone-based or petroleum-based. Rear Brake Light Switch Inspection and If any abnormality is found, replace the front brake Adjustment light switch with a new one.Refer to “Front Brake Hose Routing Diagram (Page 4A-1)”.Special Tools and Equipment. NOTE The right and left calipers, brake pads and discs are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. B827H14206002 Refer to “Front Brake System Inspection in Section 0B CAUTION (Page 0B-15)”. Replace the brake pads as a set, otherwise braking performance will be adversely Front Brake Pad Replacement affected. Boots Inspect the boots for damage or wear.If any defects are found, replace the mounting Removal pins with new ones. 1) Remove the front wheel assembly.Refer to “Front 3) Remount the front brake caliper.Special Tools and Equipment. Schematic and Routing Diagram Rear Brake Breather Hose Routing Diagram B827H14302001 “A”. Refer to “Rear Brake Related Parts Inspection (Page 4C-8)”. CAUTION Replace the cotter pin with a new one. V-belt Type Continuously Variable Automatic Transmission Removal and Installation B827H15106005 Removal. Assembly B827H15106007 1) Hold the movable driven face assembly (1) with the special tool and vise, loosen the movable driven face ring nut with the special tool. WARNING Since a high spring force applies to the movable driven face, care must be used so as not to cause the movable driven face to come off abruptly. Inspect the contact surface of the drive belt for cracks or damage and measure the width of the drive belt with the NOTE. Installation Install the clutch shoe in the reverse order of removal. 7) Remove the one way clutch (6).V-belt Outer Cover Bearing Removal and Installation CAUTION B827H15106021 Removal Use new gasket to prevent oil leakage. 1) Remove the V-belt outer cover. Refer to “V-belt Type Continuously Variable Automatic Transmission Removal and Installation (Page 5A-7)”. Installation is in the reverse order of removal.Assembly Assembly is in the reverse order of disassembly.Special Tools and Equipment. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed. Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”. Special Tools and Equipment. Remove 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-7)”. 2) Remove the right footrest mudguard. I827H1530008-01 10) Remove the clutch sleeve hub nut using the special I827H1530011-01 tool.Replace the drive plates found to have worn Assembly down to the limit. Inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the Special tool clutch plates. Measure the inside diameter of the clutch clutch for a smooth movement. Removal 1) Remove the speedometer cover. Refer to “Speedometer Removal and Installation in Section 9C (Page 9C-2)”. 2) Remove the throttle lever case (1), front brake master cylinder (2) and right grip (3). I827H1620022-02 Steering Shaft I827H1620019-01 1) Remove the speedometer and handlebars. Refer to “Speedometer Removal and Installation in Section 9C (Page 9C-2)”. NOTE If there are wear or damage, remove the steering shaft bushing (8). Tie-rod End Inspect the tie-rod ends for smooth movement. Refer to “Wiring Harness Routing ones. Component Location Electrical Components Location B827H19003001 Refer to “Electrical Components Location in Section 0A (Page 0A-6)”. B827H19206003 Removal 1) Disconnect the headlight coupler (1).I827H1920009-01 4) Reinstall the removed parts. I827H1920007-01 NOTE Installation Install the headlight in the reverse order of removal. Pay Properly fit the socket cover and headlight attention to the following point: housing cover. Installation B827H19206010 Removal 1) Remove the rear combination light coupler (1).Special Tools and Equipment. Removal 1) Remove the indicator light lenses (1). 2) Remove the speedometer cover bolts and ignition switch ring nut (2). Refer to (Page 9C-2)”. I827H1940007-01 Installation Installation is in the reverse order of removal. Fuel Tank Upper Cover Refer to “Fuel Tank Removal and Installation in Section I827H1940004-01 1G (Page 1G-13)”. I827H1940013-02 I827H1940010-01 I827H1940014-02 I827H1940011-01 Installation Installation is in the reverse order of removal. I827H1940012-01 Installation Installation is in the reverse order of removal. Removal 8) Remove the front fender with the headlight Remove the engine under cover (1). assemblies. I827H1940015-01 I827H1940018-03 I827H1940021-01 I827H1940019-03 9) Remove the headlight assemblies from the front Installation fender. Refer to “Rear Carrier Removal and Installation in Section 9E (Page 9E-4)”. 2) Remove the CDI unit (1) from the bracket. I827H1940023-01 3) Remove the side covers. 4) Remove the footrest mudguards. 5) Remove the battery (2). Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-3)”. Special Tools and Equipment Recommended Service Material. The photos you see here are just a small sample of what you’ll get in our online shop manual. Why pay more for poor quality photos elsewhere? 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