repair manual for suzuki ltz400 2004
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repair manual for suzuki ltz400 2004If modifi- If you do not have the proper knowledge and tools, ask your authorized If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them.Terminal voltage check with a low battery voltage will lead to erroneous diagnosis. 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 or equivalent. DC: Direct Current Ex. SAE term (Abbreviation): Former SUZUKI term DMC: Dealer Mode Coupler. SUZUKI LT-Z400 (2009-model) Right side “B” I933H1010004-01 Fuel and Oil Recommendation B933H20101006 Fuel (for USA and Canada) Water other than distilled water JASO.Suzuki recommends the use of SAE 10W-40 engine oil.Code Country or area Effective frame No.Mode select switch coupler 16. GP switch 13. Fuel level gauge (Thermistor) 17. Fuel pump 21. CKP sensor 14. IAP sensor 18. ECT sensor 22. Generator 15. TP sensor 19. Starter motor. Dimensions and dry mass Item Specification Overall length 1 830 mm (72.0 in) Overall width 1 190mm (46.9 in) Overall height 1 145 mm (45.1 in) Wheelbase 1 245 mm (49.0 in) Front track. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience. Air cleaner element cleaning Every 3 months Inspect and clean the air cleaner element in the following procedures: 1) Remove the air cleaner element. Inspect valve clearance Initially at 1 month and every 6 months thereafter Inspection Tappet clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing. These figures the cam. If the clearance is out of specification, indicate the thickness of the shim, as illustrated.http://www.nameadvance.com/userfiles/cytospin-manual.xml
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Refer to “Engine Top Side Assembly in Section 1D (Page 1D- 20)”. 7) Rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement, then check the clearance again to confirm that it is within the specified range. B933H20206012 Replace engine oil 4) Install the boot correctly. Initially at 1 month and every 6 months thereafter Replace oil filter Initially at 1 month and every 6 months thereafter Oil should be changed while the engine is warm. If the filter is installed improperly, serious engine damage may result. 1) Drain engine oil as described in the engine oil replacement procedure. B933H20206014 Inspect clutch lever play NOTE Initially at 1 month and every 6 months thereafter Face the triangle mark “A” on the cap Inspect and adjuster the clutch lever play “a”. CAUTION Replace the gasket with a new one.Radiator Hoses Replacement CAUTION Replace radiator hoses. SUZUKI recommends to use this standard drive chain as a replacement. “A” I933H1020041-01 Rear I933H1020040-01. Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased. In this case, “FI” light is lighted in the indicator panel and vehicle can run. The injection signal is stopped, when the crankshaft position sensor signal, tip-over sensor signal, ignition signal, injector signal, fuel pump signal or ignition switch signal is not sent to ECM. Circuit Terminal No.Use of mode select switch 4) Turn the special tool’s switch ON. NOTE 5) Check the DTC to determine the malfunction part. Refer to “DTC Table (Page 1A-18)”. B933H21104003 NOTE 5) Check the DTC to determine the malfunction part. The malfunction code is memorized in the Refer to “DTC Table (Page 1A-18)”. I705H1110006-01 I705H1110008-01 8) Close the SDS tool and turn the ignition switch OFF. 9) Disconnect the SDS tool and install the left side cover.http://www.priom.com.br/userfiles/cytovision-user-manual.xml After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time. XXX kPa Check the engine coolant temperature.XXX kPa I933H1110077-01 Example of trouble Three data; value 3 (current data 3), value 2 (past data 2) and value 1 (past data 1); can be made in comparison by showing them in the graph. Fail-Safe Function Table B933H21104007 FI system is provided with fail-safe function to allow the engine to start and the vehicle to run in a minimum. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model:. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS. Go to Step 2. Replace the CKP sensor with a new one. 2) Check the CKP sensor coupler for loose or poor contacts. If OK, then measure the CKP sensor resistance. I933H1110013-01 3) Disconnect the CKP sensor coupler and measure the resistance. Refer to “ECM Removal Go to Step 2. Y wire shorted to VCC and Installation in Section 1C (Page 1C-2)”.Go to Step 2. Y or R wire open, or Y wire shorted to ground. 5) Check the continuity between Y wire and ground. If sound is not heard from the tester, the circuit condition is OK. If OK, then check the ECT sensor lead wire continuity. I933H1110039-01 3) Disconnect the ECT sensor coupler. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-12)”. If OK, then check the IAP sensor lead wire continuity. I933H1110027-01 3) Disconnect the IAP sensor coupler. Refer to “IAP Sensor Removal ground, or poor “6”, sensor with a new one. If OK, then check the IAT sensor lead wire continuity. Go to Step 2.https://www.becompta.be/emploi/boss-br-900-cd-manual-espa-ol Replace the TO sensor with a new one. Refer to 2) Remove the left side cover. Refer to “Exterior Parts “TO Sensor Removal Removal and Installation in Section 9D (Page 9D-4)”. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”. DTC “C31” (P0705): GP Switch Circuit Malfunction B933H21104017 Detected condition and possible cause Detected condition Possible cause No gear position switch voltage. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-12)”.Step Action 1) Turn the ignition switch OFF. Refer to “Headlight Removal and Installation in Section 9B (Page 9B-2)”. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-12)”.At this time, if an operation sound is heard from the cooling fan relay and cooling fan motors are operated, the function is normal. I933H1110080-02 5) Click the “Stop” (3) to check the operation properly. I933H1110081-02 Specifications Service Data. Schematic and Routing Diagram Oil Return Tank Hose Routing Diagram B933H21202001 “ a ” Forward “A” “B”. If it is 3) Disconnect the breather hoses (1).Component Location Engine Electrical Components Location B933H21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Refer to “Battery Removal and Installation in Section 1J (Page 1J- IAP Sensor Removal and Installation 12)”. Refer to “Exterior Parts Removal 1) Drain engine coolant. Refer to “Cooling System and Installation in Section 9D (Page 9D-4)”. Inspection in Section 0B (Page 0B-13)”. Malfunction in Section 1A (Page 1A-52)”. Inspect the ECT sensor in the following procedures: TO Sensor Removal and Installation 1) Remove the ECT sensor. B933H21404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-7)”. Compression Pressure Check B933H21404002 The compression pressure reading of a cylinder is a good indicator of its internal condition. Refer to “Clutch Parts Refer to “Clutch Removal in Refer to “Clutch Installation Clutch plates Inspection in Section 5C.https://domoticaaplicada.com/images/carver-pxm-450-manual.pdf Throttle Cable Removal and Installation B933H21406005 5) Remove the air cleaner box (5) by removing the air Removal cleaner box mounting bolts. 1) Remove the fuel tank and fuel tank lower cover. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. Removal Pay attention to the following points: 1) Remove the front fender.B933H21406011 Refer to “Throttle Body Inspection in Section 0B CAUTION (Page 0B-10)”. After disconnecting the throttle cable, do not snap the throttle valve from full open to full Throttle Body Removal and Installation close. CAUTION Replace the O-ring with a new one. I933H1140030-01 CAUTION Never remove the throttle valve (9). B933H21406015 Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is CAUTION sequentially explained in the following steps: Never turn the L-joint (6) while pushing it. Refer to “Exterior Parts Removal 12) Disconnect the fuel pump lead wire coupler (9) and and Installation in Section 9D (Page 9D-4)”. I933H1140046-01 13) Disconnect the ECT sensor coupler (11). Refer to “Gear Position (GP) Switch Removal and 22) Remove the gear shift lever (23) and spacers. Installation in Section 5B (Page 5B-12)”. NOTE Mark the gearshift shaft head at which the gearshift lever slit set for correct. Refer to “Oil Return Tank Cylinder head Removal and Installation in Section 1B (Page 1B-2)”. 1) Remove the exhaust pipe (1).Cylinder 1) Disconnect the breather hose (1).When installing the cylinder head (3), keep NOTE the cam chain taut. Refer to “Throttle Body specification, tighten the cylinder head bolts (4) and Removal and Installation (Page 1D-9)”.Starting from the roller pin that is faces and camshaft journal holders. NOTE NOTE Make sure that the “UP” mark “A” comes to Camshaft journal holders marked “EX”. Move the automatic decompression weight by hand to inspect if it is operating smoothly.Refer to “Engine B933H21406021 Top Side Disassembly (Page 1D-17)”. The cam chain tension adjuster is maintained at the 4) Remove the cam chain guide No. 2 (2). proper tension by an automatically adjusted. Refer to “Clutch B933H21406024 Installation in Section 5C (Page 5C-9)”. Inspect the cam chain tensioner in the following 8) Reinstall the cylinder head. Refer to “Engine Top procedures: Side Assembly (Page 1D-20)”. CAUTION To prevent damage of the tappet sliding surface with the special tool, use the sleeve. CAUTION Use the new O-ring (4) to prevent engine coolant leakage. Support the valve using V-blocks, as shown in the figure, and check its runout using the dial gauge.Replace any Measure the valve stem O.D. using the micrometer. If it valve with an abnormally worn face. The thickness of the is out of specification, replace the valve with a new one.A 1) Visually check for valve seat width on each valve weakened spring results in reduced engine power output face. If the valve face has worn abnormally, replace and often accounts for the chattering noise coming from the valve. Refer to “Engine Top Side Disassembly (Page 1D-17)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remove it. If any of the clearances exceed the limit, replace both the piston and piston “C” “D” rings.Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. Remove the starter torque limiter (1). I933H1140153-01 Clutch Remove the clutch component parts (1). Refer to “Clutch I933H1140150-01 Removal in Section 5C (Page 5C-7)”. NOTE Do not drop the snap ring (1) into the crankcase.Gear position switch 1) Remove the gear position switch (1). 2) Remove the switch contacts (2) and springs (3). Refer to “Generator Removal and Installation in Section 1J (Page 1J-5)”. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling. Oil pump idle gear shaft Install the oil pump idle gear shaft (1) and new snap ring (2). CAUTION The removed snap ring (16) must be replaced with a new one.Refer to “Generator Removal and Installation in Section CAUTION 1J (Page 1J-5)”. Replace the new O-rings with new ones. This Section 1E (Page 1E-4)”. If the 1) Separate the crankcase, left and right. Refer to runout exceeds the service limit, replace the crankshaft “Engine Bottom Side Disassembly (Page 1D-41)”. Refer to “Clutch Installation in Section 5C (Page 5C-9)”. Schematic and Routing Diagram Engine Oil Hose and Pipe Routing Diagram B933H21502001 “A” I933H1150035-03 1. Engine oil tank 5. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Incorrect engine oil. Change. CAUTION Use a new gasket to prevent oil leakage.I933H1150007-01 3) Install the oil sump filter. Refer to “Oil Sump Filter Removal and Installation (Page 1E-4)”. I933H1150009-02 5) Remove the pin (4) and washer (5). Oil Pump Components 6) Remove the oil pump assembly (6). B933H21506009 Inspect the oil tank oil leaks. If any defects are found, replace the oil tank with a new one. Refer to “Oil Tank Removal and Installation (Page 1E-9)”. I933H1150020-01 I933H1150017-01 Engine Oil Pipe Removal and Installation. Install the engine oil pipes in the reverse order of 6) Remove the engine oil pipes (3). removal. Pay attention to the following points: Apply engine oil to the O-rings. CAUTION Replace the O-rings with new ones to prevent oil leakage. Install the oil tank in the reverse order of removal.Make sure that the oil pipes are not clogged. If it is clogged, clean the oil passage using a wire of the proper size and compressed air. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace. Refer to Inspect the radiator cap in the following procedures: “Exterior Parts Removal and Installation in Section 1) Remove the radiator cap. Refer to “Cooling Circuit 9D (Page 9D-4)”. I933H1160007-03 4) Disconnect the cooling fan motor lead wire coupler (3). I933H1160011-02 Installation Install the radiator in the reverse order of removal. B933H21606005 Removal 1) Remove the side covers, left and right. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”. 2) Disconnect the cooling fan motor lead wire coupler (1) and cooling fan motor fuse box coupler (2). Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”. Inspect the radiator reservoir tank in the following 2) Apply thread lock to the reservoir tank mounting procedures: bolts and tighten them. 1) Remove the left side cover.Removal CAUTION NOTE Replace the O-rings with new ones.Disassembly 1) Remove the water pump cover (1). I933H1160039-01 5) Remove the oil seal (6). NOTE If there is no abnormal condition, the oil seal removal is not necessary. Visually inspect the oil seal for damage, with particular attention given to the lip. Replace the oil seal that shows indications of leakage. I933H1160048-01 Water Pump Related Parts Inspection I933H1160050-01. The fuel is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe. Clean or replace. hard to start (No fuel Defective fuel pump. Replace. B933H21706002 4) Place the measuring cylinder and insert the fuel Turn the ignition switch ON and check that the fuel pump hose end into the measuring cylinder.Refer to “DTC “C41” (P0230): FP Relay Circuit Malfunction in Section 1A (Page 1A-63)”. Fuel Hose Inspection B933H21706005 Refer to “Fuel Line Inspection in Section 0B (Page 0B- 11)”. B933H21706010 8) Place a rag under the fuel feed hoses (7) and fuel Removal hose (8). WARNING 9) Disconnect the fuel feed hoses (7) and fuel hose (8). 10) Remove the fuel tank. Refer to “Fuel Valve Removal and Installation (Page 1G-10)”. 5) Reinstall the fuel tank. Refer to “Fuel Tank Removal and Installation (Page 1G-9)”. 2) Disconnect the injector coupler (1). I933H1170022-02 CAUTION 3) Remove the fuel delivery pipe (2) with the injector. I933H1170031-01 Installation 1) Connect the fuel feed hose (1) to the fuel pump until it locks securely (a click is heard). Engine stop switch Ignition Fuse sensor coil Ignition switch Fuse Battery sensor sensor switch I933H1180001-02 Ignition System Components Location B933H21802002 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections. Removal WARNING Ignition Coil and Plug Cap Inspection B933H21806003 The hot engine can burn you. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- Engine Stop Switch Inspection 4)”. Engine stop Ignition Starter switch switch relay Fuse (10A) Fuse (20A) Starter motor Starter button Clutch switch I933H1190001-01 Component Location. Troubleshooting Step Action 1) Shift the transfer to neutral. Go to step 2. Go to step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”. Refer to Removal “Wiring Harness Routing Diagram in Section 9A 1) Turn the ignition switch OFF and disconnect the (Page 9A-3)”. Carbon brush Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. Removal If the commutator surface is discolored, polish it with 1) Turn the ignition switch OFF position. Refer to “Starter Relay Inspect the gear position switch in the following Removal and Installation (Page 1I-6)”. Refer to “Generator Removal Removal and Installation in Section 1J (Page 1J-5)”. Starter torque limiter 1) Remove the starter torque limiter cover (1). Installation Install the starter clutch in the reverse order of removal.Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 1) Remove the starter driven gear. Diagnostic Information and Procedures Charging System Symptom Diagnosis B933H21A04001 Condition. Replace the battery.B933H21A06004 Removal 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-11)”. 2) Disconnect the reverse lock release cable. (for transmission side) Refer to “Gear Position (GP) Switch Removal and Installation in Section 5B (Page 5B-12)”. Install the generator in the reverse order of removal.Use CAUTION nonflammable cleaning solvent to wipe off oily or greasy matter to make these surfaces completely dry. Use a new gasket to prevent oil leakage. Refer generator cover bolts.NOTE If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.Refer to “Battery Installation Removal and Installation (Page 1J-12)”. Install the battery in the reverse order of removal. Pay attention to following point: CAUTION Never use anything except the specified battery. 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. Removal 1) Loosen the muffler connecting bolt (1). I933H11B0004-07 I933H11B0001-01 7) Remove the exhaust pipe gasket (5). 2) Remove the muffler (2) by removing the mounting bolts. Exhaust System Inspection B933H21B06003 Inspect the exhaust pipe connection and muffler NOTE connection for exhaust gas leakage and mounting When installing new connector, remove the condition. If any defect are found, replace the exhaust old sealer from the exhaust pipe and muffler. Special Tools and Equipment Recommended Service Material B933H21B08001 Material SUZUKI recommended product or Specification Note Muffler seal MUFFLER SEAL LOCTITE 5920 — (Page 1K-4) 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. Snap ring 23. Front hub plate 2. Upper wishbone arm 13.If (Softest) (Stiffest) any damages are found, replace the front shock 288.5 mm 295.5 mm 281.5 mm “a” absorber with a new one. (11.36 in) (11.63 in) (11.08 in) Refer to “Front Brake and Installation (Page 2B-6)”. Inspect the steering knuckle for damage. If any defects are found, replace the steering knuckle with a new one. Pay attention to the following points. I933H1220056-01 I933H1220059-03 Inside. B933H22306008 NOTE Removal The conical side of washer (2) faces outside. 1) Remove the cotter pin (1) and loosen the hub nut (2). Refer to “Rear Suspension Assembly Construction (Page 2C-2)”. Removal 1) Remove the cushion lever cover (1). Dust seal 1) Remove the collars and spacers. If 1) Remove the dust seals. Refer to “Cushion Lever any defect is found, replace them with new ones.Install the swingarm in the reverse order removal.Removal NOTE 1) Remove the swingarm. Chain buffer Inspect the chain buffer for wear and damage.Do not reuse the valve which has been once 2) After removing the air valve cap, release the tire removed. CAUTION Before inflating the tire, check the MAXIMUM Wheel OPERATING PRESSURE rating of the tire. Inspect the sealing portion of the rim for contamination This is indicated by a “. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Suzuki recommends to use this standard drive chain as a replacement. Removal 1) Remove the engine sprocket cover (1). I933H1310004-01 5) Remove the engine sprocket (6) with drive chain. Install the rear sprocket in the reverse order of removal.Rear sprocket flange Inspect the rear sprocket flange for damage and wear of spline. NOTE When positioning the joint plate (10) on the tool, its stamp mark must face the joint plate. Refer to “Drive Chain Inspection and Adjustment in Section 0B (Page 0B-15)”. “a” I649G1310036-03 Drive Chain Roller Construction B933H23106008 I933H1310048-02 1. Drive chain roller 3. Replace the drive chain control Removal roller bearings if there is anything unusual. Refer to 1) Remove the rear sprocket. NOTE The rear axle housing bolts are different length. “A” I933H1310030-01 7) Remove the snap ring (6), washer (7) and nut (8).B933H23106013 Removal 1) Remove the rear axle housing. Do not use or mix different types of fluid, such as silicone-based or petroleum-based. Clean disc and pads. Worn disc. Refer to “Exterior Parts Brake Hose Inspection Removal and Installation in Section 9D (Page 9D- B933H24106006. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- Tightening torque 4)”. Refer to “Brake Fluid Replacement “C” (Page 4A-8)”. 2) Place a rag underneath the brake hose union bolt (1) on the master cylinder to catch any spilt brake fluid. 3) Remove the brake hose union bolt (1) and “B”. Disassembly 1) Remove the reservoir cap (1) and diaphragm (2). I933H1410028-03 Assembly Assemble the master cylinder in the reverse order of. B933H24106015 Removal 1) Remove the right footrest mud guard. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-4)”. Refer to “Brake Fluid Replacement (Page 4A-8)”.Removal 1) Remove the fuel tank cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D- 4)”. Refer to “Air Bleeding from Brake Fluid Circuit (Page 4A-6)”. Rubber parts Inspect the primary cup, secondary cup and dust boot for wear or damage. Refer to “Brake System Inspection in Section 0B 6) Install the new brake pads. (Page 0B-17)”. CAUTION Front Brake Pad Replacement Replace the brake pads as a set, otherwise B933H24206003 braking performance will be adversely 1) Remove the front wheel assembly. If any damage is found, damage. If any damage is found, replace it with a new replace the piston with a new one. Refer to “Front 1) Remove the front wheel assembly. Rear Wheel Removal and Installation in Section 2D 2) Inspect the brake disc for damage or cracks and (Page 2D-2)”. Refer to “Brake System Inspection in Section 0B (Page 0B-17)”. NOTE When removing the pads, push the piston all Rear Brake Pad Replacement the way into the brake caliper. B933H24306004 8) Apply a small quantity of thread lock to the brake Removal caliper mounting bolts (4). 1) Drain brake fluid. Refer to “Parking Brake Removal and Installation in Section 4D (Page 4D- 1) Apply a small quantity of thread lock to the brake 2)”.NOTE 7) Force out the piston by pushing the piston pin (7). If there is no abnormal condition, the caliper holder pin removal is not necessary. CAUTION 6) Remove the rear brake disc plate housing (3) from the rear axle. The removed stopper ring must be replaced with a new one. Replace the brake disc if the thickness is less than the service limit or if defect is found.Parking Brake Cable Removal and Installation B933H24406002 Removal 1) Loosen the parking brake cable adjuster lock-nut (1) while holding the adjuster (2). I933H1440009-01 I933H1440012-03 5) Set the parking brake shaft (6) in neutral position by 10) Adjust the parking brake. Replace countershaft. B933H25206002 6) Disconnect the reverse lock cable (7) by remove the Removal rotor (8). 1) Remove the reverse lock release knob (1) from the front fender. I933H1520022-01 I933H1520019-02 2) Install the reverse idle gear (3) and shaft (4). 3) Install the wave washer (5) and washer (6).Pay attention to the following points: B933H25206006 Refer to “Transmission Removal and Installation (Page 5B-5)”. Replace the bearing if there is anything unusual. I649G1520056-03 Gearshift fork groove width Measure the gearshift fork groove width using the. Refer to Inspect the oil seal lips for wear or damage. If any “Transmission Removal and Installation (Page 5B- defects are found, replace the oil seal with new ones. Installation CAUTION The removed oil seals and bearings must be replaced with new ones. 1) Install the bearings using the special tool.I933H1520044-02 7) Install the oil seal retainer (4). I933H1520042-01 3) Install the bearing retainers (2). I933H1520058-01 6) Remove the gearshift pawl lifter (8) and gearshift cam driven gear (9). Inspect the gearshift shaft oil seal lip for damage or 4) Remove the bearing (2) with the special tools. wear. If any defect is found, replace the oil seal with a Special tool new one. B933H25306002 5) Remove the clutch cable bracket (7) and disconnect Refer to “Clutch Inspection and Adjustment in Section the clutch cable (8). 0B (Page 0B-13)”. Clutch Cable Removal and Installation B933H25306003 Removal 1) Loosen the cable adjuster lock-nut (1) and adjuster. Removal 1) Disconnect the clutch cable (1) and parking brake cable (2). Install the clutch lever in the reverse order of removal.Pay attention to the following points: B933H25306006 Removal CAUTION 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D The removed bearing and oil seal must be (Page 1D-13)”. Refer to “Engine Oil NOTE and Filter Replacement in Section 0B (Page 0B-11)” and “Cooling System Inspection in Section 0B Loosen the clutch spring set bolts little by (Page 0B-13)”. I933H1530027-01 9) Remove the spring washer (7) and its seat (8). I933H1530031-01 14) Remove the washer (11) and clutch sleeve hub (12). B933H25306009 NOTE 1) Install the spacer (1). The concave side of clutch sleeve hub nut (6) 2) Apply engine oil to the spacer (1) and bushing of the faces inside. Three kinds of the drive plate (No. 1, No. 2 and No. 3) are equipped in the clutch system, they can be distinguished by the inside diameter “D”. Refer to “Water Hose Routing Diagram in Section 1F 18) Tighten the clutch spring set bolts securely in (Page 1F-3)”.Refer to “Rear Brake 19) Install the gasket (17) and the dowel pins. Move the inner race by finger and inspect for smooth movement. If any defects are found, replace the Clutch drive plate claw width clutch release bearing with a new one. Removal 1) Remove the throttle lever case (1). I933H1620005-03 6) Remove the left grip (6) and starter lever (7). I933H1620016-01 6) Disconnect wheel side tie-rod ends using the special tool. I933H1620020-01 10) Draw out the steering shaft (9).CAUTION CAUTION Replace the O-rings (8) with new ones.Refer to “Handlebars Removal Tie-rod end and Installation (Page 6B-3)”. Inspect the tie-rod ends for smooth movement.Inspect the steering shaft bushing for wear or damage. If 4) Check that the distance “C” and “D” are equal, as any defects are found, replace the steering shaft bushing shown. Component Location Electrical Components Location B933H29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-7)”. Refer to “Exterior Parts B933H29206002 Removal and Installation in Section 9D (Page 9D- Removal 4)”. 1) Remove the headlight bulb. Refer to “Headlight Bulb 2) Remove the headlight adjusting bolt (1). Replacement (Page 9B-2)”. I933H1920006-04 3) Tighten the headlight adjusting bolt (1). Rear Combination Light Components B933H29206005 I933H1920015-02. B933H29206008 If any abnormality is found, replace the handlebar Inspect the dimmer switch in the following procedures: switch assembly with a new one. 1) Disconnect the headlight coupler (1). Refer to Refer to “Handlebars Removal and Installation in “Headlight Bulb Replacement (Page 9B-2)”. If the bulb remains lit, replace the unit terminals.