Suzuki ATV Or Quad Factory Service Manual Download Links

 

Suzuki Service Manuals 

Download Manuals Below

1985-1990 Suzuki LT230S LT230GE LT250S Repair Manual

1987-2006 Suzuki LT80 Repair Manual

1987-1992 Suzuki LT250R Repair Manual

2002-2007 Suzuki Vinson 500 Repair Manual LT-A500F

2002-2007 Suzuki Eiger 400 Repair Manual LT-F400

2002-2009 Suzuki Ozark Repair Manual LT-F250

2003-2008 Suzuki Z400 Repair Manual LT-Z400

2004-2009 Suzuki LTZ250 Repair Manual LT-Z250

2005-2007 Suzuki King Quad 700 Repair Manual LT-A700X

2006-2009 Suzuki LT-R450 Repair Manual

2006-2009 Suzuki LT-Z50 Repair Manual

2007-2009 Suzuki LTZ90 Repair Manual

2007-2009 Suzuki King Quad 450AXI Repair Manual LT-A450X

2008-2009 Suzuki King Quad 750AXI X/XP Repair Manual

2008-2009 Suzuki King Quad 400 Repair Manual LT-A400 & LT-F400

2009-2010 Suzuki King Quad 500 AXI Repair Manual LT-A500XP-XPZ

2009-2012 Suzuki Z400 Repair Manual LT-Z400

 


The Suzuki service manual downloads for the above listed models describes the service procedures for the complete vehicle. Follow the Maintenance Schedule recommendations to ensure that the all-terrain vehicle (ATV)(Quad) is in peak operating condition and the emission levels are within the standards set by the your states/county Resources Board. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the ATV or Quad vehicle.
 
All chapters in the Suzuki service manuals apply to the whole vehicle and illustrates procedures for removal & installation of components that are in detailed step-by-step fashion.
 
Most all service manual chapters start with an assembly or system illustration, diagrams, exploded parts view, quality pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of the trouble, go to the troubleshooting page for a list of causes and effects to determine the problem.

 


Related Suzuki ATV - Quad Searches:


CHAPTER 1
GENERAL INFORMATION 1

VEHICLE IDENTIFICATION
MODEL IDENTIFICATION
ENGINE DESIGNATION NUMBER
VIN IDENTIFICATION
ENGINE SERIAL NUMBER LOCATION
VEHICLE IDENTIFICATION NUMBER (VIN) LOCATION
TRANSMISSION I.D. NUMBER LOCATION
VEHICLE DIMENSIONS
GENERAL SPECIFICATIONS
GENERAL:
DETAILED:
VEHICLE INFORMATION
PUBLICATION NUMBERS
PAINT CODES
REPLACEMENT KEYS
SPECIAL TOOLS
MISC. SPECIFICATIONS AND CHARTS
CONVERSION TABLE
STANDARD TORQUE SPECIFICATIONS
SAE TAP / DRILL SIZES
METRIC TAP / DRILL SIZES
DECIMAL EQUIVALENTS
GLOSSARY OF TERMS

CHAPTER 2
MAINTENANCE

2 PERIODIC MAINTENANCE CHART
BREAK-IN PERIOD / MAINTENANCE CHART KEY
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL
50 - 100 HOUR MAINTENANCE INTERVAL
100 - 300 HOUR MAINTENANCE INTERVAL
SERVICE PRODUCTS AND LUBRICANTS
GENERAL COMPONENT LOCATION
MAINTENANCE REFERENCES
GENERAL VEHICLE INSPECTION AND MAINTENANCE
PRE-RIDE / DAILY INSPECTION
FRAME, NUTS, BOLTS, AND FASTENERS
SHIFT LINKAGE INSPECTION / ADJUSTMENT
FUEL SYSTEM AND AIR INTAKE
FUEL LINES / FUEL FILTER / VENT LINES
THROTTLE PEDAL INSPECTION
THROTTLE FREEPLAY ADJUSTMENT / CABLE ADJUSTMENT
CHOKE ADJUSTMENT
IDLE SPEED ADJUSTMENT
PILOT SCREW
PILOT SCREW ADJUSTMENT
CARBURETOR DRAINING
AIR INTAKE INSPECTION
AIR FILTER SERVICE
ENGINE
COMPRESSION AND LEAKDOWN TEST
BREATHER FILTER INSPECTION / BREATHER HOSE
FLYWHEEL HOUSING
ENGINE OIL LEVEL
ENGINE OIL AND FILTER CHANGE
OIL PUMP PRIMING PROCEDURE
VALVE CLEARANCE
INTAKE / EXHAUST VALVE CLEARANCE ADJUSTMENT
EXHAUST PIPE
TRANSMISSION / REAR GEARCASE
TRANSMISSION LUBRICATION
REAR GEARCASE LUBRICATION
COOLING SYSTEM
COOLANT LEVEL INSPECTION
RADIATOR COOLANT LEVEL INSPECTION
COOLANT STRENGTH / TYPE
COOLING SYSTEM HOSES
RADIATOR
COOLANT DRAIN / RADIATOR REMOVAL
FINAL DRIVE / WHEEL AND TIRE
WHEEL AND HUB TORQUE TABLE
CV SHAFT BOOT INSPECTION
WHEEL REMOVAL / INSTALLATION
TIRE INSPECTION / TIRE PRESSURE
ELECTRICAL AND IGNITION SYSTEM
BATTERY MAINTENANCE
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY)
BATTERY REMOVAL / INSTALLATION
BATTERY STORAGE
BATTERY CHARGING
SPARK PLUG SERVICE
ENGINE TO FRAME GROUND
STEERING AND SUSPENSION
STEERING
TIE ROD END / STEERING INSPECTION
WHEEL TOE ALIGNMENT INSPECTION
TOE ADJUSTMENT
FRONT SUSPENSION
REAR SUSPENSION
REAR SUSPENSION ADJUSTMENT
REAR SPRING ADJUSTMENT
BRAKE SYSTEM
BRAKE FLUID INSPECTION
BRAKE HOSE AND FITTING INSPECTION
BRAKE PAD / DISC INSPECTION
PARKING BRAKE CABLE ADJUSTMENT
PARKING BRAKE PAD INSPECTION

CHAPTER 3
ENGINE

ENGINE
SPECIAL TOOLS
SPECIFICATIONS
TORQUE SPECIFICATIONS
ENGINE SERVICE DATA
ENGINE SERVICE DATA
ENGINE FASTENER TORQUE PATTERNS
GENERAL ENGINE SERVICE
PISTON IDENTIFICATION
ACCESSIBLE COMPONENTS
ENGINE REMOVAL
ENGINE INSTALLATION NOTES
CRANKSHAFT STRAIGHTENING
ENGINE LUBRICATION
OIL PRESSURE TEST
OIL FLOW
OIL FLOW DIAGRAM
ENGINE EXPLODED VIEW
COOLING SYSTEM
COOLING SYSTEM SPECIFICATIONS (NON-EFI)
COOLING SYSTEM LAYOUT AND TESTING
ENGINE DISASSEMBLY
ENGINE REMOVAL
CAM CHAIN TENSIONER / ROCKER ARM /CAMSHAFT REMOVAL
CAM CHAIN TENSIONER INSPECTION
ROCKER ARM / SHAFT INSPECTION
CAMSHAFT REMOVAL
AUTOMATIC COMPRESSION RELEASE REMOVAL / INSPECTION
AUTOMATIC COMPRESSION RELEASE INSTALLATION
CAMSHAFT INSPECTION
CYLINDER HEAD REMOVAL
CYLINDER HEAD EXPLODED VIEW
CYLINDER HEAD INSPECTION
CYLINDER HEAD WARPAGE
CYLINDER HEAD DISASSEMBLY
VALVE INSPECTION
COMBUSTION CHAMBER
VALVE SEAT RECONDITIONING
CYLINDER HEAD ASSEMBLY
VALVE SEALING TEST
VALVE CLEARANCE ADJUSTMENT (INTAKE AND EXHAUST)
CYLINDER / PISTON REMOVAL AND INSPECTION
PISTON REMOVAL
CYLINDER INSPECTION
CYLINDER HONE SELECTION / HONING PROCEDURE
HONING TO OVERSIZE
CLEANING THE CYLINDER AFTER HONING
PISTON-TO-CYLINDER CLEARANCE
PISTON / ROD INSPECTION
PISTON RING INSTALLED GAP
CRANKCASE DISASSEMBLY
STARTER DRIVE REMOVAL / INSPECTION
FLYWHEEL AND STATOR REMOVAL / INSPECTION
CAM CHAIN / TENSIONER BLADE
ONE WAY VALVE
CRANKCASE SEPARATION
OIL PUMP REMOVAL / INSPECTION
OIL PUMP ASSEMBLY
COUNTER BALANCER SHAFT REMOVAL / INSPECTION
CRANKSHAFT REMOVAL / INSPECTION
CRANKCASE BEARING INSPECTION
OIL SEAL / MECHANICAL SEAL REMOVAL (ENGINE DISASSEMBLED)
CRANKCASE INSPECTION
BEARING INSTALLATION
END PLAY INSPECTION / ADJUSTMENT
CRANKSHAFT END PLAY ADJUSTMENT
COUNTER BALANCER SHAFT END PLAY ADJUSTMENT
OIL PUMP SHAFT END PLAY ADJUSTMENT
ENGINE REASSEMBLY
PUMP SHAFT OIL SEAL INSTALLATION
CRANKSHAFT / COUNTER BALANCE / OIL PUMP INSTALLATION
CRANKCASE ASSEMBLY
WATER PUMP MECHANICAL SEAL INSTALLATION
WATER PUMP MECHANICAL SEAL REMOVAL (ENGINE INSTALLED)
ONE WAY VALVE INSTALLATION
CAM CHAIN DRIVE SPROCKET INSTALLATION
TENSIONER BLADE INSTALLATION
PISTON RING INSTALLATION
PISTON INSTALLATION
CYLINDER INSTALLATION
CYLINDER HEAD INSTALLATION
CAM CHAIN / CAMSHAFT INSTALLATION
CAMSHAFT TIMING
CAMSHAFT TIMING ILLUSTRATION
CAM CHAIN TENSIONER INSTALLATION
STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION
ROCKER SHAFT / ROCKER ARM ASSEMBLY INSTALLATION
THERMOSTAT INSTALLATION
OIL PIPES
OIL PUMP PRIMING PROCEDURE

CHAPTER 4
CARBURETION SYSTEM

SPECIAL TOOLS
CARBURETOR JETTING
JETTING GUIDELINES
MIKUNI JET PART NUMBERS
MIKUNI CV CARBURETOR
EXPLODED VIEW
SYSTEM FUNCTION - CARB
VENT SYSTEMS - CARB
OPERATION - CARB
PILOT SYSTEM (IDLE AND SLOW SPEED)
STARTER SYSTEM (CHOKE OR ENRICHMENT)
FLOAT SYSTEM
MAIN SYSTEM
PILOT SCREW
CARBURETOR SERVICE
CARBURETOR REMOVAL
CARBURETOR DISASSEMBLY
CARBURETOR CLEANING
CARBURETOR INSPECTION
FLOAT HEIGHT ADJUSTMENT
NEEDLE AND SEAT LEAKAGE TEST
FUEL LEVEL
CARBURETOR ASSEMBLY
AIR BOX ASSEMBLY
EXPLODED VIEW
FUEL TANK ASSEMBLY
FUEL TANK / FUEL PUMP EXPLODED VIEW
FUEL TANK REMOVAL
FUEL TANK INSTALLATION
FUEL PUMP
REPLACEMENT
TROUBLESHOOTING
FUEL STARVATION / LEAN MIXTURE
RICH MIXTURE
IDLE TOO HIGH
IDLE TOO LOW
ERRATIC IDLE

CHAPTER 5
BODY / STEERING / SUSPENSION

TORQUE SPECIFICATIONS
SPECIAL TOOLS
BODY COMPONENT REMOVAL
REMOVAL PROCEDURES
LOWER BODY COMPONENTS
HOOD / DASH COMPONENTS
DASH INSTRUMENTS AND CONTROLS
CAB FRAME
ASSEMBLY / REMOVAL
CHASSIS / MAIN FRAME
EXPLODED VIEW
SEAT / HEAD REST
SEAT BACK / HEAD RESTS
STEERING ASSEMBLY
EXPLODED VIEW
STEERING AND SUSPENSION
EXPLODED VIEW
FRONT A-ARM
REPLACEMENT
FRONT STRUT
EXPLODED VIEW
FRONT STRUT CARTRIDGE REPLACEMENT
BALL JOINT REPLACEMENT
REAR A-ARM
REPLACEMENT
REAR STABILIZER BAR
REMOVAL / INSTALLATION
REAR CARGO BOX
CARGO BOX - PANELS
CARGO BOX - TAILGATE / BOX SUPPORT
BOX REMOVAL
BOX INSTALLATION
DECAL REPLACEMENT

CHAPTER 6
CLUTCHING

SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT SYSTEM OVERVIEW
GENERAL OPERATION
DRIVE CLUTCH OPERATION
DRIVEN CLUTCH OPERATION
PVT BREAK-IN (DRIVE BELT / CLUTCHES
MAINTENANCE / INSPECTION
OVERHEATING / DIAGNOSIS
PVT SYSTEM SERVICE
PVT SEALING, GUARD, AND DUCTING COMPONENTS
DISASSEMBLY
ASSEMBLY
DRIVE BELT
BELT DEFLECTION (TENSION)
BELT REMOVAL
BELT INSPECTION
BELT INSTALLATION
PVT BREAK-IN (DRIVE BELT / CLUTCHES)
CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCE
CLUTCH ALIGNMENT
CLUTCH OFFSET
CLUTCH CENTER DISTANCE
DRIVE CLUTCH SERVICE
SPRING SPECIFICATIONS
SHIFT WEIGHTS
EXPLODED VIEW
CLUTCH INSPECTION
CLUTCH DISASSEMBLY
SPIDER REMOVAL
ROLLER, PIN, AND THRUST WASHER INSPECTION
BUSHING SERVICE
MOVEABLE SHEAVE - BUSHING REMOVAL
MOVEABLE SHEAVE - BUSHING INSTALLATION
CLUTCH COVER - BUSHING REMOVAL
CLUTCH COVER - BUSHING INSTALLATION
CLUTCH ASSEMBLY
DRIVEN CLUTCH SERVICE
EXPLODED VIEW
CLUTCH DISASSEMBLY / INSPECTION
BUSHING SERVICE
MOVEABLE SHEAVE - BUSHING INSTALLATION
CLUTCH ASSEMBLY
TROUBLESHOOTING

CHAPTER 7
FINAL DRIVE

SPECIAL TOOLS
TORQUE SPECIFICATIONS
WHEEL, HUB, AND SPINDLE TORQUE TABLE
FRONT HUB
HUB REMOVAL / INSPECTION
HUB INSTALLATION
EXPLODED VIEW
REAR HUB / BEARING CARRIER
HUB INSPECTION / REMOVAL
HUB DISASSEMBLY / ASSEMBLY
HUB INSTALLATION
EXPLODED VIEW
REAR DRIVE SHAFT REMOVAL
OUTER CV JOINT / BOOT REPLACEMENT
INNER PLUNGING JOINT / BOOT REPLACEMENT
DRIVE SHAFT EXPLODED VIEW
INSTALLATION
REAR PROPSHAFT
REMOVAL / INSTALLATION
REAR GEARCASE
GENERAL OPERATION
OPERATION MODES
GEARCASE REMOVAL
GEARCASE DISASSEMBLY
REAR GEARCASE ASSEMBLY
REAR GEARCASE INSTALLATION
REAR GEARCASE EXPLODED VIEW

CHAPTER 8
TRANSMISSION

TORQUE SPECIFICATIONS
SHIFT LEVER
REMOVAL / INSTALLATION
SHIFT LINKAGE
INSPECTION
ADJUSTMENT
TRANSMISSION SERVICE
TRANSMISSION REMOVAL
TRANSMISSION DISASSEMBLY
TRANSMISSION ASSEMBLY
TRANSMISSION INSTALLATION
TROUBLESHOOTING
TROUBLESHOOTING CHECKLIST
TRANSMISSION EXPLODED VIEW

CHAPTER 9
BRAKES

GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
SPECIAL TOOLS
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
HYDRAULIC BRAKE SYSTEM OPERATION
BRAKE SYSTEM EXPLODED VIEW
MASTER CYLINDER
REMOVAL / INSTALLATION
FOOT BRAKE PEDAL
PEDAL REMOVAL / INSTALLATION
BRAKE BLEEDING / FLUID CHANGE
PARKING BRAKE
INSPECTION / CABLE TENSION ADJUSTMENT
PARKING BRAKE CALIPER SERVICE\
CALIPER REMOVAL
CALIPER DISASSEMBLY / INSPECTION
NEW BRAKE PAD INSTALLATION
CALIPER INSTALLATION
PARKING BRAKE DISC SERVICE
DISC INSPECTION / REMOVAL
FRONT BRAKE PADS
PAD REMOVAL / INSPECTION
PAD ASSEMBLY / INSTALLATION
BRAKE BURNISHING PROCEDURE
FRONT CALIPER SERVICE
CALIPER REMOVAL
CALIPER DISASSEMBLY
CALIPER INSPECTION / ASSEMBLY
CALIPER INSTALLATION
FRONT BRAKE DISC
DISC INSPECTION / REPLACEMENT
REAR BRAKE PADS
PAD REMOVAL / INSPECTION
PAD INSTALLATION
REAR CALIPER SERVICE
CALIPER REMOVAL
CALIPER DISASSEMBLY / INSPECTION
CALIPER ASSEMBLY / INSTALLATION
REAR BRAKE DISC
DISC INSPECTION / REPLACEMENT
TROUBLESHOOTING
BRAKES SQUEAL / POOR BRAKE PERFORMANCE
PEDAL VIBRATION
CALIPER OVERHEATS (BRAKES DRAG)
BRAKES LOCK

CHAPTER 10
ELECTRICAL

GENERAL INFORMATION
SPECIAL TOOLS / HEADLIGHT SWITCH / REAR DIFFERENTIAL SWITCH
DIFFERENTIAL SOLENOID
PARKING BRAKE SWITCH
INDICATOR LAMP CIRCUIT OPERATION / LAMP REPLACEMENT
HEADLIGHTS
HEADLIGHT ADJUSTMENT / BULB REPLACEMENT / HOUSING REMOVAL
HEADLIGHT HOUSING INSTALLATION
TAIL LIGHT / BRAKE LIGHT
LAMP REPLACEMENT
POWER DISTRIBUTION MODULE
PDM BLOCK DIAGRAM / TROUBLESHOOTING
SOLID STATE CIRCUIT BREAKERS
PDM FAN MOTOR TROUBLESHOOTING
PDM CHASSIS POWER TROUBLESHOOTING
TIMING CHECK PROCEDURE
COOLING SYSTEM
COOLING SYSTEM BREAK-OUT DIAGRAM
FAN CONTROL CIRCUIT OPERATION / TESTING / BYPASS TEST
COOLANT TEMPERATURE SENSOR TEST
DC / CDI IGNITION SYSTEM
IGNITION SYSTEM TROUBLESHOOTING
CRANKING OUTPUT TESTS USING PEAK READING ADAPTOR OR VOM
RESISTANCE TESTS / FLYWHEEL IDENTIFICATION
IGNITION SYSTEM TESTING FLOW CHART
COMPONENTS OF DC / CDI IGNITION
CHARGING SYSTEM
CURRENT DRAW - KEY OFF / “BREAK EVEN” TEST
CHARGING SYSTEM ALTERNATOR TESTS
CHARGING SYSTEM TESTING FLOW CHART
BATTERY SERVICE
BATTERY TERMINALS / BOLTS / TERMINAL BLOCK
BATTERY ACTIVATION
BATTERY INSPECTION / REMOVAL / INSTALLATION
BATTERY TESTING / OCV - OPEN CIRCUIT VOLTAGE TEST
SPECIFIC GRAVITY TEST / LOAD TEST
OFF SEASON STORAGE
CHARGING PROCEDURE
STARTER SYSTEM
TROUBLESHOOTING / VOLTAGE DROP TEST
STARTER MOTOR DISASSEMBLY
BRUSH INSPECTION / REPLACEMENT
ARMATURE TESTING
STARTER ASSEMBLY
STARTER DRIVE
STARTER SOLENOID BENCH TEST / OPERATION
STARTING SYSTEM TESTING FLOW CHART
ELECTRIC BOX LIFT ACTUATOR


TROUBLESHOOTING

Engine

Engine Turns Over But Fails to Start

• No fuel
• Dirt in fuel line or filter
• Fuel will not pass through fuel valve
• Fuel pump inoperative/restricted
• Tank vent plugged
• Carb starter circuit
• Engine flooded
• Low compression (high cylinder leakage)
• No spark (Spark plug fouled)

Engine Does Not Turn Over

• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure

Engine Runs But Will Not Idle

• Restricted carburetor pilot system
• Carburetor misadjusted
• Choke not adjusted properly
• Low compression
• Crankcase breather restricted

Engine Idles But Will Not Rev Up

• Spark plug fouled/weak spark
• Broken throttle cable
• Obstruction in air intake
• Air box removed (reinstall all intake components)
• Incorrect or restricted carburetor jetting
• ETC switch limiting speed
• Reverse speed limiter limiting speed
• Carburetor vacuum slide sticking/diaphragm damaged
• Incorrect ignition timing
• Restricted exhaust system

Engine Has Low Power

• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check compression)
• PVT not operating properly
• Restricted exhaust muffler
• Carburetor vacuum slide sticking/diaphragm damaged
• Dirty carburetor

Piston Failure - Scoring

• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated

Excessive Smoke and Carbon Buildup

• Excessive piston-to-cylinder clearance
• Wet sumping
• Worn rings, piston, or cylinder
• Worn valves, guides or seals
• Restricted breather
• Air filter dirty or contaminated

Low Compression

• Decompressor stuck
• Cylinder head gasket leak
• No valve clearance or incorrectly adjusted
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon accumulated on sealing surface)
• Rocker arm sticking

Backfiring

• ETC or speed limiter system malfunction
• Fouled spark plug or incorrect plug or plug gap
• Carburetion faulty - lean condition
• Exhaust system air leaks
• Ignition system faulty:

Spark plug cap cracked/broken

Ignition coil faulty

Ignition or kill switch circuit faulty

Ignition timing incorrect

Sheared flywheel key

• Poor connections in ignition system
• System wiring wet
• Valve sticking
• Air leaks in intake
• Lean condition

Spark Plug Fouling

• Spark plug cap loose or faulty
• Choke cable adjustment or plunger/cable sticking
• Foreign material on choke plunger seat or plunger
• Incorrect spark plug heat range or gap
• Carburetor inlet needle and seat worn
• Jet needle and/or needle jet worn or improperly adjusted
• Excessive carburetor vibration (loose or missing needle jet locating pins)
• Loose jets in carburetor or calibration incorrect for altitude/temperature
• Incorrect float level setting
• PVT system calibrated incorrectly or components worn or mis-adjusted
• Fuel quality poor (old) or octane too high
• Low compression
• Restricted exhaust
• Weak ignition (loose coil ground, faulty coil, stator, or ETC switch)
• ETC switch mis-adjusted
• Restricted air filter (main or pre-cleaner)
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
• Restricted oil tank vent

Cooling Troubleshooting
Overheating

• Low coolant level
• Air in cooling system
• Wrong type of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins or restriction to air flow, passages blocked in radiator, lines, pump, or water jacket)
• Lean mixture (restricted jets, vents, or fuel pump)
• Fuel pump output weak
• Restricted radiator (internally or cooling fins)
• Water pump failure
• Cooling system restriction
• Cooling fan inoperative or turning too slowly
• Ignition timing misadjusted
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Radiator is missing its internal diverter plate not allowing coolant to flow through entire radiator

Temperature Too Low

• Thermostat stuck open

Leak at Water Pump Weep Hole

• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)

TROUBLESHOOTING

Fuel Starvation / Lean Mixture

Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic.

• No fuel in tank
• Restricted tank vent, or routed improperly
• Fuel lines or fuel valve restricted
• Fuel filter plugged
• Carburetor vent line(s) restricted
• Plugged or restricted inlet needle and seat screen or inlet passage
• Clogged jets or passages
• Float stuck, holding inlet needle closed or inlet needle stuck
• Float level too low
• Fuel pump inoperative
• Air leak at impulse line
• Restricted impulse line (kinked, pinched)
• Intake air leak (throttle shaft, intake ducts, airbox or air cleaner cover)
• Ruptured vacuum slide diaphragm, Vacuum slide stuck closed or sticky
• Improper spring
• Jet needle position incorrect
• Incorrect pilot screw adjustment

Rich Mixture

Symptoms: Fouls spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine runs rough/ misses, poor performance, bog, engine loads up, backfire.

• Air intake restricted (inspect intake duct)
• Air filter dirty/plugged
• Choke plunger sticking, incorrectly adjusted choke
• Choke cable binding or improperly routed
• Incorrect pilot air/fuel screw adjustment
• Faulty inlet needle and seat
• Faulty inlet needle seat O-Ring
• Float level too high
• Poor fuel quality (old fuel)
• Loose jets
• Worn jet needle/needle jet or other carburetor parts
• Dirty carburetor (air bleed passages or jets)
• Weak or damaged vacuum piston return spring
• Fouled spark plug

Idle Too High

• Idle adjusted improperly/idle mixture screw damaged
• Sticky vacuum slide
• Throttle cable sticking, improperly adjusted, routed incorrectly
• Choke cable sticking, improperly adjusted, routed incorrectly
• Plugged or restricted idle jet

Idle Too Low

• Choke cable bending or incorrectly adjusted
• Idle speed set incorrectly
• Idle mixture screw misadjusted or damaged
• Belt dragging
• Ignition timing incorrect
• Worn jet needle/needle jet
• Plugged or restricted idle jet

Erratic Idle

• Choke cable bending or incorrectly adjusted
• Throttle cable incorrectly adjusted
• Air leaks, dirty carburetor passages (pilot circuit)
• Pilot mixture screw damaged or adjusted incorrectly
• Tight valves
• Ignition timing incorrect
• Belt dragging
• Dirty air cleaner
• Engine worn
• Spark plug fouled
• Idle speed set incorrectly (speed limiter)
• Worn jet needle/needle jet
• Plugged or restricted idle jet

TROUBLESHOOTING

Troubleshooting Checklist

Check the following items when shifting difficulty is encountered.
• Idle speed adjustment
• PVT alignment
• Transmission oil type/quality
• Transmission torque stop adjustment (where applicable)
• Engine torque stop adjustment (where applicable)
• Drive belt deflection
• Loose fasteners on rod ends
• Loose fasteners on selector box
• Worn rod ends, clevis pins, or pivot arm bushings
• Linkage rod adjustment and rod end positioning
• Shift selector rail travel
• *Worn, broken or damaged internal transmission components

NOTE: To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the transmission by disconnecting linkage rod from transmission bellcrank. Manually select each gear range at the transmission bellcrank, and test ride vehicle. If it functions properly, the problem is outside the transmission. If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear.

TROUBLESHOOTING

Brakes Squeal / Poor Brake Performance

• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator

Pedal Vibration

• Disc damaged
• Disc worn (runout or thickness variance exceeds service limit)

Caliper Overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Parking brake lever incorrectly adjusted
• Brake pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes

Brakes Lock

• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components

Ignition System Troubleshooting

No Spark, Weak or Intermittent Spark

• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high tension lead
• Related wiring loose, disconnected, shorted, or corroded
• Faulty ignition switch
• Wire harness or connections wet, corroded.
• Poor ignition coil ground (e.g. coil mount loose or corroded)
• Faulty stator (measure resistance of all ignition related windings)
• Incorrect wiring (inspect color coding in connectors etc.)
• Faulty ignition coil winding (measure resistance of primary and secondary)
• Worn magneto (RH) end Crankshaft bearings
• Sheared flywheel key
• Flywheel loose or damaged
• Trigger coil air gap too wide (where applicable) - should be .016 - .030" (.4 - .75 mm)
• Excessive crankshaft runout on magneto (RH) end - should not exceed .0024”
• Faulty CDI module

Troubleshooting

Starter Motor Does Not Run

• Battery discharged - Low specific gravity
• Loose or faulty battery cables or corroded connections (see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be rotated easily)

Starter Motor Turns Over Slowly

• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see Voltage Drop Test)
• Engine problem - seized or binding (can engine be rotated easily)
• Faulty or worn brushes in starter motor

Starter Motor Turns - Engine Does Not Rotate

• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel


Common Suzuki ATVs Searches:

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