Suzuki Eiger LT-F400/400F ATV Service Manual 2002–2007 (P/N 99500-43054-01E)

Suzuki’s factory service manual for the LT-F400 and LT-F400F Eiger 400 combines the 2002 base manual with model-year supplement chapters through 2007. The original cover identifies this edition as P/N 99500-43054-01E.

Bookmarks, Wiring Detail and PDF Format

Search and chapter access: PDF text search is not available. Embedded bookmarks provide access to the main service sections and model-year supplements. Small wiring labels require zooming, and some printed pages appear out of sequence.

One printable, English-language PDF contains 420 pages: 5 cover and introductory pages, 341 base-manual pages, 1 repeated Special Tools page, and 73 pages of model-year supplements.

Engine, Driveline and Electrical Service

These selected service topics outline the manual’s coverage rather than reproduce its complete contents. Additional subjects include fuel-level gauge inspection and spark-arrester maintenance.

• Engine repair: Engine removal and installation, cylinder-head and valve servicing, piston inspection, crankshaft work, crankcase separation, and camshaft timing.

• Clutch and transmission: Centrifugal clutch engagement and lock-up checks, clutch inspection, transmission disassembly, transfer gearshift servicing, and recoil-starter repair.

• Front and rear drive: Gear-case removal and reassembly, bearing and seal replacement, universal-joint inspection, shim selection, backlash measurement, and tooth-contact checks.

• Fuel system: KEIHIN carburetor removal, disassembly, cleaning, component inspection, float-height adjustment, pilot-screw settings, and fuel-hose routing.

• Oil cooling and lubrication: Compression and oil-pressure tests, oil-cooler servicing, cooling-fan inspection, temperature-switch testing, and lubrication circuit diagrams.

• Brakes and chassis: Front caliper and master-cylinder service, hydraulic bleeding, rear drum-brake repair, wheel bearings, suspension inspection, steering service, and toe-in adjustment.

• Electrical troubleshooting: Charging, starter and ignition diagnostic charts, relay and switch tests, starter-motor overhaul, wiring diagrams, and harness-routing views.

Suzuki wrote this manual for readers who already have service knowledge, mechanical skills, and the necessary tools, including special tools.

Engine Inspection and Reassembly Detail

The engine chapter identifies components that can be serviced with the engine still installed, helping you assess whether a job requires engine removal. Inspection data covers piston diameters, connecting-rod deflection, camshaft wear, internal clearances, and service limits for evaluating parts during a rebuild.

Camshaft timing illustrations and assembly views support reassembly. The clutch section identifies the centrifugal clutch shoe nut’s left-hand thread and specifies tools such as rotor holder 09930-44540 and clutch sleeve hub holder 09920-53730.

Carburetor Service and Oil Cooling

Carburetor specifications distinguish market-specific identification numbers and settings. The cleaning instructions warn that compressed air can damage the diaphragm while it remains installed.

The Cylinder Head Oil Cooling Circuit and Engine Lubrication System Chart show how oil reaches the head and internal components. Cooling-fan and temperature-switch tests address the electrical controls alongside oil-cooler and hose inspection.

The oil-pump section warns that attempted overhaul can damage the thread-locked case screw; the pump is supplied only as a complete replacement unit.

Drive-Gear Setup and Chassis Work

The driveline sections distinguish inboard bevel gears, the front differential gear case, and the rear final drive. Shim-selection tables and tooth-contact illustrations explain how gear engagement is evaluated alongside backlash.

Front differential limit: The differential assembly itself is not intended for internal disassembly. The surrounding gear-case procedures cover bearings, seals, the pinion, and the selectable-drive mechanism.

Chassis coverage separates hydraulic front disc brakes from the mechanical rear drum brake. Caliper and master-cylinder inspections extend beyond pad replacement, while steering and suspension sections cover bushings, hub bearings, and alignment checks.

Always observe standard shop safety practices, support the ATV securely during chassis work, and follow the brake-system precautions.

Fault Tracing and Model-Year Changes

Charging, starter, and ignition circuit diagrams accompany diagnostic flowcharts for a discharging battery, a starter that will not run, and missing or weak spark. The ignition tests distinguish measurements at the CDI and generator couplers, helping separate wiring faults from component faults.

Use the applicable supplements with the earlier chapters. They include K3-I and K3-II specifications, revised gearshift linkage and driveline details, updated chassis fastener requirements, and later engine-oil recommendations. The 2007 supplement addresses front brake hose routing and refers back to preceding chapters for other service information.

Examples of Valve, Oil-Fill and Bevel-Gear Specifications

The valve-clearance section specifies an intake clearance of 0.05–0.10 mm with the engine cold. Its illustrations identify the timing references used for the inspection.

The capacity data distinguishes an engine oil-and-filter change at 3.2 L from the LT-F400F front differential’s 300 ml gear-oil fill.

For internal driveline reassembly, the drive bevel gear nut is specified at 100 N·m. Separate component torque tables accompany the engine, differential, and chassis sections.