Suzuki LT-V700F / Twin Peaks 700 2004–2005 ATV Service Manual (P/N 99500-46051-01E)

Suzuki factory Service Manual P/N 99500-46051-01E, 2nd Edition, October 2004, covers the 2004 Suzuki LT-V700FK4 and 2005 Suzuki LT-V700FK5, sold as the LT-V700F Twin Peaks 700 4x4. It covers the carbureted, liquid-cooled SOHC V-twin, belt converter, and selectable shaft-drive system.

PDF Search, Bookmarks, and Diagram Detail

Search and navigation: Body text and service tables are searchable, but labels within the main wiring diagrams are not. Embedded bookmarks cover the chapters and many subsections; some entries incorrectly return to the cover. Small labels in the main wiring diagrams are readable when enlarged.

One printable English PDF contains 508 pages, including 18 opening pages with the cover, introductory material, and tool-conversion lists, and two closing publication/cover pages. These pages are included in the total.

V-Twin Overhaul, Converter Service, and Electrical Diagnosis

The following selected service topics show the manual’s repair coverage. Additional subjects include recoil-starter inspection and spark-arrester cleaning.

• Engine and transmission repair: Step-by-step engine removal and installation, crankcase separation, crankshaft and connecting-rod service, cylinder and piston work, valve-guide and seat repair, and internal transmission inspection.

• Converter and engine brake: Drive-belt inspection and deflection adjustment, converter-cover service, drive and driven pulley overhaul, spider-shoe clearance adjustment, installation-length checks, and actuator-lever inspection.

• Fuel, cooling, and lubrication: Carburetor synchronization and overhaul, cooling-system pressure testing, water-pump seal replacement, thermostat inspection, and oil-pressure, pump, screen, and relief-valve service.

• Final drive and chassis: Output-bevel-gear repair, propeller-shaft and axle service, variable-differential controls, LSD clutch-torque testing, final-gear-case overhaul, wheel alignment, suspension, and steering work.

• Brake service: Front master-cylinder and caliper disassembly, brake-line bleeding, hose and pad replacement, disc wear and runout checks, rear cable adjustment, and internal wet-brake assembly.

• Electrical fault tracing: Charging, ignition, starter, vehicle-down sensor, fan, fuel-pump, meter, switch, and lighting tests, plus actuator troubleshooting and drive-belt failure-mode memory clearing.

• Factory service references: Maintenance schedules, component-specific torque and locking-agent tables, lubricant specifications, pressure-test data, clearances, service limits, shim tables, electrical test values, and exploded assembly views.

Written primarily for trained mechanics in a properly equipped shop, the manual also supports owners with mechanical knowledge and proper tools for basic maintenance and repair. Internal overhaul and electrical fault isolation require the relevant workshop skills and measuring equipment.

K4/K5 Differences and Base-Manual Terminology

Suzuki compiled this publication from the Kawasaki KVF700 service manual. The opening cross-reference maps KVF700-A1/A2 and B1/B2 terminology to the Suzuki K4/K5 models and supplies Suzuki equivalents for materials and special tools. Some photographs may differ in detail from the actual LT-V700F.

Separate K4/K5 information addresses rocker-arm service, rocker-shaft specifications and fasteners, cam-chain intermediate-shaft retention, valve-spring identification, oil-pump chain guides, engine-brake actuator-lever part numbers, and drive-pulley assemblies. Cooling-hose routing also differs, as does the K4 radiator-fan fuse versus the K5 breaker.

Retained Kawasaki model and VIN-break references belong to the base manual; they do not establish a Suzuki VIN range.

Engine Inspection and Carburetor Service

Rocker-case and camshaft procedures cover cam-chain timing and the KACR automatic compression-release mechanism. Internal inspection includes compression testing, shaft runout, bearing clearances, wear limits, and transmission shift-mechanism checks.

The paired Keihin CVKR-32 carburetors have procedures for fuel-level measurement, synchronization, separation, joining, cleaning, and inspection. High-altitude information links carburetor jet selection with converter ramp-weight and spring-spacer configurations. This is carburetor service information, rather than EFI diagnosis.

Cooling coverage extends to radiator-cap testing, fan-switch checks, coolant-filter cleaning, and water-pump mechanical-seal replacement. The lubrication chapter includes the Engine Oil Flow Chart and explains which components to investigate when oil pressure is above or below specification.

Converter Setup and Repair Precautions

Installation-length measurements distinguish the appropriate pulley covers and engine-brake actuator levers. The manual includes model-specific replacement tables alongside the inspection procedures.

The converter chapter warns that switching the ignition from ON to OFF with the cover removed can trigger incorrect engine-brake learning. It also identifies the drive-pulley bolt as left-hand threaded and warns that incorrect holder placement can damage the cover’s threaded holes.

Final-Drive Adjustment and Suspension Limits

Final-drive procedures cover backlash, tooth-contact patterns, and shim selection for the output bevel gears and front/rear gear cases. Incorrect backlash or tooth contact can cause gear noise and damage.

Chassis procedures address hubs, suspension arms, the swingarm, steering stem, knuckles, and tie rods. Suspension coverage includes spring replacement and rear preload adjustment; the front shock absorbers are sealed units inspected externally, rather than internally rebuilt. Front-axle boot service is included, but the outboard joint itself cannot be disassembled.

Fault Charts, Wiring References, and Special Tools

Actuator diagnosis combines failure-indicator patterns with numbered tests for the 2WD/4WD actuator, engine-brake actuator, controller, speed sensor, shift switch, and forward/reverse sensor. This links an alternating 2WD/4WD indication to specific circuit and component checks before replacement decisions are made.

Named references include the Coolant Flow Chart, Ignition System Troubleshooting chart and circuit, Actuator Control System Troubleshooting and circuit, Drive Belt Failure Detection System Circuit, and two-page Wiring Diagram. Electrical parts-location views and cable, wire, and hose-routing drawings support connector tracing and reassembly.

Suzuki tool-conversion lists include fuel level gauge 09913-14511, compression gauge 09915-64512, valve spring compressor 09916-14510, and drive-pulley measurement tool K5700-11498.

Several diagnostic procedures require the ATV to be securely supported with the wheels free to turn. Follow the manual’s brake-fluid, high-voltage ignition, rotating-pulley, lifting, and electrical-isolation precautions before starting repair work.

Examples of Valve-Clearance and Carburetor Test Data

For both cylinders, the manual specifies cold valve clearances of 0.10–0.15 mm at the intake valves and 0.20–0.25 mm at the exhaust valves. These values apply with the engine at room temperature.

Carburetor synchronization is checked at idle, with a specified intake-vacuum difference of less than 2.7 kPa between the carburetors.