2008–2009 Suzuki KingQuad 400 LT-A400/F, LT-F400/F Service Manual (P/N 99500-43072-01E)

• Coverage and document scope: Covers the 2008 K8 LT-A400/LT-A400F automatic models and LT-F400/LT-F400F manual models. The 516-page PDF contains 502 pages of K8 service material followed by a 14-page K9 update for the 2009 model family.
• Engine repair depth: Documents engine removal, top- and bottom-end disassembly, cylinder-head and valve service, cam-chain work, piston and ring inspection, crankshaft and connecting-rod checks, and bearing replacement.
• Transmission-specific procedures: Separates LT-A V-belt CVT service from LT-F five-speed constant-mesh transmission and centrifugal clutch repair, including removal, internal inspection, adjustment, and reassembly coverage.
• Driveline and axle work: Includes front drive-shaft and differential repair for F models, rear axle and final-drive service, transfer components, output shafts, bevel-gear contact checks, backlash measurement, and shim selection.
• Chassis and brake service: Covers front double-wishbone and rear swingarm components, hubs, knuckles, bushings, steering shaft and tie rods, front disc-brake bleeding and caliper overhaul, rear drum brakes, and parking-brake adjustment.
• Electrical diagnosis and diagrams: Provides market- and model-specific wiring diagrams, wiring-harness routing, component locations, ignition/starting/charging fault charts, connector checks, and lighting and meter service.

This Suzuki Motor Corporation factory publication, copyright 2007, is a repair and service reference for the carbureted KingQuad 400 platform. Suzuki states that it is written for people with the knowledge, skills, equipment, and special tools needed to service its vehicles, making it appropriate for experienced technicians and well-equipped owners rather than first-time repair work.

Model and Market Coverage

The main manual identifies K8 configurations by country code and effective frame number. The 2WD LT-A400K8 and LT-F400K8 listings begin at 5SAAK48A87100001, while the 4WD LT-A400FK8 and LT-F400FK8 listings begin at 5SAAK49A87100001. Coverage tables identify U.S., Canadian, Australian, and Swedish versions by configuration. The front drive-shaft and differential repair sections apply specifically to F models.

The final 14 pages form the LT-A400F/LT-F400F K9 ('09 model) supplement. It supplies changed K9 specifications, service-data tables, and a revised front-suspension component layout; it does not duplicate the full K8 repair procedures as a separate 2009 manual.

Engine, Fuel, and Electrical Service

Engine coverage starts with symptom diagnosis, compression testing, and oil-pressure testing, then moves into full mechanical repair. The manual addresses the 376 cc OHC single-cylinder engine, cylinder head, valves, camshaft and cam-chain components, piston and rings, crankshaft, connecting rod, balancer shaft, oil pump and cooler, cooling fan, and temperature switches. LT-A and LT-F configurations receive separate service data.

The KEIHIN CVK32 carburetor chapter includes fuel-tank and valve work, carburetor disassembly, float-height adjustment, cleaning, cable adjustment, and fuel-level gauge testing. Electrical sections provide no-spark and starting-system diagnosis, starter and recoil-starter overhaul, battery leakage and charging tests, generator and regulator/rectifier checks, CDI inspection, and switch or relay testing.

Named illustrations include the Engine Lubrication System Chart Diagram, Cylinder Head Cooling System Chart Diagram, Ignition System Diagram, Starting System Diagram, model-specific Wiring Diagrams, and the Wiring Harness Routing Diagram. These are supported by connector-handling instructions and electrical test specifications rather than a single generic schematic.

Transmission, Driveline, and Chassis Repair

For the LT-A, the automatic transmission section covers the cooling ducts, drive belt, movable drive and driven faces, clutch shoe assembly, engagement and lock-up checks, and cover bearings. LT-F material instead follows the five-speed gearbox, shift forks, countershaft and driveshaft gears, reverse gearshift cam, gear-position switch, shift linkage, and wet multi-plate centrifugal clutch. Both variants receive their own symptom charts and service limits.

Shaft-drive coverage includes transfer removal and internal inspection, front differential teardown on F models, rear final-drive disassembly, universal-joint and bearing inspection, output-shaft work, gear-tooth contact, backlash, and shim selection. Suspension, steering, wheel, front master-cylinder and caliper, rear drum, and parking-brake chapters add removal, inspection, assembly, bleeding, and adjustment procedures for major chassis repair.

Factory Data, Tools, and Repair Cautions

Reference tables include component-specific tightening torques, fluid types and capacities, wear limits, clearances, electrical resistance and peak-voltage tests, clutch inspection data, and differential/final-drive adjustment specifications. Suzuki special tools are identified by number, including the 09900-25008 multi-circuit tester set, 09915-64512 compression gauge, 09920-13120 crankcase separating tool, 09922-31430 clutch spring compressor, and 09924-64510 final driving gear coupling holder.

The repair cautions are component-specific. Suzuki warns against driving the crankshaft into the crankcase with a hammer because crankshaft alignment accuracy can be lost, and it warns that incorrect meter connections can damage the CDI unit. Support the ATV securely before axle, suspension, brake, or engine work, and observe the manual's precautions for fuel, brake fluid, hot components, and electrical isolation.