Suzuki quad factory service manual

The ATV repair manual can teach you how to repair virtually every major area of your vehicle, such as the steering system, exhaust system, starting system, electrical system, fuel system, suspension system, and so on. This is helpful for any ATV user who is not an experienced mechanic. That way, the instructions and tutorials in the manual will perfectly match what you see under the vehicle. This makes it so much easier for inexperienced users to understand what to do quickly.

The PDF file gets stored on your computer or mobile device for safekeeping. Make sure you keep a handy set of tools with you. The ATV repair manual will recommend the best tools to have readily available to make the most common repairs. Heed this advice. ATV Manuals. Suzuki Motor of America, Inc. Apply engine oi l to the cover gaskel surface.

Then place the cover on the new gasket material and apply pressure wilh your hands. The oil will leave a very accurate outline on the gasket materiallhat can be cut arounr:l. When purchasing gasket material to make a gasket, measure the thickness of the old gasket and purchase gasket material with the same approximate thickness. Heavy grease can be used to hold small pans in place if they tend to fall out during assembly.

The carburetor is beSI cleaned by disassembling il and soaking the pans in a commercial cleaning solvent. Never soak gaskets and rubber pans in these cleaners.

Never use wire to clean OUI jets and air. They areeasilydamaged. Use compressed air to blowout the carburetor only if the noat has been removed firs!. There are many items avai lable that can be used on your hands before and after working on your vehicle. Before starting out, work Vaseline. This will make cleanup a lot easier. For cleanup. After riding it in extremely diny areas, wash il down thorough ly.

Doi ng this will make maintenance and serv ice procedures quick and easy. More imponant. When cleaning your Suzuki. Many owners use a coin-operated car wash. Coin-operated car washes are convenient and quick.

If you use a car wash to clean YOllr vehicle. NOTE A safe biodegradable, nontoxic anti. Simple Green con be purchasetJ thr0l4gh same supermarkets, hardware. Follow the directions on the container for recommended dilution ratios. When cleaning yo ur vehicle and especially when using a spray type degreaser. If you can, use a degreaser al a coin-operated car wash. If you are cleaning your vehicle at home, place thick cardboard or newspapers underneath the vehicle to calch the oil and grease deposits that are ri nsed off.

Place the vehicle on level ground and SCI the parking brake. Check the followin g before washing the vehicle:. Make sure the gas filler cap is screwed on tightly. Make sure the engine oil. Plug the mumer opening with a large cork or. Wash the vehicle from top to botlom with soapy water. Use the scrub brush to get excess din out of thc wheel rims and engine crannies.

Concentrate on the upper controls, engine. Wrap a plastic bag around the ignition coil and COl unit. Concentrate the second wash cycle on the frame tube members. Direct the hose underneath the engine. Wash this area thoroughly. If this area is extremely diny.

Protect the fini sh when placing the vehicle in this position. The final step is rinsing. Use cold water wi thout soap and spray the entire vehicle again. Use as much time and care when rinsing the vehicle as when washing it. Built up soap deposits will quickly corrode elecuical connections and remove the natural oi ls from tires, causing premature cracks and wear. Make sure you thoroughly rinse the vehicle 01T. Tip the vehicle from side-to-side to allow any water thaI has collected on horizontal surfaces to drain off.

If you are washing the vchicle at home. Idle the cngine to bum olT any residual moisture. Before taking the vehicle into the garage. Inspect the machine as you dry it for funhersignsof din and grime.

Spray any worn-down spots with WDor Bel-Ray6-in-1 to prevent rust from building on the bare metal. When the vehicle is back at your work area you can repaint the bare areas with touch-up paint after thoroughly c1eaningoffall WO40 residue. A quick shot from a touch-up paint can each time you work on the vehicle will keep it looking sharp and stop rust from building and weakening pans. Existing torque wrenches calibrated in meier kilograms can be used by perfonning a simple conversion.

All you have to do is move the decimal point. This conversion is accurate enough for mechanical work even though the ex act mathematical conversion is 3. Refer to Table 3 for standard IOrque specifications for various size screws, bolls and nuts that may nOI be listed in the respective chapters. To use the [able,. Use a vernier caliper and measure the inside dimension of. Fastener design detemlines the type of tool required to work the fastener.

Fastener material is carefully selected to decrease the possibility of physical failure. Nuts, bol ts and screws are manufactured in a wide range of thread patterns. To join a nut and bolt, the diameter of the bolt and the diameter of the hole in the nut must be the same.

It is just as imponantlhal the threads on both be properly matched. The best way to tell if the threads on 2 fasteners are matched is to tum the nut on Ihe bolt or the bolt into the threaded hole in a piece of equipment with fingers only.

Be sure both pieces are clean. If much force is required, check the thread condition on each fastener. If the thread condition is good but the fasteners jam. A thread pitch gauge Figure 8 can also be used to detennine pitch.

Most threads are cut so that the fastener ntust be turned clockwise to tighten it. These are called righthand threads. Some fasteners have left-hand threads: they must be turned counterclockwise to be tightened. Left-hand threads are used in locations where nonnal rotation of the equipment would tend to loosen a right-hand threaded fastener.

The ISO coarse pitch is used for most all common fastener applications. The fine pilch thread is used on cenain precision tools and instrumeniS. The constanl pitch thread is used mainly on machine pans and not for fasteners.

The constant pitch thread, however. The measurement across 2 flals on the head of the bolt Figure 10 indicates the proper wrench size to be used. Wing nuts are designed for fast removal by hand. Wing nuts are used for convenience in non-critical locations.

To indicate the sizcofa metric nut, manufacturers specify the diameter o f the opening and the thread pitch. This is similar to bolt specifications. The measurement across 2 nats on the nUl indicates the proper wrench size to be used Figure Always measure bolt. Machine Screws There are many differe nt types of machine screws. Figure 13 shows a number of screw heads requiring different types of turning tools. Can you help or direct me to a legit link?

A downloadable all-terrain vehicle repair manual is an electronically delivered instructional handbook for leaning how to service or restore the off-road vehicle to working order. Whether replacing a spark plug or completely overhauling the engine, a repair manual covers it all. Download Manuals Below. The Suzuki service manual downloads for the above listed models describes the service procedures for the complete vehicle.

Performing the scheduled maintenance is very important.