Hi. I'm new to ATVs but handy with tools. I have a 2006 Eiger 400 Lt-A400F. I'm replacing the flywheel and just about ready to put everything back together, but I'm stumped on exactly how to place the shifter rod back in. It has a white dot on it, but it appears that it will go back in in two different positions. I don't want to mess this up and have to take the case off again. Does anyone know how to be sure it's put back properly? Also, several gears have white paint/dots on them. Is this significant?
Thanks.

Stumped on how to put this back in in the right position.

 

https://www.suzukipartshouse.com/oem...ing-2-model-k3
I have a feeling that gear (5) has a pip on it that the round paint mark should line up with. The sub shaft assembly has things on it that have to line up correctly so the shaft lines up with the reverse "lock out" mechanism in the crankcase, and there are matching marks on the shaft or cam (I think) to ensure you get it right.

 

There is a gear on the crankcase side of the sub shaft assembly and it does have some paint markings on it. I'm just wondering if it matters which side of the painted tooth on that gear I should put the tooth of the shifter shaft (which I have pictured here). i.e. does it matter?

 

Sorry to be slow with the reply, I wanted to check the workshop manual, according to that, the mark should be a centre pop on the shifter shaft so looks like Suzuki have been saving money using paint, perhaps that is why there are two blobs on the segment, go for the tooth between them. Also in the book, something I had forgotten, I had a nearly new Eiger, seized in low ratio, due to a gear seizing on the bush it was supposed to spin on, why? The splined ring has an oil hole that has to line up with one in the splined shaft it sits on, I suspect they hadn't done this on assembly at the factory.

 

Very helpful thank you. Is the "shop" manual the same as the "service" manual. I have a "service" manual but I didn't see what you're talking about. Do you know what page it was on?
Thanks

 

Manual is at work, computer at home, and I usually forget to check when at work. If/when I remember, I will check. It is near the end of the engine rebuild section.

 

OK. Thanks I'm looking through my manual and still haven't found "exacting" enough info to put case back together on the first try I did see diagrams, but not really a discussion of paint marks.
I had so much trouble taking it off and damaging it in the process, I dread the thought of having to take it off again, because I put a gear in incorrectly.

 

Use that parts diagram I linked to for how everything goes together, but the pictures and text about the setting up marks on the assemblies is on Service Manual page 3-93, that is for the 400LTF foot change model. LTA autos are a bit different.

 

Thanks again for your help. The shop manual must be different from the service manual I have. There is no 3-93 in my manual. I think there is some rule about manuals on this forum and I don't want to violate any rules so I will search for the manual you have and see if I can come up with a legitimate copy. Also, I have seen some diagrams for LTF and mine is an LTA so I hope they are close enough to get what I need.

 

Right, if it is an LTA the parts drawings are https://www.suzukipartshouse.com/oem.../gear-shifting and 2006 Suzuki LT-A400F Transmission (2) | Babbitts Suzuki Parts House If you got that segment one tooth out, I suspect all you would need to do is put the select arm (27) on a different spline to the one it came off.