Suzuki LT-A450XK7 Setup Manual

Brand: Suzuki

Model: LT-A450XK7

Type: Setup Manual

Sep. ’06 Printed in United States (CLA) 28

99505-01017-01E

SUZUKI MANUFACTURING OF AMERICA CORPORATION

FOREWORD

This vehicle has been designed and produced utilizing Suzuki’s most modern tech-

nology. The finest product, however, cannot perform properly unless it is correctly

assembled and serviced. This set-up manual has been produced to aid you in prop-

erly assembling and servicing this vehicle.

Please review this set-up manual carefully before performing any work. Take special

care to properly perform the required assembly and servicing marked by either a

Warning or a Caution. Failure to follow the directions in either of these two (2) cate-

gories could lead to serious problems. and  areas are

denoted to emphasize certain areas and carry the following meanings:



Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in vehicle damage.

This set-up manual is based on a vehicle of standard specification. Some minor dif-

ferences from this manual may be found in other specifications.

PREPARATION

WORKSHOP

A: Packed vehicle

B: Working space

SELF PROTECTION

A: Safety gear

B: Appropriate clothing

UNCRATING THE VEHICLE

For Canada only

Apply a knife to cut the carton as indicated on the car-

ton to separate it from the crate base.

A: Perforate line

Except for Canada

1. Remove the screws and cut the tie straps.

2. Remove the carton and the plastic cover.

A: Screws

B: Tie Straps

C: Carton

D: Plastic cover

The workshop where the machine is assembled

should be clean, spacious, and have a level

floor.

The operators should wear appropriate cloth-

ing, including long sleeve shirt, long pants, and

safety gear, as shown in the illustration, for

handling crates.

1. Remove the bolts to take off the center pole.



2. Remove the top frame first, and then vertical

frames.

A: Bolts

B: Center pole

C: Top frame

D: Vertical frame

Remove the battery electrolyte stored in the front grip.

A: Battery electrolyte container

Remove the nuts and take off the J hook of the vehicle

stopper.

A: J hook

B: Nuts

C: Washer

D: Cardboard

E: Rubber

1. Lift the vehicle with a hoist, then balance the vehi-

cle.

2. Pull the crate base forward.

3. Place the vehicle in a clean working area and

remove the hoist and hooks.

Remove the bolts carefully while holing the

center pole as it may fall. Be careful not to

scratch the ATV.

NOTE: The J hook, nuts, cardboard, washer,

and rubber are no longer needed and may be

discarded.

LOCATION OF PARTS

Check the components as shown.

Parts listed above are installed respectively into the position as follows.

Item Part Name Q’ty Remarks

Battery holder 1

Flange bolt 2 6 × 16 mm

Trailer tow bracket 1

Flange bolt 3 10 × 30 mm

Warning label 1

Warning label (French) 1 For limited market

Battery electrolyte

container

D Owner’s manual set 1

Item Part Name Q’ty Remarks

E Warning label set 1 For E-17 market

Mud guard front fender 2 Right and Left

Fastener 8

Mud guard rear fender 2 Right and Left

Fastener 6

Reflex reflector 2 For E-17 market

Flange nut 2 5 mm

I DVD 1 For E-17 market

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The small parts of item A, B, D, E and I are in the tail box.

The parts shown as Item E, F, G, H and I in the table are supplied for limited markets.

Please hand over the parts shown as Item D and I in the table to your customer together with vehicle.

BA, C

H, G

COMPONENT PARTS

Check the component parts stored in the tail box.

A: Tail box

B: Owner’s manual

Trai l e r t o w k i t

Warning label set (Limited market)

DVD (Limited market)

Battery holder kit

Before assembling the vehicle, thoroughly under-

stand the “Safety Check Out” described on

page 27.

After completion of assembly, carefully check the

vehicle referring to the “Safety Check Out”, then

deliver the vehicle to the customer.

ASSEMBLY

TRAILER TOW BRACKET

Install the trailer tow bracket.

" Trailer tow bracket mounting bolt:

60 N·m (6.0 kgf-m)

A: Trailer tow bracket

B: 10 × 30 mm flange bolt

C: Mark (UP)

Stick the warning label.

A: Warning label

B: Warning label (French) .....For limited market

REMOVING THE TAPE

Remove the tapes from the front and rear fenders.

A: Tape

UPUP

NOTE:

Install the bracket placing its UP mark faced

upward.

NOTE: (Limited market)

Stick the warning label both

A and B.

MUD GUARD FRONT FENDER

(FOR E-17, E-24 MARKET)

Align the mud guard front fender to the front fender.

A: Mud guard front fender

B: Front fender

Fix the mud guard front fender using fasteners.

A: Mud guard front fender

B: Fastener

NOTE:

To install the fastener, pull the center pin as C

and fix the fastener by pushing the center pin

as D.

MUD GUARD REAR FENDER

(FOR E-17, E-24 MARKET)

Check that the cushion is stuck to the correct position.

A: Cushion

B: Mud guard rear fender

REFLEX REFLECTOR (FOR E-17 MARKET)

Align the boss of reflex reflector to the hole of mud

guard rear fender.

Install the reflex reflector to the mud guard rear fender.

A: Mud guard rear fender

B: Reflex reflector

C: Boss

D: Hole

E: 5 mm flange nut

Align the mud guard rear fender to the rear fender.

A: Mud guard rear fender

B: Rear fender

Fix the mud guard rear fender using fasteners.

A: Mud guard rear fender

B: Fastener

NOTE:

Stick the cushion on the end of radius.

NOTE:

To install the fastener, pull the center pin as C

and fix the fastener by pushing the center pin

as D.

WARNING LABEL

(FOR E-17 MARKET)

Select the appropriate language label for your country.

FRONT (RIGHT)

Stick the label selected for your country.

A: Warning label (General warning)

B: Warning label (Tire information)

C: Warning label (Age 16)

D: Warning label (Gear shifting) .....For French only

E: Front fender (Right)

F: Rear fender (Right)

REAR (RIGHT)

FRONT (RIGHT)

NOTE:

Eight kind of labels: French, Finnish, Danish,

German, Spanish, Dutch, Portuguese, Swedish.

CHECK

A: Throttle cable

B: Front brake hose

C: Front brake switch lead wire

D: 2WD/4WD DIFF LOCK selection switch wiring harness

E: Rear brake lever cable

F: Rear brake switch lead wire

G: Left switch wiring harness

H: Parking brake switch lead wire

I: Horn switch lead wire (For E-17, 24 market)

J: Emergency switch lead wire (For E-17 market)

K: Starter Cable

The line drawings on page 23, 24, 25 and 26

show the proper routing of the control cables,

hose and wirings.

Refer to them in addition to following the

instructions carefully.

SERVICING

BATTERY

Battery is located under the seat.

Pull the seat lock lever and remove the seat.

A: Seat

B: Seat lock lever

Remove the battery from the vehicle.

A: Battery

Filling electrolyte

Remove the aluminium tape sealing the battery elec-

trolyte filler holes.

A: Aluminium tape

B: Electrolyte filler hole

Remove the caps from the electrolyte container.

A: Caps

B: Sealed area

NOTE:

Use the removed caps as the sealed caps of

battery filler holes.

Do not remove or pierce the sealed areas of the

electrolyte container.

With just enough force to break the nozzle seal of elec-

trolyte container, push each nozzle of the electrolyte

container into the battery’s electrolyte filler ports and

hold the container firmly so that it does not fall.

Take precaution not to allow any of the fluid to spill.

A: Electrolyte containers

Make sure air bubbles are coming up in each electro-

lyte container, and leave in this position for about 20

minutes.

A: Air bubbles

NOTE:

If no air bubbles are coming up from a filler

port, tap the bottom of the container two or

three times.

Never remove the container from the battery.

After confirming that the electrolyte has entered the

battery completely, remove the electrolyte containers

from the battery.

Wait for around 20 minutes.

Insert the caps into the filler holes, pressing in firmly so

that the top of the each caps does not protrude above

the upper surface of the battery’s top cover.

A: Caps



Charge the battery with a battery charger.



After charging the battery, install the battery in the

vehicle as follows.



1. Set the battery to the box.

2. First connect the + lead to the + positive terminal

of the battery.

3. Cover + terminal with rubber boot.

4. Connect the - lead to the - negative terminal of

the battery.

A: + lead

B: - lead

C: Rubber boot

Never use anything except the specified battery

electrolyte.

Once the sealing cap has been installed in the

battery, do not remove the sealing cap.

For charging the battery, make sure to use the

charger specially designed for MF battery.

Otherwise, the battery may be overcharged

resulting in shortened service life.

Do not remove the cap during charging.

Position the battery with the cap facing upward

during charging.

When attaching the wiring harness battery

leads to the battery terminals, observe the cor-

rect polarity.

NOTE:

The terminal bolts and nuts are attached to the

battery.

Install the battery holder.

A: Battery holder

B: 6 × 16 mm flange bolt

Reinstall the seat.

Insert the seat hook into the seat hook retainer and

push the seat down firmly.

A: Seat assembly

B: Seat hook

C: Seat hook retainer

BRAKE FLUID

Keep the vehicle upright and place the handlebars

straight.

Check the brake fluid level in the front master cylinder

reservoir.

If the fluid level is below the lower level indicated in the

figure, add the correct type of brake fluid.

Refer to the chart below for the proper selection



A: Lower level line

Specification and Classification

DOT 4

Be careful not to spill any brake fluid on the

paint or plastic components as they will be

damaged.

BRAKE AIR BLEEDING

Any air which may have been trapped in the brake fluid

circuit must be bled completely.

If the brake lever feels spongy or weak, then most

likely there is air in the hydraulic circuit.

To bleed the air from the front brake, use the following

procedure:

1. Connect a clear hose to the air bleeder valve and

run the hose into a suitable clear container.

2. Pour approximately 1/2 in of brake fluid into the con-

tainer so that the end of the clear hose is sub-

merged and cannot draw any additional air back into

the circuit during the air bleeding servicing.

3. Close the valve, pump and squeeze the lever, and

open the valve while squeezing brake lever.

4. Repeat this process until the fluid flowing into the

receptacle no longer contains air bubbles.

5. After bleeding the brake circuit, tighten the bleeder

valve to the specified torque.

Reinstall the rubber protective cap.

6. Be sure to check the brake fluid level in the reservoir

tank.

" Brake caliper air bleeder valve:

6.0 N·m (0.60 kgf-m)

A: Bleeder valve

THROTTLE CABLE

Check the throttle cable play at the throttle lever end.

Throttle cable play: 3.0–5.0 mm

If adjustment is necessary, carry out the procedure

below:

1. Loosen the throttle cable adjuster lock nut B.

2. Turn the adjuster A to obtain the correct play.

3. Tighten the lock nut B while holding the adjuster A.

Place the rubber boot C.

NOTE:

Do not drop brake fluid level below lower level

line while bleeding air.

After the adjustment is completed, check that

handlebar movement does not raise the engine

idle speed and that the throttle lever returns

smoothly and automatically.

REAR/PARKING BRAKE

Adjust the rear brake by adjusting the brake pedal first

and then adjust the brake lever.

Brake pedal

Check the rear brake pedal height.

Rear brake pedal height: 12–22 mm

If the rear brake pedal height is not correct, adjust in

the following manner:

1. Loosen the lock nut A.

2. Adjust the brake pedal height by turning the brake

pedal stopper bolt B to locate the pedal to the cor-

rect height above the top face of the footrest C.

3. Tighten the lock nut A.

Check the brake pedal free travel.

Rear brake pedal free travel: 20–30 mm

If adjustment is necessary, turn the adjuster A to

obtain the correct free travel.

The rear brake lever and rear brake pedal oper-

ate the rear brake in a complementary manner.

When one of these is misadjusted, the brake

system as a whole will not operate properly.

This could cause brake dragging or inadequate

braking performance.

Be sure to adjust both the brake pedal and

brake lever within the specified ranges.

Brake Lever (Parking Brake)

Check the brake lever play at the lever holder when the

lever is lightly pulled in towards the grip.

Rear brake (Parking brake) lever play: 6.0–8.0 mm

If adjustment is necessary, carry out the procedure

below:

1. Loosen the lock nut B and turn in the adjuster A as

far as it will go.

2. Turn the adjuster C clockwise or counterclockwise

to obtain the specified play.

3. Minor adjustments can now be made with the brake

lever adjuster A.

Tighten the lock nut B.

Set the lever cover D.

4. After adjusting the play, check that the rear wheels

roll freely with the brake disengaged, the transmis-

sion in neutral, and the rear wheels off the ground.

5. Set the parking brake and check that the rear

wheels are locked by trying to move the vehicle

back and forth while it is in neutral.

6. Readjust the rear brake lever play if the rear wheels

could not roll freely or if the rear wheels didn’t lock in

step (2).

FRONT

FRONT AND REAR SUSPENSION ADJUSTMENT

Check for the spring setting of front and rear suspen-

sion.

This vehicle is delivered from the factory with its

adjusters set to the following positions.

A: Adjuster

REAR

Standard

setting

FRONT REAR

When adjusting either of the suspensions, be

sure to adjust both the right and left springs to

the same preload setting.

TIRE PRESSURE

Using an accurate air gauge, check the air pressure of

the front and rear tires.

The pressure should be as shown.

COLD INFLATION TIRE PRESSURE

HEADLIGHT BEAM ADJUSTMENT (RIGHT AND LEFT)

The headlight beam can be adjusted vertically if nec-

essary.

To adjust the beam vertically:

Turn the adjuster screw clockwise or counterclockwise.

A: Adjuster screw

ENGINE COOLANT

The engine coolant level should be kept between the

“FULL” and “LOW” level lines as shown in the photo-

graph.

Inspect the level with the vehicle held upright on level

ground.

A: Engine coolant reservoir

B: “FULL” level line

C: “LOW” level line

D: Radiator

LOAD

TIRE PRESSURE

FRONT REAR

Up to 172 kg

380 lbs

35 kPa

0.35 kgf/cm

5.1 psi

30 kPa

0.30 kgf/cm

4.4 psi

1. Remove the radiator cap lid.

A: Radiator cap lid

B: Boss

2. Remove the filler cap and add 50 : 50 mixture of

engine coolant and distilled water to the “FULL” level

line from the engine coolant filler hole.

3. Reinstall the filler cap and the lid.

C: Filler cap

FRONT DIFFERENTIAL GEAR OIL

Place the vehicle on a level ground.

Check the front differential gear oil levels as follows.

Remove the oil level bolt.

If the oil level is below the level hole, add the gear oil

through the filler hole until the oil flows out from the

level hole.

Reinstall the oil level bolt and the oil filler plug tighten

them securely.

A: Oil filler plug

B: Oil level bolt

NOTE:

Use hypoid gear oil SAE 90, API grade GL-5.

If the vehicle is ridden where the ambient tem-

perature is below 0°C or 32°F, use the hypoid

gear oil SAE 80, API grade GL-5.

FINAL GEAR OIL

Place the vehicle on a level ground.

Check the final gear oil levels as follows.

Remove the oil filler plug.

If the oil level does not reach the bottom of the filler

hole, add the gear oil through the filler hole until the oil

level reaches the bottom of the oil filler hole.

Reinstall the oil filler plug and tighten it securely.

A: Oil filler plug

ENGINE OIL



Remove the fasteners to take off the footrest guard lid.

A: Footrest guard lid

B: Fastener

Check the engine oil level with the engine oil dipstick.

1. Place the vehicle on level ground.

2. Start the engine and allow it to run for a few minutes

at idling speed.

Stop the engine and wait about three minutes.

3. Remove the oil filler plug.

The engine oil dipstick comes out together with the

oil filler plug.

Wipe the oil from the dipstick with a clean rag.

4. Reinsert the dipstick until the threads touch the filler

neck, but do not screw the plug in.

5. Draw out the dipstick and check the oil level.

The level found on the dipstick should be between

“L” (Low) and “F” (Full) line.

6. If the oil level is below the “L” line, add fresh oil from

the filler hole until the oil level reaches to “F” line.

If the level is above the “F” line, drain oil to “F” line.

7. Reinstall the drain plug and engine oil filler plug.

Tighten them securely.

8. Reinstall the footrest guard lid.

A: Engine oil filler plug

B: Engine oil dipstick

NOTE:

Use Mobil Fluid 424 or an equivalent.

This vehicle is shipped from factory with the

engine filled with engine oil.

Be sure to check oil level.

NOTE:

To remove the fastener, pull the center pin as C

and pull out the fastener as D.

Page is loading ...

Suzuki LT-A450XK7 Setup Manual

Suzuki LT-A450XK7 Setup Manual

Suzuki LT-A450XK7 Setup Manual

Related papers

Other documents