Suzuki LT-A450XK7 Setup Manual
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Suzuki LT-A450XK7 Setup Manual

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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.
SUZUKI MANUFACTURING OF AMERICA CORPORATION
99505-01017-01E
Sep. '06 Printed in United States (CLA) 28

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Summary of Contents for Suzuki LT-A450XK7

  • Page 1 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.
  • Page 2 PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed vehicle B: Working space SELF PROTECTION The operators should wear appropriate cloth- ing, including long sleeve shirt, long pants, and safety gear, as shown in the illustration, for handling crates.
  • Page 3 1. Remove the bolts to take off the center pole. Remove the bolts carefully while holing the center pole as it may fall. Be careful not to scratch the ATV. 2. Remove the top frame first, and then vertical frames. A: Bolts B: Center pole C: Top frame...

  • Page 4: Table Of Contents

    LOCATION OF PARTS Check the components as shown. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Battery holder Warning label set For E-17 market Flange bolt 6 × 16 mm Mud guard front fender Right and Left Trailer tow bracket Fastener Flange bolt 10 ×...
  • Page 5 COMPONENT PARTS Check the component parts stored in the tail box. A: Tail box B: Owner’s manual C: Battery holder kit Trailer tow kit Warning label set (Limited market) DVD (Limited market)

  • Page 6: Trailer Tow Bracket

    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.

  • Page 7: Fastener

    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. NOTE: To install the fastener, pull the center pin as C and fix the fastener by pushing the center pin as D.

  • Page 8: Mud Guard Rear Fender

    MUD GUARD REAR FENDER (FOR E-17, E-24 MARKET) Check that the cushion is stuck to the correct position. NOTE: Stick the cushion on the end of radius. 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.

  • Page 9: For E-17 Market

    WARNING LABEL (FOR E-17 MARKET) Select the appropriate language label for your country. NOTE: Eight kind of labels: French, Finnish, Danish, German, Spanish, Dutch, Portuguese, Swedish. 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...
  • Page 10 CHECK 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. 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...
  • Page 11 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.
  • Page 12 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...
  • Page 13 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.
  • Page 14 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.
  • Page 15 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.
  • Page 16 REAR/PARKING BRAKE Adjust the rear brake by adjusting the brake pedal first and then adjust the brake lever. 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.
  • Page 17 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.
  • Page 18 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 TIRE PRESSURE LOAD FRONT REAR 35 kPa 30 kPa Up to 172 kg 0.35 kgf/cm 0.30 kgf/cm 380 lbs...
  • Page 19 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.
  • Page 20 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.
  • Page 21 API: American Petroleum Institute JASO: Japanese Automobile Standards Organization ENGINE OIL VISCOSITY RATING SELECTION CHART SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine 20W - 50 oil. If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the following chart.
  • Page 22 Energy Conserving Suzuki does not recommend the use of “ENERGY CONSERVING” oils. Some engine oils which are API SH or greater have the “ENERGY CONSERVING” indication in API classi- fication doughnut mark. 10W-40 10W-40 These oils can affect engine life and clutch perfor- mance.
  • Page 23 TIGHTENING TORQUE Item Part Name N·m kgf-m Item Part Name N·m kgf-m STEERING, FRONT SUSPENSION AND FRONT BRAKE REAR SUSPENSION AND REAR BRAKE Handlebar clamp bolt Rear shock absorber mounting nut (upper) Handlebar holder nut Rear shock absorber mounting nut Front hub nut 11.0 (lower)
  • Page 24 CABLE ROUTING Frame Throttle cable Parking brake cable Wiring harness Parking brake cable Stater cable Frame Parking brake cable Location of cable and harness: as shown Sterter cable Wiring harness Parking brake cable Parking brake cable guide Fix foot brake cable to the footrest bar Handlebar Locate throttle cable as shown.
  • Page 25 Wiring harness Parking brake cable Rear fender Parking brake cable Tie protector with clamp as shown. Screw Frame Protector Frame Parking brake cable Rear fender Foot brake pedal Parking brake cable Washer Adjust nut Front side Cotter pin Rear brake assy Foot brake cable Fix foot brake cable to the footrest...
  • Page 26 HARNESS ROUTING Clamp Horn switch lead wire (E-17, E-24) Set the sag under Emergency switch lead wire (E-17) combination meter Handle switch lead wire (L) To combination meter Parking brake switch lead wire Handle switch lead wire (L) Brake lever switch lead wire (L) Parking brake switch lead wire Brake lever switch lead wire (L) Brake lever switch lead wire (R)
  • Page 27 60~80 mm (2.3 – 3.1 in) Clamp Wiring harness Ignition coil Wiring harness Clamp To power source Clamp Wiring harness Clamp Clamp Hose Wiring harness Clamp Wiring harness Cooling fan thermo switch lead wire Brake light/taillight lead wire TP/IAP/IAT Wiring harness Wiring harness Back up relay (E-17) Clamp...

  • Page 28: For E-17 Market

    SAFETY CHECK OUT COLD INFLATION TIRE PRESSURE TIRE PRESSURE After completion of the setting-up the vehicle LOAD FRONT REAR all the following items should be double- 35 kPa 30 kPa Up to 172 kg checked to confirm that the operation and func- 0.35 kgf/cm 0.30 kgf/cm 380 lbs...

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