Table of Contents
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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 read this manual and follow its instructions carefully. To emphasize special
information, the symbol
and the words WARNING, CAUTION, NOTICE and
NOTE have special meanings. Pay particular attention to messages highlighted by
these signal words:
Indicates a potential hazard that could result in death or serious injury
Indicates a potential hazard that could result in minor or moderate injury.
Indicates a potential hazard that could result in vehicle or equipment damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
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.
L2
99505-01042-01E
EN
© COPYRIGHT SUZUKI MANUFACTURING OF AMERICA CORPORATION
Aug. '11 (CLA) 28
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Table of Contents
Related Manuals for Suzuki LT-A400
Summary of Contents for Suzuki LT-A400
- 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 CAUTION Assembling the vehicle in poor working condi- tion can be hazardous. Place the packed vehicle on a level floor where it is clean and spacious. A: Packed vehicle B: Working space SELF PROTECTION CAUTION Assembling the vehicle without proper clothes and protective gear can be hazardous.
- Page 3 UNCRATING THE VEHICLE CAUTION Crate has nails and may have sharp splinters that could cause injury. Wear proper protective clothes and gear. Use a cutter to separate the top part of the crate along the perforated line. CAUTION Careless use of cutter can injure a person.
- Page 4 Use a cutter to open the crate along the perforated line. CAUTION Careless use of cutter can injure a person. Wear proper protective clothes and gear. Use a cutter with the proper method. NOTE: • Cut the carton from the top to the bottom along the perforated lines on both sides at each end.
- Page 5 Remove the nut to take off the J hook of the vehicle stopper. NOTE: The J hook, nut, cardboard, washer, and rubber are not necessary to assemble the machine. A: J hook B: Nut C: Washer D: Cardboard E: Rubber Carefully remove a component parts package from the crate.
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Page 6: Location Of Parts
LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Mud guard front fender Right and Left Reflex reflector For E-17 Fastener Flange nut 5 mm 5 ×... -
Page 7: Component Parts
COMPONENT PARTS Check that the component parts are in the box. A: Owner’s manual (For E-24, 28) B: Battery holder kit C: Box... - Page 8 Before assembling the vehicle, thoroughly under- stand the “Safety Check Out” described on page 32. After completion of assembly, carefully check the vehicle referring to the “Safety Check Out”, then deliver the vehicle to the customer. ASSEMBLY REMOVING THE WRAP FILM Remove the wrap film from the front and rear fenders.
- Page 9 Secure 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 • Arrows show direction of fasteners. A: Mud guard front fender B: Fastener Align the parts and secure them with the screw E.
- Page 10 Secure the mud guard rear fender using fasteners. NOTE: • To install the fastener, pull the center pin as C and fix the fastener by pushing the center pin as • Arrows show direction of fasteners. A: Mud guard rear fender B: Fastener Align the parts and secure them with the screw E.
- Page 11 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: Warning label (Trailer tow) F: Front fender (Right) G: Rear fender (Right) REAR (RIGHT) Stick the label.
- Page 12 CHECK OWNER’S MANUAL / COMPONENT PARTS The owner’s manual and component parts are located in the box under the seat. Pull the seat lock lever, and remove the seat. A: Seat B: Seat lock lever Pull the clips up and remove the cover. A: Cover B: Clip C: Hook...
- Page 13 NOTE: • The line drawings on page 28, 29, 30 and 31 show the proper routing of the control cables, hose and wirings. • Refer to them in addition to following the instruc- tions carefully. A: Throttle cable B: Front brake hose C: Rear brake lever cable D: Choke cable E: Left switch wiring harness...
- Page 14 SERVICING BATTERY 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. NOTE: • Use the removed caps as the sealing cap of bat- tery filler holes.
- Page 15 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 16 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 17 1. Reinstall the battery in the battery 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.
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Page 18: Brake Fluid
BRAKE FLUID Place the vehicle on the level ground and keep the handlebars straight. Check the brake fluid level in the front master cylinder reservoir. If the fluid level is below the “LOWER” level, add the correct type of brake fluid. Refer to the chart below for the proper selection. -
Page 19: Throttle Cable
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 following pro- cedure. 1. Shift the rubber boot C. 2. Loosen the throttle cable adjuster lock nut B. 3. - Page 20 Brake Pedal Check the rear brake pedal free travel. Rear brake pedal free travel: 20–30 mm If adjustment is necessary, adjust the free travel by turning the adjuster A. Brake Lever (Parking Brake) Check the brake lever play at the lever holder when squeezing the lever until pressure is felt.
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Page 21: Tire Pressure
2WD/4WD SELECTION LEVER (FOR LT-A400F) Set the selection lever to “4WD” position as shown in the photograph. (Align it with the white mark.) Check that there is no play in the cable. A: 2WD/4WD selection lever B: Mark If there is any play in the cable, adjust it in the following manner. -
Page 22: Headlight Beam Adjustment
HEADLIGHT BEAM ADJUSTMENT (RIGHT AND LEFT) The headlight beam can be adjusted up and down if necessary. To adjust the beam up and down: Turn the adjuster screw clockwise or counterclockwise. A: Adjuster screw FRONT DIFFERENTIAL GEAR OIL (FOR LT-A400F) Place the vehicle on a level ground. -
Page 23: Engine Oil
ENGINE OIL NOTE: This vehicle is shipped from factory with the engine filled with engine oil. NOTICE Operating the engine with too little or too much oil can damage the engine. Place the ATV on level ground. Check the oil level with the engine oil dipstick before each use of the vehicle. - Page 24 API: American Petroleum Institute JASO: Japanese Automobile Standards Organization SAE Engine Oil Viscosity ENGINE OIL VISCOSITY RATING SELECTION CHART 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 left chart.
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Page 25: Idle Speed Adjustment
IDLE SPEED ADJUSTMENT Remove the seat. Remove the fasteners. NOTE: • To remove the fastener B, pull the center pin and pull out the fastener. • To remove the fastener C, turn the center pin counter clockwise while holding outer and pull out the fastener. - Page 26 SPEEDOMETER Set the meter to odometer, then press and hold func- tion change button for 2 seconds to switch the display. Select km/h or mph properly to comply with traffic reg- ulations. Check km/h and mph display after adjusting the instru- ment panel display.
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Page 27: Tightening Torque List
TIGHTENING TORQUE TIGHTENING TORQUE LIST 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) Front hub nut 11.0 Rear shock absorber mounting nut Front wheel set nut (lower) Front brake caliper air bleeder... -
Page 28: Tightening Torque Chart
TIGHTENING TORQUE CHART Thread diameter Unit Bolt type (Nominal diameter) N·m kgf-m lbf-ft “A” [mm] 0.15 0.30 0.55 21.0 32.5 47.0 10.5 76.0 A equivalent of 4T strength bolt without flange 16.0 115.5 Thread diameter Unit Bolt type (Nominal diameter) N·m kgf-m lbf-ft... -
Page 29: Cable Routing
CABLE ROUTING Pass the throttle cable through the Transfer cable (LT-A400F) concave of transfer lever bracket. (LT-A400F) Parking brake cable Starter cable Throttle cable Front brake hose Pass the starter cable and parking brake cable through the guide. Starter cable Parking brake Front brake switch lead wire Throttle cable... - Page 30 Pass the parking brake cable Throttle cable Fix the rubber of throttle to outside of the throttle cable. cable to the cable guide. Throttle cable Starter cable Frame Starter cable Parking brake cable INSIDE Pass the throttle cable and Clamp parking brake cable through the guide.
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Page 31: Harness Routing
HARNESS ROUTING Starter relay Battery lead wire Pass the starter motor lead wire under the hose Starter motor assembly Battery lead wire Clamp Headlight lead wire (R) Mud protector (E-24) Clamp Clamp Clamp Pass over the bridge Clamp Wiring harness Starter cable Headlight lead wire (L) Wiring harness guide (E-28) - Page 32 Handlebar switch lead wire (L) Gear in start switch lead wire Pass the stop switch Stop lamp switch lead wire lead wire behind the Horn switch lead wire (E-17, 24) Starter cable throttle cable. Clamp Clamp Throttle cable Handlebar switch lead wire Headlight lead wire (L) Ignition switch lead wire Horn switch lead wire (E-17, 24)
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Page 33: Safety Check-Out
SAFETY CHECK OUT COLD INFLATION TIRE PRESSURE NOTE: TIRE PRESSURE FRONT REAR • After completion of the setting-up the vehicle all 32.5 kPa 30 kPa the following items should be double-checked to 0.325 kgf/cm 0.30 kgf/cm confirm that the operation and function of the 4.7 psi 4.4 psi vehicle are satisfactory.