Suzuki LT-A450X Off-road Vehicle Manuals

Suzuki LT-A450X Off-road Vehicle Manuals

Manuals and User Guides for Suzuki LT-A450X Off-road Vehicle. We have 1 Suzuki LT-A450X Off-road Vehicle manual available for free PDF download: Manual

Suzuki LT-A450X Manual

Suzuki LT-A450X Manual (528 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 17 MB

Table of Contents

General Information 1

9
- Electrical System
  1
- General Information
  1
- Periodic Maintenance
  1
- Servicing Information
  1
- How to Use this Manual
  3
- Table of Contents
  9
- General Information
  9
- General Precautions
  10
- Warning/Caution/Note
  10
- Serial Number Location
  12
- Suzuki Lt-A450Xk7 ('07-Model)
  12
- Fuel, Oil and Engine Coolant Recommendation
  13
  - Fuel (for Usa and Canada)
    13
  - Fuel (for Other Countries)
    13
  - Engine Oil (for Usa)
    13
  - Engine Oil (for Other Countries)
    13
  - Front Differential Gear Oil
    13
  - Rear Drive (Final) Gear Oil
    13
  - Brake Fluid
    13
  - Engine Coolant
    14
- Break-In Procedures
  15
- Information Labels
  16
- Specifications
  17
  - Dimensions and Dry Mass
    17
  - Engine
    17
  - Drive Train
    17
Electrical

18
- Capacities
  18
- Chassis
  18
- Periodic Maintenance Schedule
  20
  - Periodic Maintenance Chart
    20
- Maintenance and Tune-Up Procedures
  21
  - Air Cleaner Element
    21
  - Exhaust Pipe Nuts and Muffler Mounting Bolts
    23
  - Valve Clearance
    23
  - Spark Plug
    25
  - Spark Arrester
    26
  - Fuel Line
    26
  - Engine Oil and Oil Filter
    27
  - Front Differential Gear Oil
    29
  - Final Gear Oil
    30
  - Throttle Cable Play
    31
  - Throttle Body
    31
  - Engine Coolant
    32
  - Radiator
    33
  - Radiator Hoses
    33
  - Drive Belt
    34
  - Drive Shaft Boots
    38
  - Brakes
    39
  - Rear Brake Plates
    41
  - Brake Fluid
    42
  - Brake Hoses
    44
  - Tires
    44
  - Steering
    45
  - Suspensions
    45
  - Chassis Nuts and Bolts
    46
  - General Lubrication
    49
- Compression Pressure Check
  50
  - Compression Test Procedure
    50
- Oil Pressure Check
  51
  - Oil Pressure Test Procedure
    51
- Initial Engagement and Clutch Lock-Up Inspection
  52
  - Initial Engagement Inspection
    52
  - Clutch Lock-Up Inspection
    53
- Sds Check
  54
Engine

57
- Engine Components Removable with Engine in Place
  58
  - Engine Left Side
    58
  - Engine Right Side
    58
  - Engine Center
    58
- Engine Removal and Remounting
  59
  - Engine Removal
    59
  - Engine Remounting
    64
- Engine Disassembly
  67
- Engine Components Inspection and Service
  85
  - Cylinder Head Cover
    85
  - Cylinder Head
    87
  - Automatic Decomp
    96
  - Camshaft
    96
  - Cam Sprocket
    97
  - Cam Chain Tension Adjuster
    98
  - Cam Chain Tensioner/Guide
    98
  - Cylinder
    98
  - Piston and Piston Ring
    99
  - Piston Diameter
    99
  - Conrod
    101
  - Crankshaft
    102
  - Crank Balancer, Balancer Driven Gear and Drive Gear
    103
  - Crankshaft Runout
    103
  - Starter Clutch
    103
  - Starter Idle Gear No.1 and No.2
    105
  - Movable Drive Face and Driven Face
    106
  - Drive Belt
    113
  - Clutch Shoe
    113
  - Clutch Housing
    113
  - Oil Pump
    114
  - Oil Sump Filter
    114
  - Transfer
    115
  - Gearshift Fork and Gear
    118
  - Gearshift Cam
    119
  - Gearshift Shaft
    121
  - Front Output Shaft
    122
  - Rear Output Shaft
    126
  - Transfer Output Drive/Driven Gear
    128
  - Shim Adjustment
    129
  - Crankcase
    133
  - Generator Cover
    138
  - Clutch Housing Case
    140
  - Movable Drive Face Cover
    141
  - Recoil Starter
    143
- Engine Reassembly
  147
Drive Train

171
- Front Drive Train (Differential)
  172
  - Construction
    172
  - Removal
    173
  - Disassembly
    174
  - Inspection
    179
  - Reassembly
    181
  - Remounting
    187
  - Shim Adjustment
    188
  - Reassembly Information
    191
- Front Propeller Shaft
  192
  - Removal
    192
  - Inspection
    192
  - Reassembly
    193
- Rear Drive Train
  195
  - Construction
    195
  - Removal
    196
  - Disassembly
    197
  - Inspection
    201
  - Reassembly
    202
  - Remounting
    205
  - Shim Adjustment
    206
  - Reassembly Information
    209
- Rear Propeller Shaft
  210
  - Removal and Disassembly
    210
  - Inspection
    212
  - Reassembly and Installation
    213
Fi System Diagnosis

216
- Precautions in Servicing
  218
  - Electrical Parts
    218
  - Fuse
    219
  - Ecm/Various Sensors
    219
  - Electrical Circuit Inspection Procedure
    221
  - Using the Multi-Circuit Tester
    224
- Fi System Technical Features
  225
  - Injection Time (Injection Volume)
    225
  - Compensation of Injection Time (Volume)
    226
  - Injection Stop Control
    226
  - Fi System Parts Location
    227
  - Fi System Wiring Diagram
    229
- Ecm Terminal
  230
- Self-Diagnosis Function
  231
  - User Mode
    231
  - Dealer Mode
    232
  - Tps Adjustment
    233
- Fail-Safe Function
  234
- Fi System Troubleshooting
  235
- Ckp Sensor Inspection
  275
- Ckp Sensor Removal and Installation
  275
- Ect Sensor Removal and Installation
  275
- Iap Sensor Inspection
  275
- Iat Sensor Inspection
  275
  - Ect Sensor Inspection
    275
- Tp Sensor Inspection
  275
- To Sensor Inspection
  276
- To Sensor Removal and Installation
  276
Fuel System and Throttle Body

277
- Fuel Delivery System
  278
- Fuel System
  279
  - Fuel Tank Removal
    279
  - Fuel Tank Installation
    279
  - Fuel Pressure Inspection
    280
  - Fuel Pump Inspection
    281
  - Fuel Discharge Amount Inspection
    281
  - Fuel Pump Relay Inspection
    282
  - Fuel Pump and Fuel Mesh Filter
    283
  - Fuel Tank Pressure Control (Ftpc) Valve Inspection
    284
- Throttle Body
  285
  - Construction
    285
  - Air Cleaner Box Removal
    286
  - Air Cleaner Box Installation
    286
  - Throttle Body Removal
    287
  - Throttle Body Disassembly
    288
  - Throttle Body Inspection
    290
  - Throttle Body Reassembly
    290
  - Throttle Body Installation
    290
  - Fuel Injector Removal
    291
  - Fuel Injector Inspection
    291
  - Fuel Injector Installation
    291
Cooling and Lubrication System

292
- Engine Coolant
  293
- Cooling Circuit
  294
  - Cooling Circuit Inspection
    294
- Radiator and Water Hose
  295
  - Radiator Removal
    295
  - Radiator Cap Inspection
    296
  - Radiator Inspection and Cleaning
    297
  - Radiator Installation
    297
  - Water Hose Inspection
    298
  - Radiator Reservoir Tank
    298
- Cooling Fan
  299
  - Removal
    299
  - Installation
    300
  - Inspection
    300
- Cooling Fan Thermo-Switch
  301
  - Removal
    301
  - Inspection
    301
  - Installation
    301
- Ect Sensor
  302
  - Removal
    302
  - Inspection
    302
  - Installation
    303
- Thermostat
  303
  - Removal
    303
  - Inspection
    304
  - Installation
    305
- Water Pump
  306
  - Removal and Disassembly
    306
  - Inspection
    308
  - Reassembly and Installation
    309
- Lubrication System
  313
  - Oil Filter
    313
  - Oil Pressure
    313
  - Oil Pump
    313
  - Oil Sump Filter
    313
  - Engine Lubrication System Chart
    314
  - Engine Lubrication System
    315
Chassis

318
- Exterior Parts
  320
  - Construction
    320
  - Fastener Removal and Installation
    322
  - Removal
    324
- Front and Rear Wheels
  336
  - Construction
    336
  - Removal
    336
  - Installation
    336
- Tires
  337
  - Tire Replacement
    337
- Front Drive Shaft
  339
  - Construction
    339
  - Removal and Disassembly
    339
  - Inspection and Reassembly
    341
  - Installation
    343
- Front Brake
  344
  - Construction
    344
  - Brake Pad Replacement
    346
  - Brake Fluid Replacement
    347
  - Brake Caliper Removal and Disassembly
    347
  - Brake Caliper Inspection
    349
  - Brake Caliper Reassembly and Installation
    350
  - Brake Disc Removal and Disassembly
    352
  - Brake Disc Inspection
    353
  - Brake Disc Reassembly and Installation
    353
  - Master Cylinder Removal and Disassembly
    354
  - Brake Master Cylinder Inspection
    356
  - Brake Master Cylinder Reassembly and Installation
    356
- Front Suspension
  358
  - Construction
    358
  - Removal
    359
  - Inspection and Disassembly
    361
  - Reassembly and Installation
    365
- Handlebars
  370
  - Construction
    370
  - Removal
    371
  - Inspection
    372
  - Installation
    372
- Steering
  375
  - Construction
    375
  - Removal
    376
  - Inspection and Disassembly
    378
  - Reassembly and Installation
    380
  - Toe Adjustment
    383
- Front Wheel, Front Brake, Front Suspension Front Drive Shaft and Steering Reassembling Information
  384
- Rear Drive Shaft
  385
  - Construction
    385
  - Removal
    385
  - Inspection and Reassembly
    387
  - Installation
    389
- Rear Brake
  390
  - Construction
    390
  - Removal and Disassembly
    391
  - Inspection
    395
  - Reassembly
    397
  - Remounting
    399
- Rear Suspension
  401
  - Construction
    401
  - Removal
    402
  - Inspection and Disassembly
    404
  - Reassembly and Installation
    408
- Rear Wheel Rear Suspension and Rear Drive Shaft Reassembling Information
  413
- Transfer Gear Shift Lever
  414
  - Construction
    414
  - Removal
    415
  - Inspection
    415
  - Installation
    416
  - Shift Rod Adjustment
    416
Electrical System

418
- Cautions in Servicing
  420
  - Connector
    420
  - Coupler
    420
  - Clamp
    420
  - Fuse
    420
- Battery
  421
  - Semi-Conductor Equipped Part
    421
  - Connecting the Battery
    421
  - Wiring Procedure
    421
  - Using the Multi-Circuit Tester
    422
- Location of Electrical Components
  423
- Main Fuse
  423
- Charging System
  425
  - Troubleshooting
    425
  - Inspection
    426
- Fuse
  429
- Starter System
  429
  - Troubleshooting
    429
  - Starter Motor Removal
    430
  - Starter Motor Disassembly
    431
  - Starter Motor Inspection
    432
  - Starter Motor Reassembly
    433
  - Starter Motor Installation
    433
  - Starter Relay Inspection
    434
  - Neutral Relay Inspection
    434
  - Parking Brake Relay Inspection
    435
  - Parking Brake Switch
    435
- Ignition System
  436
  - Troubleshooting
    436
  - Inspection
    438
- 4Wd/Diff-Lock System
  442
  - Inspection
    442
- Combination Meter
  444
  - Description
    444
  - Operating Procedure
    445
  - Removal and Disassembly
    446
  - Inspection
    448
- Headlight
  451
- Lamps
  451
  - Headlight Installation
    452
- Brake Light/Taillight
  453
  - Reversing Light (for E-17)
    453
- Diode
  454
- Reversing Light Relay (for E-17)
  454
- Switches
  455
- Battery
  456
  - Specifications
    456
  - Initial Charging
    456
  - Servicing
    458
  - Recharging Operation
    458
Servicing Information

459
- Troubleshooting
  460
  - Fi System Malfunction Code and Defective Condition
    460
  - Engine
    462
  - Drive Train
    468
  - Radiator (Cooling System)
    469
  - Chassis
    469
  - Brakes
    471
  - Electrical
    472
  - Battery
    473
- Wiring Harness, Cable and Hose Routing
  474
  - Wiring Harness Routing
    474
  - Cable Routing
    476
  - Fuel Hose Routing
    478
  - Fuel Tank Breather Hose Routing
    479
  - Cooling System Hose Routing
    480
  - Rear Drive Breather Hose Routing
    481
  - Front Brake Hose and Pipe Routing
    482
  - Fender Installation
    483
  - Rear Fender Heat Shield Installation
    485
  - Belt Cooling Duct Installation
    486
  - Rear Brake Pedal
    487
  - Rear Side Reflex Reflector Installation (for E-28)
    488
  - Trailer Tow Plate Installation
    489
  - Engine Mounting
    490
  - RADIATOR GUARD INSTALLATION (for E-24)
    491
  - Special Tools
    492
- Tightening Torque
  496
  - Engine
    496
  - Drive Train
    497
  - Fi System, Intake Air System and Fuel System
    497
  - Cooling System
    497
  - Chassis
    498
  - Tightening Torque Chart
    499
- Service Data
  500
  - Reversing Light
    507
  - Speedometer Light
    507
  - Neutral Indicator Light
    507
  - High Beam Indicator Light
    507
  - Reverse Indicator Light
    507
    
    Emission Control Information
    511
    
    Emission Control Systems
    512
    
    Fuel Injection System
    512
    
    Crankcase Emission Control System
    513
  - Information Labels
    516
  - Front Suspension
    517
  - Dust Seal
    517
  - Front Suspension Reassembling Information
    518
  - Bush
    518
  - Rear Suspension
    519
  - Dust Seal
    519
  - Rear Suspension Reassembling Information
    520
  - Fuel Level Gauge Inspection
    521

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