Suzuki LT-A400 User guide

99505-01042-01E

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.

PREPARATION

WORKSHOP

A: Packed vehicle

B: Working space

SELF PROTECTION

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.

CAUTION

Assembling the vehicle without proper clothes

and protective gear can be hazardous. You can

be injured if you do not wear proper clothes

and protective gear.

Be sure to wear proper clothes and shoes for

assembling and wear protective glasses, mask

or gloves as necessary.

UNCRATING THE VEHICLE

Use a cutter to separate the top part of the crate along

the perforated line.

A: Perforated line

Lift the top part to separate it from the crate.

A: Top part of crate

CAUTION

Crate has nails and may have sharp splinters

that could cause injury.

Wear proper protective clothes and gear.

CAUTION

Careless use of cutter can injure a person.

Wear proper protective clothes and gear.

Use a cutter with the proper method.

CAUTION

Careless crate separation can injure a person.

Lift the top part with two persons.

Wear proper protective clothes and gear.

Use a cutter to open the crate along the perforated

line.

A: Perforated line

Open the sides of the crate.

Dismantle the crate from the base of the crate.

A: Crate base

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.

• Be careful not to damage the vehicle.

CAUTION

Careless inappropriate handling of the disman-

tled crate can injure a person.

Wear proper protective clothes and gear.

Remove the nut to take off the J hook of the vehicle

stopper.

A: J hook

B: Nut

C: Washer

D: Cardboard

E: Rubber

Carefully remove a component parts package from the

crate.

Remove the battery electrolyte container stored in the

front grip.

A: Component parts box

B: Battery electrolyte container

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.

NOTE:

The J hook, nut, cardboard, washer, and rubber

are not necessary to assemble the machine.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

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

Item Part Name Q’ty Remarks

Mud guard front fender 2 Right and Left

Fastener 10

Screw 2 5 ×25 mm

Washer 2 OD:20.0 ID:5.5

Rubber cushion (with nut) 2 5 mm L:21.0

BBattery holder 1

Flange bolt 2 6 ×16 mm

Mud guard rear fender 2 Right and Left

Fastener 10

Screw 2 5 ×20 mm

Screw 2 5 ×25 mm

Washer 4 OD:20.0 ID:5.5

Rubber cushion (with nut) 4 5 mm L:21.0

Item Part Name Q’ty Remarks

DReflex reflector 2 For E-17

Flange nut 2 5 mm

E Warning label set 1 For E-17

F DVD 1 For E-17

GBattery electrolyte

container 1

HOwner’smanual 1

NOTE:

• Item B and H are located in the box under the seat (H: For E-24, 28).

• The parts shown as Item A, C, D, E and F in the above table are supplied for limited markets.

• Please hand over the parts shown as Item F and H in the above table to your customer together with vehi-

cle.

COMPONENT PARTS

Check that the component parts are in the box.

A: Owner’s manual (For E-24, 28)

B: Battery holder kit

Box

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.

A: Wrap film

MUD GUARD FRONT FENDER (FOR E-17, 24)

Remove screws, washers and rubber cushions

(with nuts).

A: Screw, washer, rubber cushion (with nut)

Align the mud guard front fender to the front fender.

A: Mud guard front fender

B: Front fender

NOTE:

The screws, washers and rubber cushions (with

nuts) are not necessary to assemble the vehicle.

Secure the mud guard front fender using fasteners.

A: Mud guard front fender

B: Fastener

Align the parts and secure them with the screw E.

E: 5 x 25 mm screw

F: Washer OD:20.0 mm ID:5.5 mm

G: Rubber cushion (with nut) 5 mm L:21.0 mm

H: Foot board

I: Front fender

J: Mud guard front fender

REFLEX REFLECTOR (FOR E-17)

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

MUD GUARD REAR FENDER (FOR E-17, E-24)

Align the mud guard rear fender to the rear fender.

A: Mud guard rear fender

B: Rear fender

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.

Secure the mud guard rear fender using fasteners.

A: Mud guard rear fender

B: Fastener

Align the parts and secure them with the screw E.

E: 5 x 25 mm screw

F: Washer OD:20.0 mm ID:5.5 mm

G: Rubber cushion (with nut) 5 mm L:21.0 mm

H: Foot board

I: Rear fender

J: Mud guard rear fender

Align the parts and secure them with the screw A.

A: 5 x 20 mm screw

B: Washer OD:20.0 mm ID:5.5 mm

C: Rubber cushion (with nut) 5 mm L:21.0 mm

D: Mud guard rear fender

E: Extension bracket

WARNING LABEL (FOR E-17)

Select the appropriate language label for your country.

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.

NOTE:

Six kind of labels: French, Finnish, Danish, Span-

ish, Portuguese, Swedish.

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