Suzuki LT-A450XK7 User guide

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

ABattery 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

CBattery electrolyte

container 1

D Owner’s manual set 1

Item Part Name Q’ty Remarks

E Warning label set 1 For E-17 market

FMud guard front fender 2 Right and Left

Fastener 8

GMud guard rear fender 2 Right and Left

Fastener 6

HReflex 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 F

COMPONENT PARTS

Check the component parts stored in the tail box.

A: Tail box

B: Owner’s manual

Tr a i 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 Aand 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.

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