Suzuki LT-A700XK5 Benutzerhandbuch

September ’04 Printed in Japan (TK) 28

99505-01125-01E

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 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.

UNCRATING THE VEHICLE

FRONT REAR

Remove the carton.

Remove the bolts and brackets.

A: Bolt

B: Bracket

C: Vinyl tube

Loosen the front brake master cylinder mounting bolts.

Remove the master cylinder from the bracket.



A: Bolt

B: Front brake master cylinder

Remove the bolts from the crate, then lift the steel

frame to separate it from the base of the crate.

NOTE:

The brackets, bolts and vinyl tube are no longer

needed and these may be discarded.

Keep the position of front brake master cylinder

with its cap facing upwards until it is installed.

LOCATION OF PARTS

Check off each of the components as shown in the photograph.

AABBCC

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

Item Part Name Q’ty Remarks

Headlight assembly 1

Flange bolt 2 8 × 12 mm

Spacer 1 L:11

Allen bolt 1 5 × 20 mm

Headlight cover (Upper) 1

Headlight cover (Lower) 1

Fastener (Small) 2

Fastener (Medium) 1

Meter cover 1

Meter rubber cushion 1

Fastener (Medium) 1

Tapping screw 2 5 × 16 mm

DBattery 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

Item Part Name Q’ty Remarks

F Wheel center cap 4

GMud guard rear fender 2 Right and Left

Fastener (Large) 6

HReflex reflector 2

Flange nut 2 5 mm

I Warning label set

3For E-17 CG

selection

2For E-17 CH

selection

3For E-17 CI

selection

J Fuel label 1 For limited market

Battery 1

Battery electrolyte

container 1

L Owner’s manual 1

M Safety video 1 For limited market

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item E, G, H, I, J and M in the above table are supplied for limited markets.

EA B C D, K J

FFFG, H F

The photograph shown indicates the parts dismounted

from the model in addition to the items shown in the

preceding page.

A: Handlebar assembly

B: Front brake master cylinder

C: Ignition switch

D: Meter assembly

E: Front brake switch lead wire

F: Wiring harness

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

HANDLEBARS

Loosen the handlebar clamp bolts.

A: Handlebar clamp bolt

A: Handlebars

B: Clamp (Upper)

C: Clamp (Lower)

D: Flange bolt

E: Dot mark

NOTE:

Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

Tighten the handlebar clamp bolts to the specified torque.



"Handlebar clamp bolt: 26 N·m (2.6 kgf-m)

A: Flange bolt

B: Flange bolt

C: Dot mark

FRONT BRAKE MASTER CYLINDER

Remove the bolts and holder from the front brake mas-

ter cylinder.

A: Master cylinder

B: Bolt

C: Holder

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

"Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Front brake master cylinder

B: Bolt

C: Bolt

D: Holder

E: Dot mark

NOTE:

To install the handlebars correctly, first tighten

the bolt A

Aof the front side with specified torque

and then tighten the bolt B

Bof the rear side.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

FORWARD

NOTE:

To install the holder correctly, first tighten the

bolt B

Bof the upper side with specified torque

and then tighten the bolt C

Cof the lower side.



A: Bolt

B: Holder

C: Master cylinder

D: Handlebars

Connect the front brake light switch lead wires coupler

to the brake light switch.

A: Front brake light switch

B: Lead wire coupler

Install the front brake hose to the brake hose guide

with the protector properly in place.

A: Front brake hose

B: Brake hose guide

C: Protector

D: Recess

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for brake fluid leakage.

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)

HEADLIGHT ASSEMBLY AND METER ASSEMBLY

Install the headlight assembly onto the handlebar

mounting bracket.

A: Headlight assembly

B: 8 × 12 mm flange bolt

C: Throttle cable

D: Boss

Connect the headlight coupler correctly.

A: Headlight assembly

B: Headlight coupler

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

instructions carefully.

NOTE:

Pass the throttle cable inside the boss.

Install the meter assembly to the headlight brace.

A: Meter assembly

B: Boss

C: Rubber grommet

D: Meter wiring harness

E: 5 × 20 mm allen bolt

F: Spacer L:11 mm

HEADLIGHT COVER AND METER COVER

Fit the meter rubber cushion to the meter cover.

A: Meter cover

B: Meter rubber cushion

Align the boss of the ignition switch to the meter cover

groove.

A: Meter cover

B: Ignition switch

C: Boss

Install the ignition switch to the meter cover.

A: Meter cover

B: Ignition switch

C: Ring nut

NOTE:

Tighten the ring nut in the correct direction as

shown.

Align the meter cover to the headlight brace.

A: Headlight brace

B: Meter cover



A: Meter assembly

B: Meter rubber cushion

Fix the meter cover using fastener.

A: Fastener (Medium)

Fit the headlight cover (Upper) to the headlight cover

(Lower).

A: Headlight cover (Upper)

B: Hook

C: Headlight cover (Lower)

D: Hole

Align the meter assembly with meter rubber

cushion.

Take care so that the rubber cushion is not pro-

truded.

NOTE:

To install the fastener, pull the center pin as B

and fix the fastener by pushing the center pin

as C

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