Suzuki LT-A450X 2006 Owner'S Manual Download Page 74 | Manualshive

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Suzuki LT-A450X 2006 Owner'S Manual Download Page 74

5

5-1

INSPECTION AND MAINTENANCE

MAINTENANCE SCHEDULE  .............................................................................. 5-2
TOOLS ................................................................................................................. 5-5
BATTERY ............................................................................................................ 5-6
SPARK PLUG ...................................................................................................... 5-7
FUEL HOSE ......................................................................................................... 5-8
THROTTLE CABLE ADJUSTMENT  ................................................................... 5-9
ENGINE OIL ....................................................................................................... 5-10
ENGINE OIL AND FILTER CHANGE ................................................................ 5-11
AIR CLEANER ................................................................................................... 5-15
AIR CLEANER DRAIN TUBES  ......................................................................... 5-17
ENGINE COOLANT ........................................................................................... 5-18
GEAR OIL CHANGE  ......................................................................................... 5-19
TIRES ................................................................................................................. 5-20
FRONT BRAKE  ................................................................................................. 5-23
REAR BRAKE  ................................................................................................... 5-27
REAR BRAKE LINING WEAR LIMIT ................................................................ 5-29
FRONT AND REAR WHEEL REMOVAL  .......................................................... 5-30
SPARK ARRESTER  .......................................................................................... 5-31
DRIVE SHAFT BOOTS ...................................................................................... 5-32
LIGHT BULB REPLACEMENT  ......................................................................... 5-32
FUSES ............................................................................................................... 5-35
OUTPUT TERMINAL  ......................................................................................... 5-36
GENERAL LUBRICATION  ................................................................................ 5-37
TRAILER TOWING  ............................................................................................ 5-38

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Summary of Contents for LT-A450X 2006

Page 1: ...MANUEL DU PROPRIETAIRE HANDLEIDING This owner s manual contains important safety information Please read it carefully Never allow anyone under 16 years old to ride this ATV Ce Manuel du propriétaire contient des informations importantes concernant la sécurité Le lire soigneusement Ne jamais autoriser les enfants âgés de moins de 16 ans à piloter ce V T T Deze handleiding bevat belangrijke veilighe...

Page 2: ...nsidered a permanent part of the vehi cle and should remain with the vehicle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle ...

Page 3: ...E Indicates special information to make maintenance easier or instructions clearer WARNINGs and CAUTIONs are arranged like this WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage WARNING or CAUTION This first part will identify a POTENTIAL HAZARD This second part will describe WHAT CAN HAPPEN if you ign...

Page 4: ... quickly even during routine maneu vers such as turning and driving on hills or over obstacles if you fail to take proper precautions SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described Always follow this age recommen dation A child under 16 years old should never operate an ATV with engin...

Page 5: ...eeds Do not turn at excessive speed Never operate the ATV on hills too steep for the ATV or for your abili ties Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with exces sively slippery or loose surfaces Shift your weight forward Never ...

Page 6: ...uch as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flow ing water or in water deeper than that specified in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the lin ings Always be sure there ...

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Page 8: ...RECOMMENDATION CONTROLS EQUIPMENT AND ADJUSTMENTS RIDING YOUR ATV ACCESSORY USE AND VEHICLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING PREPARATION FOR WINTER RIDING TRANSPORTING CLEANING PROCEDURE AND STORAGE PROCEDURE CONSUMER INFORMATION SPECIFICATIONS INDEX ...

Page 9: ......

Page 10: ...1 1 1 FUEL OIL AND ENGINE COOLANT RECOMMENDATION FUEL 1 2 ENGINE OIL 1 3 DIFFERENTIAL GEAR OIL 1 4 ENGINE COOLANT SOLUTION 1 5 FRONT DIFFERENTIAL GEAR OIL 1 6 REAR DIFFERENTIAL GEAR OIL 1 6 ...

Page 11: ...rranty NOTE Oxygenated fuels are fuels which contain oxygen carrying addi tives such as MTBE or alcohol Gasoline containing MTBE Unleaded gasoline containing MTBE Methyl Tertiary Butyl Ether may be used in your ATV if the MTBE content is not greater than 15 This oxygen ated fuel does not contain alcohol Gasoline Ethanol Blends Blends of unleaded gasoline and eth anol grain alcohol also known as GA...

Page 12: ...e oil with an API American Petro leum Institute classification of SF SG or SH SJ or with a JASO classifica tion of MA API American Petroleum Institute JASO Japanese Automobile Stan dards Organization SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternative according to the following chart NOTE In very cold weather b...

Page 13: ...l classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oils Some engine oils which have an API classification of SH or higher have an ENERGY CONSERVING indication in the API classification doughnut mark These oils can affect engine life and clutch performance Not recommended Recommended DIFFERENTIAL GEAR OIL Use a SAE90 hypoid gear oil which is rated GL 5 under t...

Page 14: ...e aluminum radiator Required amount of engine coolant water solution capacity total 2500 ml 2 6 2 2 US Imp qt WARNING Engine coolant is harmful or fatal if swallowed or inhaled Do not drink antifreeze or coolant solution If swallowed do not induce vomiting Immediately con tact a poison control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If coolant gets in...

Page 15: ...hypoid gear oil which is rated GL 5 under the API classifica tion system If you normally operate the vehicle where ambient tempera ture is below 0 C 32 F use a SAE80 hypoid gear oil REAR DIFFERENTIAL GEAR OIL Use Mobil Fluid 424 or an equivalent ...

Page 16: ...TION SWITCH 2 13 LEFT HANDLEBAR 2 15 CHOKE LEVER 2 18 HORN SWITCH Australia and Sweden 2 18 EMERGENCY STOP SWITCH Sweden 2 19 RIGHT HANDLEBAR 2 19 THROTTLE LIMITER 2 20 REAR BRAKE PEDAL 2 20 RECOIL STARTER 2 21 FUEL TANK CAP 2 22 SEAT LOCK 2 23 FRONT AND REAR SUSPENSION ADJUSTMENT 2 24 FLAG BRACKET 2 25 BOX 2 25 FRONT FENDER BOX 2 26 ...

Page 17: ...NTS LOCATION OF PARTS 1 Rear brake lever 2 Left handlebar switches 3 Speedometer and indicator lights 4 Ignition switch 5 Front brake fluid reservoir 6 Front brake lever 7 Shift lever 8 Throttle lever 9 2WD 4WD DIFF LOCK selection switch ...

Page 18: ...2 3 0 Battery A Fuel tank cap B Seat lock C Recoil starter D Footrests ...

Page 19: ...2 4 E Rear brake pedal ...

Page 20: ... safe place An iden tifying number is stamped on the keys Use this number when making a replacement key Please write down your key number in the box provided for your future refer ence WARNING Indicates a potential hazard that could result in injury or death Key No ...

Page 21: ...y can not be removed in this position position The ignition circuit is complete and the headlights and taillights turn on The key cannot be removed in this position CAUTION Leaving the ignition switch in the position for a long time can damage the ATV s battery The battery will run down if the lights are no for a long time when the engine is not running Always leave the ignition switch in the OFF ...

Page 22: ...indica tor blinks when the switch is turned on and the differential gear is not locked The indicator remains lit when the switch is turned off and the gear lock is not released The indicator goes off when the differential gear lock is released Reverse Indicator 3 A red light comes on when the shift lever is in reverse gear The shift posi tion display 9 also shows R Neutral Indicator 4 A green ligh...

Page 23: ...ar lock indicator may not go off when the switch is shifted from 4WD to 2WD due to differential gear synchroniza tion mechanism The indicator will go off just after ATV starts moving Shift Position Indicator 9 The shift position indicator indicates shift lever positions R N H and L R Shift lever is in R Reverse posi tion The reverse indicator 3 also comes on N Shift lever is in N Neutral posi tion...

Page 24: ... Hour Meter Fuel Injection Indicator B The display has three functions clock hour meter and fuel injection indicator To change the display push the button 7 The display changes between clock and hour meter alter nately Clock The clock indicates 12 hour mode Follow the procedure below to adjust the clock 1 Hold in the button 7 until minute display blinks 2 Adjust the minute display by push ing the ...

Page 25: ...ehicle to an authorized Suzuki dealer If the engine stalls try restarting the engine after turning the ignition switch off Wait more than 3 sec onds before turning on the ignition switch If the display indicates FI contin uously and the symbol mark FI and red indicator light blinks the engine will not start If the engine is running keep the engine run ning and bring your vehicle to an authorized S...

Page 26: ...ture becomes high SHIFT LEVER This vehicle has an automatic trans mission Select gear positions according to how you intend to use the vehicle L Low position Carrying heavy loads or trailer towing Compared to H position this posi tion provides lower speed and greater torque to the wheels H High position Normal riding with light loads N Neutral position The transmis sion is in neutral R Reverse pos...

Page 27: ...e brake vehicle can move unexpect edly Always apply the brake before changing from Neutral to High or Reverse to help prevent the vehi cle from moving unexpectedly when you change WARNING Operating the shift lever when the ATV is moving can be hazardous If you shift into reverse gear when the vehicle is moving it could stop suddenly throwing you from the ATV If you shift from high position to low ...

Page 28: ...he wheels Select 2WD 4WD or DIFFERENTIAL LOCK according to surface condi tions WARNING Shifting the selection switch when the ATV is moving can be hazard ous Removing a hand while riding can lose control Shifting the selection lever while ATV is moving can damage the shifting mechanism Always come to a complete stop before shifting ...

Page 29: ...ENTIAL LOCK Engine power is supplied to the front and rear wheels Since the front differential gear is locked all wheels will always turn at the same speed Use this posi tion if the 4WD position does not pro vide enough traction to prevent the vehicle from getting stuck WARNING Operating the vehicle at high speeds in DIFFERENTIAL LOCK can be hazardous When in DIFFERENTIAL LOCK both front wheels tu...

Page 30: ... be limited approximately 35 km h 22 mph when the selection switch is in dif ferential lock position LEFT HANDLEBAR Rear Brake Lever 1 Apply the rear brake by squeezing the rear brake lever towards the grip Parking Brake Lock 2 Use this lock to set and lock the park ing brake Use the parking brake to help prevent the vehicle from moving when it is parked being started or at idle To lock the parkin...

Page 31: ...ormal speed limiter the rider must push the override but ton and hold it in When the switch button is released engine speed will once again be limited by the speed limiter In forward Differential Lock mode the override mode can be used for an indefinite period of time simply by holding the button in continuously When in Reverse whether in Differen tial Lock or not the override mode can only be use...

Page 32: ... switch click A starter interlock switch prevents the starter motor from turning when the transmission is in gear if the rear brake lever is not squeezed WARNING Going too fast in R Reverse can be hazardous Going too fast in R Reverse with override switch on can cause a loss of control and accident resulting in severe personal injury or death Always maintain safe speed Use the override switch only...

Page 33: ...e lever all the way to the left The choke system opens the throttle valve slightly to raise idling speed When the engine is warm you do not need to use the choke system for starting NOTE Refer to the RIDING YOUR ATV section of the manual for the engine starting procedure HORN SWITCH Australia and Sweden Push the button to sound the horn ...

Page 34: ...g and the cap is removed by pulling the cord that is attached to the cap the engine will stop running RIGHT HANDLEBAR Front Brake Lever 1 Apply the front brake by squeezing the front brake lever towards the grip Throttle Lever 2 Control the engine speed with the position of the throttle lever Operate this lever with your thumb Push it for ward to increase engine speed Release it to decrease engine...

Page 35: ...xperience To adjust the throttle limiter 1 Loosen the lock nut 1 2 Turn the throttle limiter screw 2 clockwise to restrict maximum engine power or counterclock wise to increase the maximum engine power 3 Tighten the lock nut 1 REAR BRAKE PEDAL Pressing the rear brake pedal will apply the rear brake NOTE The rear brake may also be applied by squeezing the rear brake lever ...

Page 36: ...the engine magneto cover 3 Pull the rope gently until you feel the starter engage 4 Pull the rope forcefully to start the engine 5 Immediately after the engine starts be sure to return the starter rope handle gently NOTE The engine can be started in any gear if you squeeze the rear brake lever until the interlock switch clicks Switch off the headlight when starting the engine with the recoil start...

Page 37: ...ating by the sun Fuel that overflows can catch fire Stop adding fuel when the fuel level reaches the bottom of the filler neck WARNING Improper fueling of the ATV can be hazardous Failure to follow safety precau tions when refueling could result in a fire or cause you to breathe toxic fumes Refuel in a well ventilated area Make sure the engine is off and avoid spilling fuel on a hot engine Do not ...

Page 38: ... To lock the seat slide the seat hook into the seat hook retainer and push down firmly WARNING Improperly installing the seat can be hazardous Failure to install the seat properly could allow the seat to move and cause loss of rider control Make sure to properly position and securely attach the seat when you install it ...

Page 39: ...hem by turning the spring tension ring to the desired position Position 1 provides the softest spring tension and position 5 provides the stiffest The vehicle is delivered from the fac tory with its adjuster set to the follow ing positions Front Position 2 Rear Position 2 WARNING Unevenly adjusting the right and left front suspensions can be haz ardous Making one spring stiffer than the other will...

Page 40: ...2 25 FLAG BRACKET A bracket is provided so you can mount a flag on your vehicle BOX Small and light articles such as the owner s manual rain gear or a wind breaker can be placed in the box ...

Page 41: ...an be placed in the front fender box WARNING Carrying fuel in the front fender box can be hazardous The fender box is designed for carrying dry light articles It is not designed to store fuel or other liq uids Fuel could leak and catch on fire Use the fender box only to carry dry light articles ...

Page 42: ...ING 3 3 WHAT TO WEAR 3 6 BREAK IN 3 7 STARTING THE ENGINE 3 8 STARTING OFF AND SHIFTING 3 9 BRAKING 3 14 TURNING 3 15 SKIDDING OR SLIDING 3 16 OPERATION ON HILLS 3 16 RIDING OVER OBSTACLES 3 22 RIDING THROUGH WATER 3 22 RIDING IN COLD WEATHER 3 23 RIDING IN REVERSE 3 27 PARKING 3 28 ...

Page 43: ...f you do not know where you can ride WARNING Indicates a potential hazard that could result in injury or death WARNING Operation of this ATV by children under age 16 can be hazardous Use by children under age 16 can lead to their severe injury or death Children under age 16 may not have the size strength skills or judgment needed to operate this ATV safely Do not allow any child under age 16 to ri...

Page 44: ...dous Failure to perform proper mainte nance can also be hazardous Failure to inspect and maintain your ATV increases the chances of an accident or equipment damage Always inspect your ATV each time you use it to make sure it is in safe operating condition Refer to the INSPECTION AND MAINTE NANCE section in this owner s manual WARNING Operating this ATV with improper tires or with improper or uneve...

Page 45: ...r modify this ATV through improper installation or use of accessories Refer to the ACCES SORY USE AND VEHICLE LOAD ING section in this manual WARNING Overloading this ATV or carrying or towing cargo improperly can be hazardous Overloading or improper towing could cause changes in vehicle handling which could lead to an accident Never exceed the stated load capacity for this ATV Refer to the ACCESS...

Page 46: ...damage to fuel tank or cap 4 Tank cap closed securely Lighting Proper operation of all lights Headlight Brake Taillight Reversing light Sweden Engine stop switch Proper operation Horn Australia and Sweden Correct function Engine oil Correct level Gear oil Correct level Cooling system 1 Proper coolant level 2 No leaks or damage Throttle 1 Proper cable play 2 Smooth response 3 Quick return to idle p...

Page 47: ...ar a good pair of gloves strong boots that fit over the ankle long pants and a long sleeve shirt WARNING Operating this ATV without wear ing an approved motorcycle hel met eye protection and protective clothing can be hazardous Operating without an approved motorcycle helmet or eye protec tion increases your chances of a severe head injury or death in the event of an accident Operating without pro...

Page 48: ...arts to glaze and not seat properly Allow the engine to accelerate freely through the gears without exceeding the max imum recommended throttle opening Allow the Engine Oil to Circulate Before Riding Allow enough idling time after warm or cold engine starting before revving the engine or placing the transmission in gear This allows time for the lubri cating oil to reach all critical engine compone...

Page 49: ... forcefully to start the engine If the idle speed is so low that the engine rattles just after starting it open the throttle briefly to raise the idle speed When the Engine is Cold 1 Move the choke lever all the way to the left 2 Close the throttle completely and push the electric starter button or use the recoil starter as described above to start the engine 3 Immediately after the engine starts ...

Page 50: ...tion system WARNING Running your ATV indoors where there is little or no ventilation can be hazardous When breathed in exhaust gases from the ATV can cause death or severe injury Always run your ATV outdoors where there is fresh air WARNING Carrying a passenger on this ATV can be hazardous Carrying a passenger can greatly reduce your ability to balance and steer this ATV If you carry a pas senger ...

Page 51: ...ut of control Avoid operating the ATV on paved surfaces whenever possible If you must ride on a paved surface go slowly and do not make sud den turns or stops WARNING Operating this ATV on public streets roads or highways can be hazardous You can collide with another vehi cle if you ride on public roads Never operate this ATV on any public street road or highway even a dirt or gravel one In many s...

Page 52: ...ch can result in an accident Always go at a speed that is proper for the terrain visibility and operating conditions your skills and experience WARNING Attempting wheelies jumps and other stunts can be hazardous Stunt riding increases the chance of an accident including an over turn Never attempt stunts such as wheelies or jumps Don t try to show off ...

Page 53: ...This could injure you or cause an accident Always keep both hands on the handlebars and both feet on the footrests of your ATV during oper ation WARNING Failure to use extra care when operating on excessively rough slippery or loose terrain can be hazardous Failure to use extra care can cause loss of traction or vehicle control This could result in an accident including an overturn Do not operate ...

Page 54: ...rottle to bring the engine to idling before shifting NOTE Refer to the SHIFT LEVER section in the CONTROLS EQUIP MENT AND ADJUSTMENTS WARNING Failure to use extra care when operating this ATV on unfamiliar terrain can be hazardous You can come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to overturn or go out of con trol Go slowly and be extra careful when...

Page 55: ...g hard on slippery surfaces can be hazardous The ATV can skid and go out of control if you brake too hard Apply the brakes lightly and with care on slippery surfaces WARNING Braking on hills when in 4WD can be hazardous When in 4WD using either the front brake alone or the rear brake alone will actually brake all four wheels Therefore any application of the brakes will result in braking force bein...

Page 56: ...ars in the direc tion of the turn Shift body weight slightly forward and support your weight on the outer footrest This will reduce the load on the inside rear wheel reducing its traction Lean upper body into the turn At HIGHER SPEEDS Use the same technique that you use for turning at low speeds but lean far ther into the turn Natural turning forces which can push the vehicle to the outside of the...

Page 57: ...ATION ON HILLS WARNING Skidding or sliding improperly can be hazardous You may lose control of your ATV or regain traction unexpectedly which may cause the ATV to over turn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or slid ing...

Page 58: ... ATV to overturn Always follow the proper proce dures for climbing hills as described in this section Always check the terrain care fully before you start up any hill Never climb hills with exces sively slippery or loose sur faces Shift your weight forward Never open the throttle sud denly or make sudden gear changes The ATV could flip over backwards Never go over the top of any hill at high speed...

Page 59: ...scribed in the Descending a Hill section If you lose forward movement or begin to roll backwards follow these instructions 1 Lean farther forward uphill 2 Apply the front brake to stop the ATV 3 After the vehicle has stopped apply the rear brake as well as the front brake 4 Set the parking brake and dis mount to the left side while still leaning uphill WARNING Stalling rolling backwards or imprope...

Page 60: ...e and pump the hand brake to let the vehicle roll slowly backwards This will turn the vehicle sideways to the hill Reset the parking brake Turn the handlebars to the right Stay on the uphill side Release the parking brake and pump the hand brake to let the ATV slowly roll until it points downhill Reset the parking brake 6 Remount the vehicle apply the brakes release the parking brake and ride down...

Page 61: ...use the vehicle to lean sharply to one side Go straight down the hill where possi ble WARNING Going down a hill improperly can be hazardous Going down a hill improperly can cause loss of control or cause the ATV to overturn Always follow the proper proce dures for going down hills as described in this section WARNING Braking on hills when in 4WD can be hazardous When in 4WD using either the front ...

Page 62: ...roperly can be hazardous Crossing hills or turning on hills improperly can cause loss of con trol or cause the ATV to overturn Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the CLIMBING A HILL section Practice this technique on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible ...

Page 63: ...s before you ride through any water Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard If you are unfamiliar with the area park the vehicle and inspect the stream first to find a suitable spot for crossing When crossing operate the ATV at a slow steady speed Be care ful not to damage banks when cross ing WARNING Improperly operating this ATV over o...

Page 64: ...our warm water around them to melt the ice If the brakes are frozen bring the ATV to a warmer area to thaw out the brakes CAUTION Operating the ATV in water sand or mud causes rapid brake wear Excessive brake wear can cause the brakes to be less effective After repeated operation of the ATV in these conditions bring it to your Suzuki dealer to have the brakes inspected and cleaned CAUTION Using en...

Page 65: ...r you park your ATV The frozen water can prevent the wheels from turning or the brakes from working After riding through water mud snow or slush it is important to dry the brakes before parking the ATV To dry the brakes apply them several times while riding slowly Before your next ride be sure to do a Pre ride inspection as described earlier in this section CAUTION Use of an automotive size batter...

Page 66: ...ent and prevention of hypothermia Information is available at libraries and through government agencies Plan your winter rides with safety and comfort in mind Dress for the worst conditions you might encounter Be prepared for bad weather and ATV breakdowns Wear warm water resis tant clothing such as thermal under wear snowmobile suits lined gloves and boots and wool socks WARNING Operating your AT...

Page 67: ...her hazards that can cause a loss of control Severe injury or death could occur if you lose control of the ATV Go slowly and be extra careful when riding on snow covered ter rain Always be alert to changing terrain conditions when operating the ATV WARNING Riding on a frozen lake or river can be hazardous Serious injury or death can occur if the ice breaks and you fall into the cold water Check wi...

Page 68: ...operly riding this ATV in reverse can be hazardous You could hit an obstacle or per son behind you resulting in injury When you select reverse gear make sure there are no obstacles or people behind you When it is safe back up slowly WARNING Sudden application of the throttle or making abrupt turns in reverse gear can be hazardous Throttle surges or abrupt turns could cause you to lose control of t...

Page 69: ...neu tral Neutral position can be confirmed by observing the neutral indicator light Park the ATV on a flat surface and set the parking brake lock Turn the ignition switch to the OFF posi tion Always remove the key from the ATV when leaving the ATV ...

Page 70: ...4 1 4 ACCESSORY USE AND VEHICLE LOADING ACCESSORY USE AND VEHICLE LOADING 4 2 ATV WINCH LEAD WIRES For Canada 4 4 ...

Page 71: ...help you choose accessories and install them correctly The guidelines below should help you decide how to equip your ATV and how to use it cor rectly when you use accessories or carry cargo WARNING Operating this ATV with improper modifications can be hazardous Improper installation of accesso ries or modification of the vehicle may cause changes in handling which could lead to an accident Never m...

Page 72: ...e designed to carry light items 6 Distribute cargo weight evenly between the front and rear of the vehicle as well as both sides of the vehicle Locate cargo weight as close to the center of the vehi cle as possible e g load cargo to the rear of front racks and to the front of rear racks Do not let cargo stick out beyond the edges of the racks 1 Front cargo rack 30 kg 66 lbs 2 Front fender box 0 5 ...

Page 73: ...e wir ing harness that can be used to attach a Suzuki genuine accessory ATV winch rated line pull 1134 kg 2500 lbs The part number of the Suzuki ATV winch for this vehicle is 99000 990YW 016 Consult your Suzuki dealer for details about attach ing the accessory ATV winch ...

Page 74: ...ND FILTER CHANGE 5 11 AIR CLEANER 5 15 AIR CLEANER DRAIN TUBES 5 17 ENGINE COOLANT 5 18 GEAR OIL CHANGE 5 19 TIRES 5 20 FRONT BRAKE 5 23 REAR BRAKE 5 27 REAR BRAKE LINING WEAR LIMIT 5 29 FRONT AND REAR WHEEL REMOVAL 5 30 SPARK ARRESTER 5 31 DRIVE SHAFT BOOTS 5 32 LIGHT BULB REPLACEMENT 5 32 FUSES 5 35 OUTPUT TERMINAL 5 36 GENERAL LUBRICATION 5 37 TRAILER TOWING 5 38 ...

Page 75: ...t pipe nuts and muffler mounting bolts T T T Valve clearance I I Spark plug I Replace every 6000 km 4000 miles Spark arrester C Fuel line I I Replace every 4 years Engine oil and oil filter R R Front differential gear oil I Replace every 2 years Final gear oil I Replace every year Drive shaft boots Front and rear I I I Throttle cable play I I I Throttle body I I Engine coolant Replace every 2 year...

Page 76: ... Clean R Replace T Tighten L Lubricate Interval km 200 1000 2000 miles 100 600 1200 Item months 1 3 6 Brake fluid I I Replace every 2 years Brake hoses I Replace every 4 years Tires I I Steering I I I Suspensions I Chassis nuts and bolts T T T General lubrication L L ...

Page 77: ...ce items marked with an asterisk You may perform the unmarked maintenance items by referring to the instructions in this section if you have mechanical experience If you are not sure how to do any of the jobs ask your Suzuki dealer to do the main tenance CAUTION If you use your ATV under severe conditions it will need mainte nance more often than shown in the chart Operating your ATV under severe ...

Page 78: ... seat CAUTION Using poor quality replacement parts can damage your ATV Poorly made replacement parts can cause your ATV to wear more quickly and may shorten its useful life When replacing parts on your vehicle use only genuine Suzuki replacement parts or their equiva lent ...

Page 79: ...produce flammable hydrogen gas which can explode if exposed to flames or sparks Keep flames and sparks away from the battery Never smoke when working near the battery CAUTION Exceeding the maximum charging rate for the ATV battery can dam age your ATV If you charge the battery at a rate too high it will decrease the life of the battery Never exceed the maximum charg ing rate CAUTION Reversing the ...

Page 80: ...TION Failure to use the proper spark plug can damage your ATV An improper spark plug may have an incorrect fit or heat range for your engine This may cause severe engine damage which may not be covered under warranty Use only the spark plugs listed below Consult your Suzuki dealer if you are not sure which spark plug is correct for your type of vehicle usage NGK DENSO REMARKS CR6E U20ESR N Standar...

Page 81: ... gauge to check the gap FUEL HOSE Replace the fuel hose every 4 years even if they appear to be in good con dition Damage from aging may not always be visible CAUTION Dirt can damage your ATV if it enters an open spark plug hole Dirt can damage engine parts that move Cover the spark plug hole while the spark plug is out of the hole 0 7 0 8 mm ...

Page 82: ...he correct play 4 Tighten the lock nut 1 5 Recheck the throttle cable play Readjust it if it is not within the specified limits 6 Fit the cover to the adjuster 3 0 5 0 mm WARNING Operating the vehicle with an inadequate throttle cable play can be hazardous Inadequate throttle cable play can cause engine speed to rise sud denly when you turn the handle bars This can lead to loss of rider control Ad...

Page 83: ...ipstick comes out together with the oil filler cap as shown The level on the dipstick should be between L Low and F Full lines The oil level inspection should be per formed under the following conditions Park the vehicle on level ground The oil filler cap threads are not run in but touching the filler hole upper edge F L CAUTION Operating the vehicle with an incorrect amount of oil can dam age you...

Page 84: ...n easily The procedure is as follows 1 Park the vehicle on level ground 2 Remove the fasteners and cover 3 Remove the oil filler cap 1 4 Remove the drain plug 2 from the bottom of the engine and drain the oil into a drain pan WARNING Oil can be hazardous Children or pets may be harmed from contact with oil Keep children and pets away from oil Dispose of used oil properly ...

Page 85: ...steners Remove the inner cover 3 Available from Suzuki dealer Oil filter wrench Part No 09915 40610 6 Turn the oil filter 4 counterclock wise with a Suzuki cap type oil filter wrench or a strap type filter wrench of the proper size ...

Page 86: ...e mounting surface a small resis tance will be felt NOTE To tighten the oil filter properly it is important to accurately identify the position at which the filter gasket first contacts the mounting surface CAUTION Failure to use the correct oil filter can damage your ATV Engine damage may occur if you use oil filter with the wrong design or thread specifications Be sure to use a genuine SUZUKI oi...

Page 87: ...dle for a few minutes 13 Turn the engine off and wait for three minutes Recheck the oil level with the engine oil dipstick The oil level should be at the F full mark If it is lower than the F mark add oil until it reaches the F mark Inspect the area around the drain plug and oil filter for leaks Mark top dead center Oil filter wrench In the position at which the filter gasket first contacts the mo...

Page 88: ...take box without the air cleaner element to stop it Severe engine damage can also occur if dirt enters the engine due to running the engine without the air cleaner element Never run the engine without the air cleaner element in place CAUTION Failure to inspect the air cleaner element frequently if the vehicle is used in dusty wet or muddy con ditions can damage your ATV The air cleaner element can...

Page 89: ... the air cleaner element only If air pressure is applied on the air cleaner cover side dirt will be forced into the pores of the cleaner element restricting the air flow through the cleaner element 5 Reinstall the cleaned element or new air cleaner element in reverse order of removal Be absolutely sure that the element is securely in position and is sealing properly 6 If the air cleaner element is...

Page 90: ...ge the engine Carefully examine the air cleaner element for tears during cleaning Replace it with a new one if it is torn CAUTION Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element This will cause engine damage Be sure to properly install the air cleaner element WARNING Failure to properly dispose of the drained oil or gasoline can be haz ardous O...

Page 91: ...ixture of distilled water and engine coolant WARNING Engine coolant is harmful or fatal if swallowed or inhaled Do not drink antifreeze or coolant solution If swallowed do not induce vomiting Immediately con tact a poison control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If coolant gets in eyes flush eyes with water and seek medical attention Wash thor ...

Page 92: ...changing the front and rear differen tial gear oil is as follows 1 Park the vehicle on level ground Front differential gear oil Final gear oil 2 Remove the covers under the gear case 3 Remove the oil filler cap 1 for the front differential gear or the filler cap 3 for the final gear Front differential gear oil Final gear oil 4 Remove the drain plug 4 or 5 from the bottom of the gear case and drain...

Page 93: ...l gear oil 770 ml 26 0 27 1 US Imp oz TIRES This vehicle is equipped with low pressure tubeless tires of the size and type listed below NOTE Do not mix type 1 tires and type 2 tires Use only one type tires for the vehicle WARNING Oil can be hazardous Children or pets may be harmed from contact with oil Keep children and pets away from oil Dispose of used oil properly Front Rear Size AT25 8 12 AT25...

Page 94: ... cold or misleading mea surements can result WARNING The use of very worn tires can be hazardous The traction of the vehicle will be decreased with worn tires This increases your risk of having an accident Replace the front and rear tires when the depth on the tread is 4 0 mm 0 16 in or less 4 0 mm LOAD TIRE PRESSURE FRONT REAR Up to 172 kg 380 lbs 5 1 psi 35 kPa 0 35 kgf cm2 4 4 psi 30 kPa 0 30 k...

Page 95: ...ner wheel sur face or the tire bead Tubeless Tire Repair Should a leak or flat tire occur due to a puncture the tire may be repaired using a plug type patch If the dam age is from a cut or if the puncture cannot be repaired using a plug the tire should be replaced When operat ing your vehicle in areas where trans portation or service facilities are not readily available it is strongly recom mended...

Page 96: ... the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE WARNING Operating the ATV in harsh condi tions can be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your vehicle under these conditions the brakes must be ins...

Page 97: ...e poisonous to animals Keep out of the reach of children and animals WARNING Failure to use proper brake fluid can be hazardous The use of any fluid except DOT4 brake fluid from a sealed con tainer can damage the brake sys tem and lead to an accident Use only DOT4 brake fluid from a sealed container Never use or mix different types of brake fluid WARNING Failure to keep the brake fluid res ervoir ...

Page 98: ... line bring the vehicle to your autho rized Suzuki dealer to have the brake pads replaced After inspecting or replacing a brake pads reinstall the front wheel as described in the FRONT AND REAR WHEEL REMOVAL section CAUTION Spilled brake fluid can damage your ATV Brake fluid can damage painted surfaces and plastic parts Be careful not to spill any fluid when filling the brake fluid reser voir Wipe...

Page 99: ...brake system repair or brake pedal replacement without pumping the brake lever pedal can be hazardous If you do not pump the brake lever pedal before starting you may get poor braking performance and this may result in an accident Pump the brake lever pedal sev eral times until brake pads are pressed against the brake disks and proper lever pedal stroke and firm feel are restored WARNING Replacing...

Page 100: ...free travel WARNING Misadjusting the rear brake pedal and lever can be hazardous The rear brake lever and brake pedal operate the rear brake in a complementary manner When one of these is misadjusted the brake system as a whole will not operate properly Misadjusting the rear brake lever and brake pedal can cause brake dragging or inad equate braking performance Adjust both the brake pedal and brak...

Page 101: ...ter adjusting the play check that the rear wheels roll freely with the brake disengaged the transmis sion in neutral and the rear wheels off the ground 6 Set the parking brake and check that the rear wheels are locked by trying to move the vehicle back and forth while it is in neutral 7 Readjust the rear brake lever adjusting nut if the rear wheels could not roll freely in step 5 or if the rear wh...

Page 102: ... the extension line of the index mark is within the limit Fig A 3 If the extension line is out of the limit Fig B have the brake plates replaced by your Suzuki dealer to insure safe operation WARNING Failure to check brake lining wear and replace brake shoes as rec ommended can be hazardous Riding with worn brake shoes or brake shoes that are unevenly worn will increase your chances of having an a...

Page 103: ...tening torque chart to determine the tightness of the wheel nuts Tighten the nuts in a cross wise pattern Tightening Torque FRONT 60 N m 6 0 kgf m 43 lb ft REAR 60 N m 6 0 kgf m 43 lb ft WARNING Failure to tighten the wheel nuts to the specified torque can be haz ardous If the wheel nuts are not properly tightened the wheel can come off causing an accident Be sure to tighten the wheel nuts to the ...

Page 104: ...nd cover 2 2 Remove the spark arrester 3 3 Use a brush to remove carbon deposits from the spark arrester screen Be careful not to damage the spark arrester screen Check that the screen has no holes or tears Replace the screen if nec essary 4 Reinstall the spark arrester in reverse order of removal WARNING A hot muffler can harm you You can be burned if you touch the hot muffler Wait until the muff...

Page 105: ...b is shown in the following chart When replacing a burned out bulb always use the same wattage rating Headlight 12V 35 35W 2 Brake Taillight 12V 21 5W Reversing light Sweden 12V 21W CAUTION Failure to use a light bulb with the correct wattage rating can dam age your ATV The electrical system can over load or the bulb may burn out sooner Use only the light bulbs shown in the chart as replacement bu...

Page 106: ... holder spring 4 and pull out the bulb 5 5 To replace the headlight bulb reverse the above complete sequence CAUTION Touching the headlight bulb glass with a bare hand may damage the bulb The bulb s life may be shortened by oil from your fingers if you touch it When replacing the headlight bulb be careful not to touch the glass Grasp the new bulb with a clean cloth ...

Page 107: ... Remove the bulb 3 To install a new bulb push the bulb in firmly and turn it to the right while pushing in REVERSING LIGHT Sweden Replace the reversing light bulb as follows 1 Remove the screws 1 and the cover 2 2 Push the bulb in and turn it to the left Remove the bulb 3 To install a new bulb push the bulb in firmly and turn it to the right while pushing in ...

Page 108: ...he fuse box The fuses are located under the seat One 10A and one 15A spare fuses are provided inside the fuse box The fuses are designed to open when a circuit overload exists in individual electrical system circuits If any elec trical system fails to operate then the fuses must be checked ...

Page 109: ...lectrical accessories Total electrical accessory wattage should be less than 120W Check electrical accessory voltage and watt age before attaching accessories to the output terminal CAUTION Failure to install the correct fuse can damage your ATV Installing a fuse of incorrect rating or using aluminum foil or wire instead of a fuse may seriously damage the electrical system Always replace a blown f...

Page 110: ... Suzuki dealer should do general lubri cation as shown in the MAINTE NANCE SCHEDULE Grease 1 Brake lever holder 2 Throttle lever and front brake lever holder 3 Steering shaft holder 4 Brake pedal and rod link 5 Drive shaft joint spline 6 Propeller shaft joint spline CAUTION Lubricating switches can damage your ATV Lubricating switches can damage the switches Do not apply grease and oil to the swit...

Page 111: ...fully loaded trailer on a bathroom scale Add the weights shown on the scales Tongue Weight is the downward force exerted on the hitch by the trailer cou pler when the trailer is fully loaded and the coupler is at its normal towing height This weight can be measured using a bathroom scale The weight of your loaded trailer Gross Trailer Weight should never exceed 180 kg 400 lbs when towing on uneven...

Page 112: ...e hazardous Cargo weight shifting while mov ing can affect your ability to han dle the ATV safely Make sure that the load in your trailer is properly secured and will not shift while moving WARNING Riding your ATV without extra caution when towing a trailer can be hazardous Trailer towing can affect the han dling and braking of your ATV Tow only at low speeds Avoid sudden acceleration and stop pin...

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Page 114: ...6 1 6 TROUBLESHOOTING FUEL SUPPLY CHECK 6 2 IGNITION SYSTEM CHECK 6 3 ...

Page 115: ...thorized Suzuki dealer Refer to the INSTRUMENT PANEL section for an explanation of fuel injection system indicator If the indicator does not display FI make sure there is enough fuel in the fuel tank If the indicator does not display FI and there is enough fuel the igni tion system should be checked CAUTION Failure to troubleshoot a problem correctly can damage your ATV Improper repairs or adjustm...

Page 116: ...r COMPLAINT Engine stalls 1 Make sure there is enough fuel in the fuel tank 2 Check to see that the spark plug is not fouled Remove the plug and clean it Replace it if neces sary 3 Make sure the fuel valve is not clogged Also check to be sure the air vent hose connected to the fuel tank is not clogged WARNING Performing the spark test improp erly can be hazardous You could get a high voltage elec ...

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Page 118: ...7 1 7 PREPARATION FOR WINTER RIDING ENGINE OIL CHANGE 7 2 SPARK PLUG CHANGE 7 2 BATTERY CHECK 7 2 ...

Page 119: ...ne oil viscosity Dirt and dust in the oil will affect engine performance especially when the weather is cold Change the engine oil before using your ATV in cold weather below freezing even if the oil that is in the engine is the right type for colder temperature SPARK PLUG CHANGE Cold temperature especially below 20 C 4 F can result in hard engine starting Replace the spark plug with Iridium type ...

Page 120: ...8 1 8 TRANSPORTING TRANSPORTING 8 2 ...

Page 121: ...secure the ATV to the pallet and use a forklift to lift the pallet or Using a ramp and winch mounted on the truck hook the winch cable to the center of ATV front bumper and pull the ATV up the ramp onto the truck CAUTION Failure to properly secure the ATV when transporting it can be haz ardous Failure to properly secure the vehicle may result in an accident or damage to the vehicle When transporti...

Page 122: ...DURE AND STORAGE PROCEDURE CLEANING PROCEDURE 9 2 PREPARATION FOR CLEANING 9 2 WASHING YOUR ATV 9 3 INSPECTION AFTER CLEANING 9 4 STORAGE PROCEDURE 9 4 MAINTENANCE DURING STORAGE 9 5 PROCEDURE FOR RETURNING TO SERVICE 9 5 ...

Page 123: ...ATV before any mud dries on the ATV Block or seal the end of the exhaust pipe muffler using a piece of plastic wrap cloth rag or another method to prevent water from entering the engine WARNING Built up mud and packed snow around the rear brake pedal will be hazardous Built up mud and packed snow will interfere with brake pedal operation Clean the brake pedal and foot rests thoroughly after operat...

Page 124: ...nd wash your ATV with mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure even at remote areas such as link ages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used Be careful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or sof...

Page 125: ...ler If you wish to service the machine for storage yourself follow the general guidelines below VEHICLE Place the vehicle on level ground and wash the entire vehicle FUEL Drain the fuel from the fuel tank using a hand pump or siphon WARNING Operating the ATV with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an acci dent Test your br...

Page 126: ...ure EXTERNAL Spray all vinyl and rubber parts with rubber protectant Spray unpainted surfaces with rust preventative Coat painted surfaces with car wax MAINTENANCE DURING STORAGE Once a month recharge the battery The standard charging rate is 1 4A 5 to 10hr PROCEDURE FOR RETURNING TO SERVICE Clean the entire vehicle Drain all the engine oil Install a new oil filter and fill the engine with fresh o...

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Page 128: ...10 10 1 CONSUMER INFORMATION SERIAL NUMBER LOCATION 10 2 INFORMATION REGARDING EC DIRECTIVE 10 2 LOCATION OF LABELS 10 3 ...

Page 129: ...rs here for your future reference INFORMATION REGARDING EC DIRECTIVE For European countries Noise level Noise levels of this ATV measured under related EC Directives are as follows Vibration Vibration levels of this ATV measured under the related in house engineer ing standard according to the require ments of EC Directive are as follows Frame No Engine No Regulation Condition Noise level 97 24 EC...

Page 130: ...tc away from fan Fan starts automatically and may cause injury Garder les mains les cheveux les vêtements etc à distance du ventilateur Le ventilateur se déclenche automatiquement et il pourrait provoquer des blessures WARNING Keep hands hair clothing etc away from fan Fan starts automatically and may cause injury WARNING AVERTISSEMENT NEVER carry passenger on this carrier or on ATV MAXIMUM LOAD 3...

Page 131: ...nder age 16 Improper ATV use can result in SEVERE INJURY or DEATH A L W A Y S U S E A N A P P R O V E D H E L M E T A N D P R O T E C T I V E G E A R N E V E R U S E O N P U B L I C R O A D S N E V E R C A R R Y P A S S E N G E R S N E V E R U S E W I T H D R U G S O R A L C O H O L without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collis...

Page 132: ...oper tire pressure as shown below NEVER exceed the Vehicle Load Capacity of 172 kg 380 lbs LOAD COLD TIRE PRESSURE FRONT 35 kPa 0 35 kgf cm2 5 1 psi REAR 30 kPa 0 30 kgf cm2 4 4 psi TIRE SIZE FRONT AT25 8 12 REAR AT25 10 12 UP TO 172 kg 380 lbs NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH WARNING ...

Page 133: ...carry passenger on this carrier or on ATV MAXIMUM LOAD 60kg 132 lbs AUCUN passager ne doit monter sur ce porte bagages ou ce VTT CHARGE MAXIMUM 60kg 132 lbs WARNING N E V E R c a r r y p a s s e n g e r o n t h i s c a r r i e r o r o n AT V MAXIMUM LOAD 60 kg 132 lbs ...

Page 134: ...re de puissance supérieure à 120W et de voltage autre que 12V risque d endommager à la fois le système électrique du VTT et l accessoire CAUTION Accessory must not exceed 120W rating and must be 12V type Exceeding 120W or using other than 12V accessory can damage ATV electrical system and accessory WARNING Exceeding vehicle towing limit could lead to an accident Reduce speed when towing a trailer ...

Page 135: ...ke 82 0 mm 3 228 in Displacement 454 cm3 27 7 cu in Compression ratio 10 0 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric and recoil starter Lubrication system Wet sump DRIVE TRAIN Clutch Wet shoe automatic centrifugal type Transmission Automatic variable ratio V belt Transfer 2 speed forward with reverse Gearshift pattern Transmission Automatic Transfer ...

Page 136: ...c ignition CDI Spark plug NGK CR6E or DENSO U20ESR N Battery 12V 43 2 kC 12Ah 10HR Fuse 30 10 10 10 15 15 10A Generator Three phase A C generator Headlight 12V 35 35W 2 Brake Taillight 12V 21 5W Reversing light 12V 21W Sweden Parking indicator light LED Speedometer light LED Coolant temperature FI warning light LED Neutral indicator light LED High beam indicator light LED Sweden Reverse indicator ...

Page 137: ...ENGINE OIL 1 3 5 10 ENGINE OIL AND FILTER CHANGE 5 11 ENGINE OIL CHANGE 7 2 F FLAG BRACKET 2 25 FRONT AND REAR SUSPENSION ADJUSTMENT 2 24 FRONT AND REAR WHEEL REMOVAL 5 30 FRONT BRAKE 5 23 FRONT DIFFERENTIAL GEAR OIL 1 6 FRONT FENDER BOX 2 26 FUEL 1 2 FUEL HOSE 5 8 FUEL SUPPLY CHECK 6 2 FUEL TANK CAP 2 22 FUSES 5 35 G GEAR OIL CHANGE 5 19 GENERAL LUBRICATION 5 37 H HORN SWITCH Australia and Sweden...

Page 138: ...COIL STARTER 2 21 RIDING IN COLD WEATHER 3 23 RIDING IN REVERSE 3 27 RIDING OVER OBSTACLES 3 22 RIDING THROUGH WATER 3 22 RIGHT HANDLEBAR 2 19 S SEAT LOCK 2 23 SELECTION SWITCH 2 13 SERIAL NUMBER LOCATION 10 2 SHIFT LEVER 2 11 SKIDDING OR SLIDING 3 16 SPARK ARRESTER 5 31 SPARK PLUG 5 7 SPARK PLUG CHANGE 7 2 STARTING OFF AND SHIFTING 3 9 STARTING THE ENGINE 3 8 STORAGE PROCEDURE 9 4 T THROTTLE CABL...

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