Suzuki LT-A450XK7 Setup Manual Download Page 26

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HARNESS ROUTING

Clamp

Emergency switch lead wire (E-17)

Emergency switch (E-17)

Horn switch
(E-17, E-24)

Set the matting surface

emergency switch to forward

Horn (E-17)

Clamp

DIFF-lock/transfer switch lead wire

Fix the front brake hose

Starter motor

Engine ground

DIFF-lock/transfer
relay

Set the TS coupler to the rear fender hole.

Starter motor terminal

Battery

ECM

Fuse box

Master cylinder reservoir tank

To combination meter

Set the sag under
combination meter

Pass the combination
meter wire behind the
upper bracket.

Horn switch lead wire (E-17, E-24)

Brake lever switch lead wire (L)

Handle switch lead wire (L)

Parking brake switch lead wire

Emergency switch lead wire (E-17)

DIFF-lock/transfer switch lead wire

Combination meter lead wire

Horn switch lead wire (E-17, E-24)

Brake lever switch lead wire (L)

Brake lever switch lead wire (R)

Ignition switch lead wire

Handle switch lead wire (L)

Parking brake switch lead wire

Brake lever switch lead wire (R)

10 “ 15 mm (0.3 “ 0.6 in)

Horn (E-24)

Wiring Harness

Drive Motor lead wire

Clamp

Wiring Harness

Summary of Contents for LT-A450XK7

Page 1: ... 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...

Page 2: ...m 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 illus...

Page 3: ...uts 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 wash...

Page 4: ...ty Remarks E Warning label set 1 For E 17 market F Mud guard front fender 2 Right and Left Fastener 8 G Mud guard rear fender 2 Right and Left Fastener 6 H Reflex 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 T L OD ID NOTE The small parts of item A B D E and I are in the tail box The parts shown as Ite...

Page 5: ...COMPONENT PARTS Check the component parts stored in the tail box A Tail box B Owner s manual Trailer tow kit Warning label set Limited market DVD Limited market E G H I F B B C C D D C Battery holder kit ...

Page 6: ...LY 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 UP UP NOTE Install the bracket placing its UP mark faced upward NOTE Limited market...

Page 7: ...rd 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 ...

Page 8: ...ll 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 ...

Page 9: ...el 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 ...

Page 10: ... 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 ...

Page 11: ...hicle A Battery Filling electrolyte Remove the aluminium tape sealing the battery elec trolyte filler holes A Aluminium tape B Electrolyte filler hole Remove the caps from the electrolyte container A Caps B Sealed area NOTE Use the removed caps as the sealed caps of battery filler holes Do not remove or pierce the sealed areas of the electrolyte container ...

Page 12: ...firmly so that it does not fall Take precaution not to allow any of the fluid to spill A Electrolyte containers Make sure air bubbles are coming up in each electro lyte container and leave in this position for about 20 minutes A Air bubbles NOTE If no air bubbles are coming up from a filler port tap the bottom of the container two or three times Never remove the container from the battery ...

Page 13: ...l of the battery 3 Cover terminal with rubber boot 4 Connect the lead to the negative terminal of the battery A lead B lead C Rubber boot Never use anything except the specified battery electrolyte Once the sealing cap has been installed in the battery do not remove the sealing cap For charging the battery make sure to use the charger specially designed for MF battery Otherwise the battery may be ...

Page 14: ...p the vehicle upright and place the handlebars straight Check the brake fluid level in the front master cylinder reservoir If the fluid level is below the lower level indicated in the figure add the correct type of brake fluid Refer to the chart below for the proper selection A Lower level line Specification and Classification DOT 4 Be careful not to spill any brake fluid on the paint or plastic c...

Page 15: ...e fluid flowing into the receptacle no longer contains air bubbles 5 After bleeding the brake circuit tighten the bleeder valve to the specified torque Reinstall the rubber protective cap 6 Be sure to check the brake fluid level in the reservoir tank Brake caliper air bleeder valve 6 0 N m 0 60 kgf m A Bleeder valve THROTTLE CABLE Check the throttle cable play at the throttle lever end Throttle ca...

Page 16: ... the pedal to the cor rect height above the top face of the footrest C 3 Tighten the lock nut A Check the brake pedal free travel Rear brake pedal free travel 20 30 mm If adjustment is necessary turn the adjuster A to obtain the correct free travel The rear brake lever and rear brake pedal oper ate the rear brake in a complementary manner When one of these is misadjusted the brake system as a whol...

Page 17: ... wheels roll freely with the brake disengaged the transmis sion in neutral and the rear wheels off the ground 5 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 6 Readjust the rear brake lever play if the rear wheels could not roll freely or if the rear wheels didn t lock in step 2 FRONT FRONT AND REAR SUSPENSION AD...

Page 18: ... adjust the beam vertically Turn the adjuster screw clockwise or counterclockwise A Adjuster screw ENGINE COOLANT The engine coolant level should be kept between the FULL and LOW level lines as shown in the photo graph Inspect the level with the vehicle held upright on level ground A Engine coolant reservoir B FULL level line C LOW level line D Radiator LOAD TIRE PRESSURE FRONT REAR Up to 172 kg 3...

Page 19: ... a level ground Check the front differential gear oil levels as follows Remove the oil level bolt If the oil level is below the level hole add the gear oil through the filler hole until the oil flows out from the level hole Reinstall the oil level bolt and the oil filler plug tighten them securely A Oil filler plug B Oil level bolt NOTE Use hypoid gear oil SAE 90 API grade GL 5 If the vehicle is r...

Page 20: ...er plug The engine oil dipstick comes out together with the oil filler plug Wipe the oil from the dipstick with a clean rag 4 Reinsert the dipstick until the threads touch the filler neck but do not screw the plug in 5 Draw out the dipstick and check the oil level The level found on the dipstick should be between L Low and F Full line 6 If the oil level is below the L line add fresh oil from the f...

Page 21: ...ricate clutch and transmission gears with engine oil JASO T903 specifies performance requirements for motorcycle and ATV clutches and transmission There are two classes MA and MB The oil container has following classification for con firming the standard A Code number of oil sales company B Oil classification SAE API JASO 10W 40 SF or SG 10W 40 SH or SJ MA API American Petroleum Institute JASO Jap...

Page 22: ...to switch between km h and mph Select km h and mph properly to comply with traffic regulations Check km h and mph display after adjusting the instru ment panel display A Odo Trip Button B Clock Hour Button C Speedometer display km h mph Test ride the vehicle checking all mechanical functions Tighten all nuts bolts and miscellaneous mounting parts to the proper torque specs Confirm that all cables ...

Page 23: ...iper mounting bolt 26 2 6 Item Part Name N m kgf m REAR SUSPENSION AND REAR BRAKE J Rear shock absorber mounting nut upper 60 6 0 K Rear shock absorber mounting nut lower 60 6 0 L Rear hub nut 110 11 0 M Rear wheel set nut 60 6 0 N Rear brake cam lever nut 11 1 1 O Rear brake pedal boss nut 11 1 1 OTHERS P Front footrest bolt 55 5 5 Bolt Diameter mm Conventional or 4 marked bolt 7 marked bolt N m ...

Page 24: ... Location of cable and harness as shown Parking brake cable Throttle cable Parking brake cable Stater cable Parking brake cable Sterter cable Fix foot brake cable to the footrest bar Parking brake cable guide Handlebar Pin Locate throttle cable as shown Must not locate out of pin ...

Page 25: ... foot brake cable to the footrest Foot brake cable Rear brake assy Parking brake cable Adjust nut Parking brake cable Frame Rear fender Protector Parking brake cable Parking brake cable Rear fender Screw Wiring harness Tie protector with clamp as shown Frame ...

Page 26: ...ion meter Set the sag under combination meter Pass the combination meter wire behind the upper bracket Horn switch lead wire E 17 E 24 Brake lever switch lead wire L Handle switch lead wire L Parking brake switch lead wire Emergency switch lead wire E 17 DIFF lock transfer switch lead wire Combination meter lead wire Horn switch lead wire E 17 E 24 Brake lever switch lead wire L Brake lever switch...

Page 27: ...r lead wire Foot brake switch lead wire Actuator lead wire Foot brake switch lead wire To rear fender top Speed sensor lead wire Clamp Wiring harness Injector coupler ECT sensor coupler Ignition coil To power source Clamp Clamp Wiring harness Wiring harness lead wire TP IAP IAT sensor Wiring harness Wiring harness Actuator lead wire Gear position switch lead wire Generator lead wire Hose Cooling f...

Page 28: ... all nuts and bolts Torque those listed in this manual Cotter pins and circlip Fasteners Check Paint and chrome Inspect Wash and polish Warning label For E 17 market Select Stick Appropriate language LOAD TIRE PRESSURE FRONT REAR Up to 172 kg 380 lbs 35 kPa 0 35 kgf cm2 5 1 psi 30 kPa 0 30 kgf cm2 4 4 psi ITEM CHECK FOR Light Lighting Adjust Taillight Brake light Headlight high low beam Back lamp ...

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Suzuki LT-A450XK7, Setup Manual

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