Suzuki LT-A700XK5 Setup Manual Download

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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.

Summary of Contents for LT-A700XK5

Page 1: ...re 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 po...

Page 2: ... 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 ...

Page 3: ...2 LOCATION OF PARTS Check off each of the components as shown in the photograph A A B B C C D D E E I I F F J J G G H H K K L L M M ...

Page 4: ...m Warning label 1 Warning label French 1 For limited market Item Part Name Q ty Remarks F Wheel center cap 4 G Mud guard rear fender 2 Right and Left Fastener Large 6 H Reflex reflector 2 Flange nut 2 5 mm I Warning label set 3 For E 17 CG selection 2 For E 17 CH selection 3 For E 17 CI selection J Fuel label 1 For limited market K Battery 1 Battery electrolyte container 1 L Owner s manual 1 M Saf...

Page 5: ...re 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 hand...

Page 6: ...ce 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 A A A of the front side with specified torque and then tighten the bolt B B B B of the rear side Make sure that the clamp has no clearance at...

Page 7: ...e 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 ...

Page 8: ...tch 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 the...

Page 9: ...HT 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 ...

Page 10: ...astener 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 B B B and fix the fastener by pushing the center pin as C C C C ...

Page 11: ...adlight cover to the meter cover A Headlight cover B Meter cover Fix the meter cover with the tapping screws A Meter cover B 5 16 mm tapping screw RIGHT LEFT Fix the meter cover using fasteners A Meter cover B Fastener Small NOTE To install the fastener pull the center pin as C C C C and fix the fastener by pushing the center pin as D D D D ...

Page 12: ... 1 Lift the vehicle with a hoist then balance the vehi cle 2 Pull the crate base forward Place the vehicle in a clean working area and then remove the hoist hook NOTE To install the fastener pull the center pin as C C C C and fix the fastener by pushing the center pin as D D D D ...

Page 13: ...r 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 NOTE Install the bracket placing its UP mark faced upward UP UP NOTE Limited market Stick the warning label both A A A A and B B B B ...

Page 14: ...lex 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 Large NOTE Stick the cushion on the end of radius NOTE To install the fastener pull the center pin as C C C C an...

Page 15: ...ountry 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 For E 17 CG selection German Spanish Portuguese For E 17 CH selection French Dutch For E 17 CI selection Swedish Finnish Danish ...

Page 16: ... A Rear fender Left B Fuel label BATTERY HOLDER AND BATTERY Install the battery holder and battery after the servicing of the battery is completed A Battery holder B 6 16 mm flange bolt C Battery OWNER S MANUAL Store the owner s manual in the tail box A Tail box B Owner s manual ...

Page 17: ...ust enough force to break the nozzle seal of elec trolyte container push each nozzle of the electrolyte container into the battery s electrolyte filler ports and hold the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill A Electrolyte containers NOTE Use the removed caps as the sealed caps of battery filler holes Do not remove or pierce the sealed are...

Page 18: ... 20 minutes Insert the caps into the filler holes pressing in firmly so that the top of the each caps does not protrude above the upper surface of the battery s top cover A Caps 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 Never use anything except the specified battery electrolyte Once the se...

Page 19: ...4 Connect the lead to the negative terminal of the battery A lead B lead C Rubber boot For charging the battery make sure to use the charger specially designed for MF battery Otherwise the battery may be overcharged resulting in shortened service life Do not remove the cap during charging Position the battery with the cap facing upward during charging When attaching the wiring harness battery lead...

Page 20: ...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 21: ...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 22: ... 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 23: ... 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 24: ...sary To adjust the beam vertically Turn the adjuster screw clockwise or counterclockwise A Adjuster screw AUXILIARY HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted vertically if nec essary To adjust the beam vertically Loosen the headlight fitting bolt and move the head light up or down as required Tighten the bolt A Bolt B Headlight LOAD TIRE PRESSURE FRONT REAR Up to 172 kg 380 lbs ...

Page 25: ...cle held upright on level ground A Engine coolant reservoir B FULL level line C LOW level line D Radiator 1 Remove the radiator cap lid A Radiator cap lid B Boss 2 Remove the filler cap and add 50 50 mixture of engine coolant and distilled water to the FULL level line from the engine coolant filler hole 3 Reinstall the filler cap and the lid C Filler cap ...

Page 26: ...ach the bottom of the filler hole add the gear oil through the filler hole until the oil level reaches the bottom of the oil filler hole Reinstall the oil filler plug and tighten it securely A Oil filler plug ENGINE OIL Remove the fasteners to take off the footrest guard lid A Footrest guard lid B Fastener NOTE Use hypoid gear oil SAE 90 API grade GL 5 If the vehicle is ridden where the ambient te...

Page 27: ...l the drain plug and engine oil filler plug Tighten them securely 8 Reinstall the footrest guard lid A Engine oil filler plug B Engine oil dipstick 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 and wiring harnesses are con nected and routed correctly F L NOTE Use a premium quality 4...

Page 28: ...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 29: ...on of cable and harness as shown Parking brake cable Throttle cable Parking brake cable Parking brake cable Fix the foot brake cable to the footrest bar Parking brake cable guide Handlebar Boss Locate the throttle cable as shown Must not locate the throttle cable in the outside of boss ...

Page 30: ...otrest bar 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 the protector with clamp as shown Frame ...

Page 31: ...s the combination meter wire to behind the upper bracket Rear brake switch lead wire Handlebar switch lead wire L Parking brake switch lead wire Emergency switch lead wire E 17 Horn switch lead wire E 17 24 Emergency switch lead wire E 17 Horn switch lead wire E 17 24 Combination meter lead wire Rear brake switch lead wire Front brake switch lead wire Handlebar switch lead wire L Parking brake swi...

Page 32: ...ire Foot brake switch lead wire Clamp TP sensor Injector coupler ECT sensor coupler ISC valve Clamp Clamp Wiring harness Clamp Wiring harness Wiring harness Wiring harness Wiring harness Wiring harness Actuator lead wire Gear position switch lead wire Generator lead wire Reservoir hose Cooling fan thermo switch lead wire Foot brake switch lead wire Clamp Back lamp relay lead wire E 17 Wiring harne...

Page 33: ...nd 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 Auxiliary headlight B...

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