L2© COPYRIGHT SUZUKI MANUFACTURING OF AMERICA CORPORATION Aug. ’11 (CLA) 28

99505-01042-01EEN

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 correctlyassembled and serviced. This set-up manual has been produced to aid you in prop-erly assembling and servicing this vehicle.

Please read this manual and follow its instructions carefully. To emphasize specialinformation, the symbol and the words WARNING, CAUTION, NOTICE andNOTE have special meanings. Pay particular attention to messages highlighted bythese signal words:

Indicates a potential hazard that could result in death or serious injury

Indicates a potential hazard that could result in minor or moderate injury.

Indicates a potential hazard that could result in vehicle or equipment damage.

NOTE:Indicates special information to make maintenance easier or instructions clearer.

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.

1

PREPARATIONWORKSHOP

A: Packed vehicleB: Working space

SELF PROTECTION

CAUTION

Assembling the vehicle in poor working condi-tion can be hazardous.

Place the packed vehicle on a level floor whereit is clean and spacious.

CAUTION

Assembling the vehicle without proper clothesand protective gear can be hazardous. You canbe injured if you do not wear proper clothesand protective gear.

Be sure to wear proper clothes and shoes forassembling and wear protective glasses, maskor gloves as necessary.

2

UNCRATING THE VEHICLE

Use a cutter to separate the top part of the crate alongthe perforated line.

A: Perforated line

Lift the top part to separate it from the crate.

A: Top part of crate

CAUTION

Crate has nails and may have sharp splintersthat could cause injury.

Wear proper protective clothes and gear.

CAUTION

Careless use of cutter can injure a person.

Wear proper protective clothes and gear.Use a cutter with the proper method.

CAUTION

Careless crate separation can injure a person.

Lift the top part with two persons.Wear proper protective clothes and gear.

3

Use a cutter to open the crate along the perforatedline.

A: Perforated line

Open the sides of the crate.Dismantle the crate from the base of the crate.

A: Crate base

CAUTION

Careless use of cutter can injure a person.

Wear proper protective clothes and gear.Use a cutter with the proper method.

NOTE:• Cut the carton from the top to the bottom along

the perforated lines on both sides at each end.• Be careful not to damage the vehicle.

CAUTION

Careless inappropriate handling of the disman-tled crate can injure a person.

Wear proper protective clothes and gear.

4

Remove the nut to take off the J hook of the vehiclestopper.

A: J hookB: NutC: WasherD: CardboardE: Rubber

Carefully remove a component parts package from thecrate.Remove the battery electrolyte container stored in thefront grip.

A: Component parts boxB: Battery electrolyte container

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.

NOTE:The J hook, nut, cardboard, washer, and rubberare not necessary to assemble the machine.

5

LOCATION OF PARTSCheck all the components which have been removed from the base of the crate.

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

Item Part Name Q’ty Remarks

A

Mud guard front fender 2 Right and LeftFastener 10Screw 2 5 × 25 mmWasher 2 OD:20.0 ID:5.5Rubber cushion (with nut) 2 5 mm L:21.0

BBattery holder 1Flange bolt 2 6 × 16 mm

C

Mud guard rear fender 2 Right and LeftFastener 10Screw 2 5 × 20 mmScrew 2 5 × 25 mmWasher 4 OD:20.0 ID:5.5Rubber cushion (with nut) 4 5 mm L:21.0

Item Part Name Q’ty Remarks

DReflex reflector 2 For E-17Flange nut 2 5 mm

E Warning label set 1 For E-17F DVD 1 For E-17

G Battery electrolyte container 1

H Owner’s manual 1

NOTE:• Item B and H are located in the box under the seat (H: For E-24, 28).• The parts shown as Item A, C, D, E and F in the above table are supplied for limited markets.• Please hand over the parts shown as Item F and H in the above table to your customer together with vehi-

cle.

A C

D

6

COMPONENT PARTS

Check that the component parts are in the box.A: Owner’s manual (For E-24, 28)B: Battery holder kitC: Box

7

Before assembling the vehicle, thoroughly under-stand the “Safety Check Out” described onpage 32.After completion of assembly, carefully check thevehicle referring to the “Safety Check Out”, thendeliver the vehicle to the customer.

ASSEMBLY

REMOVING THE WRAP FILMRemove the wrap film from the front and rear fenders.

A: Wrap film

MUD GUARD FRONT FENDER (FOR E-17, 24)Remove screws, washers and rubber cushions (with nuts).

A: Screw, washer, rubber cushion (with nut)

Align the mud guard front fender to the front fender.

A: Mud guard front fenderB: Front fender

NOTE:The screws, washers and rubber cushions (withnuts) are not necessary to assemble the vehicle.

8

Secure the mud guard front fender using fasteners.

A: Mud guard front fenderB: Fastener

Align the parts and secure them with the screw E.

E: 5 x 25 mm screwF: Washer OD:20.0 mm ID:5.5 mmG: Rubber cushion (with nut) 5 mm L:21.0 mmH: Foot boardI: Front fenderJ: Mud guard front fender

REFLEX REFLECTOR (FOR E-17)Align the boss of reflex reflector to the hole of mudguard rear fender.Install the reflex reflector to the mud guard rear fender.

A: Mud guard rear fenderB: Reflex reflectorC: BossD: HoleE: 5 mm flange nut

MUD GUARD REAR FENDER (FOR E-17, E-24)Align the mud guard rear fender to the rear fender.

A: Mud guard rear fenderB: Rear fender

NOTE:• To install the fastener, pull the center pin as C

and fix the fastener by pushing the center pin asD.

• Arrows show direction of fasteners.

9

Secure the mud guard rear fender using fasteners.

A: Mud guard rear fenderB: Fastener

Align the parts and secure them with the screw E.

E: 5 x 25 mm screwF: Washer OD:20.0 mm ID:5.5 mmG: Rubber cushion (with nut) 5 mm L:21.0 mmH: Foot boardI: Rear fenderJ: Mud guard rear fender

Align the parts and secure them with the screw A.

A: 5 x 20 mm screwB: Washer OD:20.0 mm ID:5.5 mmC: Rubber cushion (with nut) 5 mm L:21.0 mmD: Mud guard rear fenderE: Extension bracket

WARNING LABEL (FOR E-17)Select the appropriate language label for your country.

NOTE:• To install the fastener, pull the center pin as C

and fix the fastener by pushing the center pin asD.

• Arrows show direction of fasteners.

NOTE:Six kind of labels: French, Finnish, Danish, Span-ish, Portuguese, Swedish.

10

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 onlyE: Warning label (Trailer tow)F: Front fender (Right)G: Rear fender (Right)

REAR (RIGHT)

Stick the label.

E: Warning label (Trailer tow)…..For French only

11

CHECK

OWNER’S MANUAL / COMPONENT PARTSThe owner’s manual and component parts are located in the box under the seat.Pull the seat lock lever, and remove the seat.

A: SeatB: Seat lock lever

Pull the clips up and remove the cover.

A: CoverB: ClipC: Hook

Check the Owner’s manual stored in the box.Take out the battery holder kit from the box.Reinstall the box cover.

D: Owner’s manual (For E-24, 28)E: Battery holder kitF: Box

12

A: Throttle cableB: Front brake hoseC: Rear brake lever cableD: Choke cableE: Left switch wiring harnessF: 2WD/4WD selection cable (For LT-A400F)G: Rear brake switch lead wireH: Parking brake switch lead wireI: Front brake switch lead wireJ: Horn switch lead wire (For E-17, 24)K: Emergency switch lead wire (For E-17)

NOTE:• 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 instruc-tions carefully.

13

SERVICINGBATTERY

Remove the battery from the vehicle.

A: Battery

Filling electrolyteRemove the aluminium tape sealing the battery elec-trolyte filler holes.

A: Aluminium tapeB: Electrolyte filler hole

Remove the caps from the electrolyte container.

A: CapsB: Sealed area

NOTE:• Use the removed caps as the sealing cap of bat-

tery filler holes.• Do not remove or pierce the sealed areas of the

electrolyte container.

14

With just enough force to break the nozzle seal of elec-trolyte container, push each nozzle of the electrolytecontainer into the battery’s electrolyte filler ports andhold the container 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 20minutes.

A: Air bubbles

NOTE:• If no air bubbles are coming up from a filler port,

tap the bottom of the container two or threetimes.

• Never remove the container from the battery.

15

After confirming that the electrolyte has entered thebattery completely, remove the electrolyte containersfrom the battery.Wait for around 20 minutes.Insert the caps into the filler holes, pressing in firmly sothat the top of the each caps does not protrude abovethe upper surface of the battery’s top cover.

A: Caps

Charge the battery with a battery charger.

After charging the battery, install the battery in thevehicle as follows.

NOTE:• Use only the specified battery electrolyte.• Once the sealing cap has been installed in the

battery, do not remove the sealing cap.

NOTE:• For charging the battery, make sure to use the

charger specially designed for MF battery. Other-wise, the battery may be overcharged resulting inshortened service life.

• Do not remove the cap during charging.• Position the battery with the cap facing upward

during charging.

NOTICE

Connecting the battery lead wires with the igni-tion switch ON can damage the motorcycle.

Turn off the ignition switch before connectingor disconnecting the battery lead wires.Observe the battery lead wire polarity beforeconnecting the lead wires to the battery termi-nal.

NOTICE

Reversing the battery lead wires can damagethe charging system and the battery.

Always attach the red lead to the + positive ter-minal and the black (or black with white tracer)lead to the - negative terminal.

NOTE:The terminal bolts and nuts are attached to the bat-tery.

16

1. Reinstall the battery in the battery box.2. First connect the + lead to the + positive terminal

of the battery.3. Cover + terminal with rubber boot.4. Connect the - lead to the - negative terminal of

the battery.

A: + leadB: - leadC: Rubber boot

Install the battery holder.

A: Battery holderB: 6 × 16 mm flange bolt

Reinstall the seat.Insert the seat hook into the seat hook retainer andpush the seat down firmly.

A: Seat assemblyB: Seat hookC: Seat hook retainerD: BossE: Hole

17

BRAKE FLUIDPlace the vehicle on the level ground and keep thehandlebars straight.Check the brake fluid level in the front master cylinderreservoir.If the fluid level is below the “LOWER” level, add thecorrect type of brake fluid.Refer to the chart below for the proper selection.

BRAKE AIR BLEEDINGAny air which may have been trapped in the brake fluidcircuit must be bled completely.If the brake lever feels spongy or weak, then mostlikely there is air in the brake fluid circuit.If air bleed is necessary, carry out the following proce-dure.

1. Connect a clear hose to the air bleeder valve andrun the hose into a suitable clear container.

2. Pour approximately 1/2 in of brake fluid into the con-tainer so that the end of the clear hose is sub-merged and cannot draw any additional air back intothe circuit during the air bleeding servicing.

3. Close the valve, pump and squeeze the lever, andopen the valve while squeezing brake lever.

4. Repeat this process until the fluid flowing into thereceptacle no longer contains air bubbles.

5. After bleeding the brake circuit, tighten the bleedervalve to the specified torque.Reinstall the rubber protective cap.

6. Be sure to check the brake fluid level in the reservoirtank.

Brake caliper air bleeder valve:6.0 N·m (0.60 kgf-m)

A: Bleeder valve

Specification and ClassificationDOT 4

NOTICE

Spilled brake fluid can damage painted sur-faces and plastic parts.

Be careful not to spill any fluid when filling thebrake fluid reservoir. Wipe spilled fluid upimmediately.

NOTE:Do not drop brake fluid level below lower level linewhile bleeding air.

18

THROTTLE CABLECheck the throttle cable play at the throttle lever end.

Throttle cable play: 3.0–5.0 mm

If adjustment is necessary, carry out the following pro-cedure.

1. Shift the rubber boot C.2. Loosen the throttle cable adjuster lock nut B.3. Turn the adjuster A to obtain the correct play.4. Tighten the lock nut B while holding the adjuster A.5. Place the rubber boot C.

CHOKE CABLECheck the choke cable play.

Choke cable play: 0.5-1.0 mm

If adjustment is necessary, carry out the following pro-cedure.

1. Shift the rubber boot C.2. Loosen the lock nut B and turn the adjuster A to

obtain the correct play.3. Move the cable back and forth firmly to ensure that

the correct amount of free play is available and thatthe cable housing is properly seated in the adjusterA.

4. Tighten the lock nut B while holding the adjuster A.5. Place the rubber boot C.

REAR/PARKING BRAKEAdjust the rear brake by adjusting the brake pedal firstand then adjust the brake lever.

WARNING

Inadequate throttle cable play can cause enginespeed to rise suddenly when you turn the han-dlebars. This can lead to loss of rider control.

Adjust the throttle cable play so that engine idlespeed does not rise due to handlebar move-ment.

WARNING

The rear brake lever and brake pedal operatethe rear brake in a complementary manner.When one of these is misadjusted, the brakesystem as a whole will not operate properly.Misadjusting the rear brake lever and brakepedal can cause brake dragging or inadequatebraking performance.

Adjust both the brake pedal and brake leverwithin the specified range.

19

Brake PedalCheck the rear brake pedal free travel.

Rear brake pedal free travel: 20–30 mm

If adjustment is necessary, adjust the free travel byturning the adjuster A.

Brake Lever (Parking Brake)Check the brake lever play at the lever holder whensqueezing the lever until pressure is felt.

Rear brake (Parking brake) lever play: 3.0–5.0 mm

If adjustment is necessary, carry out the following pro-cedure.

1. Loosen the brake lever adjuster lock nut B and turnin the adjuster A as far as possible.

2. Turn the adjuster C to obtain the correct play.3. Minor adjustments can now be made with the brake

lever adjuster A.4. Tighten the lock nut B while holding the adjuster A.5. Place the lever cover D.6. After 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.

7. Set the parking brake and check that the rearwheels are locked by trying to move the vehicleback and forth while it is in neutral.

8. Readjust the rear brake lever play if the rear wheelscould not roll freely or if the rear wheels didn’t lock instep (2).

20

2WD/4WD SELECTION LEVER (FOR LT-A400F)Set the selection lever to “4WD” position as shown inthe photograph. (Align it with the white mark.)Check that there is no play in the cable.

A: 2WD/4WD selection leverB: Mark

If there is any play in the cable, adjust it in the followingmanner.

1. Remove the bolts, then remove the steering headcover.

C: BoltD: Steering head cover

2. Shift the rubber boot H.3. Loosen the lock nut F and turn out the adjuster G

slowly until resistance is felt.Then, turn the adjuster G one more turn out fromthat position.

4. Tighten the lock nut F while holding the adjuster G.5. Place the rubber boot H.6. Reinstall the steering head cover D.

E: 2WD/4WD selection cableF: Lock nutG: AdjusterH: Rubber boot

TIRE PRESSUREUsing an accurate air gauge, check the air pressure ofthe front and rear tires.The pressure should be as indicated in the tablebelow.

COLD INFLATION TIRE PRESSURE

LOADTIRE PRESSURE

FRONT REAR

Up to 172 kg(380 lbs)

32.5 kPa0.325 kgf/cm2

4.7 psi

30 kPa0.30 kgf/cm2

4.4 psi

21

HEADLIGHT BEAM ADJUSTMENT (RIGHT AND LEFT)The headlight beam can be adjusted up and down ifnecessary.

To adjust the beam up and down:Turn the adjuster screw clockwise or counterclockwise.

A: Adjuster screw

FRONT DIFFERENTIAL GEAR OIL (FOR LT-A400F)Place the vehicle on 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 oilthrough the filler hole until the oil flows out from thelevel hole.Reinstall the oil level bolt and the oil filler plug.Tighten them securely.

A: Oil filler plugB: Oil level bolt

FINAL GEAR OILPlace the vehicle on a level ground.Check the final gear oil levels as follows.Remove the oil level bolt.If the oil level is below the level hole, add the gear oilthrough the filler hole until the oil flows out from thelevel hole.Reinstall the oil level bolt and the oil filler plug.Tighten them securely.

A: Oil filler plugB: Oil level bolt

NOTE:• Use hypoid gear oil SAE 90, API grade GL-5.• If the vehicle is ridden where the ambient temper-

ature is below 0°C or 32°F, use the hypoid gearoil SAE 80, API grade GL-5.

NOTE:• Use hypoid gear oil SAE 90, API grade GL-5.• If the vehicle is ridden where the ambient temper-

ature is below 0°C or 32°F, use the hypoid gearoil SAE 80, API grade GL-5.

22

ENGINE OIL

Check the engine oil level as follows.

1. Place the vehicle on level ground.2. Start the engine and allow it to run for three minutes

at idling speed.3. Stop the engine and wait three minutes.4. Remove the oil filler plug.

The engine oil dipstick comes out together with theoil filler plug.Wipe the oil from the dipstick with a clean rag.

5. Reinsert the dipstick until the threads touch the fillerneck, but do not screw the plug in.

6. Draw out the dipstick and check the oil level.7. If the level is below the “L” (Low) line, add fresh oil

from the filler hole.If the level is above the “F” (Full) line, drain oil fromthe drain hole.

8. Reinstall the drain plug and engine oil filler plug.Tighten them securely.

9. Reinstall the footrest guard lid.

A: Engine oil filler plugB: Engine oil dipstick

NOTE:This vehicle is shipped from factory with the enginefilled with engine oil.

NOTICE

Operating the engine with too little or too muchoil can damage the engine.

Place the ATV on level ground. Check the oillevel with the engine oil dipstick before eachuse of the vehicle. Be sure the engine oil levelis always above the “L” (low) line and nothigher than the “F” (full) line.

23

Engine oilOil quality is a major contributor to your engine’s per-formance and life.Always select good quality engine oil.Use oil with an API classification of SF/SG or SH/SJ,or with a JASO classification of MA.

SAE Engine Oil ViscositySuzuki recommends the use of SAE 10W-40 engineoil.If SAE 10W-40 engine oil is not available, select analternative according to the left chart.

JASO T903The JASO T903 standard is an index to select engineoils for 4-stroke motorcycle and ATV engines.Motorcycle and ATV engines lubricate clutch andtransmission gears with engine oil.JASO T903 specifies performance requirements formotorcycle and ATV clutches and transmission.

There are two classes, MA and MB.The oil container shows the classification as shown.

A: Code number of oil sales companyB: Oil classification

Energy ConservingSuzuki does not recommend the use of “ENERGYCONSERVING” oils.Some engine oils which have an API classification ofSH or higher have an “ENERGY CONSERVING” indi-cation in the API classification doughnut mark.These oils can affect engine life and clutch perform-ance.

SAE API JASO

10W-40 SF or SG –

10W-40 SH or SJ MA

API: American Petroleum InstituteJASO: Japanese Automobile Standards Organization

NOTE:If the vehicle is used in very cold weather (below –10°C (14°F)), use SAE 5W-30 for good enginestarting and smooth operation.

-30 -20 -10 0 10 20 30 40

-22 -4 14 32 50 68 86 104

10W - 30

5W - 30

20W - 50

10W - 40 10W - 50

15W - 40 15W - 50

˚C

˚F

ENGINE OIL VISCOSITY RATING SELECTION CHART

ENGINE OIL

TEMP.

RecommendedNot recommended

EN

ERGY CONSERVIN

G

API SERVICE SJ

SAE10W-40

API SERVICE SJ

SAE10W-40

24

IDLE SPEED ADJUSTMENTRemove the seat.Remove the fasteners.

Remove the side cover.

A: Side coverB: FastenerC: FastenerD: HookE: Boss

After completing all of the service procedures, adjust the engine idle speed by turning the throttle adjust screw.

Engine idle speed: 1 400-1 600 r/minF: Throttle adjust screw

FUEL

NOTE:• To remove the fastener B, pull the center pin and

pull out the fastener.• To remove the fastener C, turn the center pin

counter clockwise while holding outer and pull outthe fastener.

NOTE:The engine idle should be adjusted with enginewarmed up.

NOTE:• Use only unleaded gasoline with an octane rating

of 91 or higher (Research method) or Use onlyunleaded gasoline of at least 87 pump octane (R/2+M/2 method).

• Unleaded gasoline can extend spark plug life andexhaust components life.

• Gasoline containing MTBE (Methyl Tertiary ButylEther), less that 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

25

SPEEDOMETER Set the meter to odometer, then press and hold func-tion change button for 2 seconds to switch the display.Select km/h or mph properly to comply with traffic reg-ulations.Check km/h and mph display after adjusting the instru-ment panel display.

A: Function change buttonB: Speedometer display (km/h,mph)

Test ride the vehicle checking all mechanical functions.Tighten all nuts, bolts, and miscellaneous mountingparts to the proper torque specs.Confirm that all cables and wiring harnesses are con-nected and routed correctly.

26

TIGHTENING TORQUETIGHTENING TORQUE LIST

Each bolts and nuts should be tightened to the torque specified in “TIGHTENING TORQUE LIST”.If no description or specification is provided, refer to the “TIGHTENING TORQUE CHART” on next page.

Item Part Name N·m kgf-m

STEERING, FRONT SUSPENSION AND FRONT BRAKE

A Handlebar clamp bolt 26 2.6

B Front hub nut 110 11.0

C Front wheel set nut 60 6.0

D Front brake caliper air bleeder 6.0 0.60

EFront shock absorber mounting bolt (upper)

55 5.5

FFront shock absorber mounting bolt (lower)

60 6.0

GFront brake master cylinder mounting bolt

10 1.0

H Front brake caliper mounting bolt 26 2.6

I Front suspension arm pivot nut 65 6.5

Item Part Name N·m kgf-m

REAR SUSPENSION AND REAR BRAKE

JRear shock absorber mounting nut (upper)

35 3.5

KRear shock absorber mounting nut (lower)

60 6.0

L Rear hub nut 121 12.1

M Rear wheel set nut 60 6.0

N Rear brake cam lever nut 11 1.1

OTHERS

O Footrest bolt 55 5.5

P Rear swingarm pivot nut 102 10.2

Q Rear axle housing nut 60 6.0

R Rear axle housing bolt 55 5.5

S Rear brake pedal boss nut 12 1.2

T Rear brake anchor panel bolt 32 3.2

27

TIGHTENING TORQUE CHART

*1: Small crown shape bolt (crown shape bolt with flange either “A = 5 & B = 7” or “A = 6 & B = 8”)

Bolt typeThread diameter

(Nominal diameter) “A” [mm]

Unit

N·m kgf-m lbf-ft

4 1.5 0.15 1.05 3.0 0.30 2.06 5.5 0.55 4.08 13 1.3 9.510 29 2.9 21.012 45 4.5 32.514 65 6.5 47.016 105 10.5 76.0

A equivalent of 4T strength bolt without flange 18 160 16.0 115.5

Bolt typeThread diameter

(Nominal diameter) “A” [mm]

Unit

N·m kgf-m lbf-ft

4 1.7 0.17 1.05 3.3 0.33 2.56 6 0.6 4.58 14 1.4 10.010 32 3.2 23.012 50 5.0 36.014 72 7.2 52.016 116 11.6 84.0

A equivalent of 4T strength bolt with flange 18 176 17.6 127.5

Bolt typeThread diameter

(Nominal diameter) “A” [mm]

Unit

N·m kgf-m lbf-ft

4 2.3 0.23 1.55 4.5 0.45 3.56 10 1.0 7.08 23 2.3 16.5

10 50 5.0 36.012 85 8.5 61.514 135 13.5 97.5

A equivalent of 7T strength bolt without flange (and small crown shape bolt) *1

16 210 21.0 152.018 240 24.0 173.5

*1

Bolt typeThread diameter

(Nominal diameter) “A” [mm]

Unit

N·m kgf-m lbf-ft

4 2.5 0.25 2.05 5 0.5 3.56 11 1.1 8.08 25 2.5 18.010 55 5.5 40.012 94 9.4 68.014 149 14.9 107.5

A equivalent of 7T strength bolt with flange(except small crown shape bolt)

16 231 23.1 167.018 264 26.4 191.0

28

CABLE ROUTING

UP

OUTSIDE

UP

Transfer cable (LT-A400F)

Pass the starter cable and parking brake cable through the guide.

Clamp (LT-A400F)

Clamp

Throttle cableFront brake switch lead wire

Transfer cable

Starter cable

Starter cable

Parking brake cable

Parking brake

Throttle cable

Front brake switch lead wire

Washer

Cotter pin

Transfer cable (LT-A400F)

Clamp

Clamp

Clamp

Throttle cable

Rear brake cable

Pass the breather hose outside of the cable.

Rear brake cable

Rear brake cable

Pin

Parking brake cable

Parking brake cable

Parking brake cable

Front brake switch lead wire

Pass the starter cable in front of the wiring harness.

Throttle cable

Front brake hose

Pass the throttle cable through the concave of transfer lever bracket. (LT-A400F)

29

Starter cableStarter cable

Fix the rubber of throttle cable to the cable guide.

Pass the parking brake cable to outside of the throttle cable.

Throttle cable

Throttle cable

Parking brake cable

Pass the throttle cable and parking brake cable through the guide.

Clamp

Starter cableWiring harness

Wiring harnessguide (E-28)

Frame

Clamp

Starter cable

Wiring harness

Frame

INSIDE

INSIDE

Clamp

Starter cableWiring harness

Wiring harness

Clamp

Starter cable

Frame

INSIDE

30

HARNESS ROUTING

Clamp

Clamp

Clamp

Clamp

Starter motor assembly

Battery lead wire

Battery lead wire

Starter relay

Clamp

Clamp

Headlight lead wire (R)

Headlight lead wire (L)Wiring harness guide (E-28)

Mud protector (E-24)

Clamp

Wiring harness

Wiring harness

Wiring harness guide (E-28)Starter cable

Starter cableCooling-fan motor lead wire

Pass over the bridge

Pass the starter motor lead wire under the hose

Mud protector (E-24)

Clamp

Back lamp lead wire (E-17)

Back lamp relay lead wire (E-17)Rear combination light lead wire

Clamp

Horn switch lead wire (E-17, 24)

31

Clamp

Clamp

Clamp

Clamp

Clamp

Wiring harness

Engine ground lead wireGear position sensor lead wireGenerator lead wireStarter motor lead wire

Starter cable

Oil temperature sensor lead wire

Oil temperature sensor lead wire

Cooling-fan motor lead wire

Headlight lead wire (L)

Clamp

Oil temperature sensor lead wire

Cooling-fan motor lead wire

Cooling-fan motor lead wire

Clamp

ClampFuel gauge lead wire

Clamp

Handlebar switch lead wireIgnition switch lead wire

Fuel gauge lead wire

Fuel cut sensor lead wire

Gear in start switch lead wire

Speedometer lead wire

Stop lamp switch lead wireHorn switch lead wire (E-17, 24)

Clamp

Handlebar switch lead wire (L)Gear in start switch lead wire

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

Clamp

Headlight lead wire (L)

Horn switch lead wire (E-17, 24)

Speed sensor lead wire

Mud protector (E-24)

Throttle cable

Stop lamp switchSpeed sensor

Horn (E17, 24)

Starter cable

Pass the stop switchlead wire behind thethrottle cable.

High tension cord

Starter cable

Starter cable

Wiring harness guide (E-28)

Wiring harness

Wiring harness guide

Wiring harness

Frame

ClampClamp

INSIDE

E-28

Frame

Except for E-28

E-28

Wiring harness guide

32

SAFETY CHECK OUT

ENGINE AND TRANSMISSION

CHASSIS

COLD INFLATION TIRE PRESSURE

ELECTRICALS

ROAD TEST INSPECTION

NOTE:• After completion of the setting-up the vehicle all

the following items should be double-checked toconfirm that the operation and function of thevehicle are satisfactory.

• Now, setting-up the vehicle and pre-deliveryinspection have been completed and the vehiclecan be passed to the customer.

ITEM MEASURE SPECIFICATIONSEngine oil Check/Refill 2 800 ml Fuel tank Drain/Fill 16.0 L Throttle cable Check/Adjust Play: 3.0–5.0 mmChoke cable Check/Adjust Play: 0.5–1.0 mmIdle r/min Check/Adjust 1 400–1 600 r/minExhaust system LeakageFuel systemconnection

Circlip/Leakage

Front differential gear oil (For LT-A400F)

Check/Refill 300 ml

Final gear oil Check/Refill 350 ml

ITEM MEASURE SPECIFICATIONSDisc brake Clean/Fluid levelRear/Parking brake lever

Check/Adjust Play: 3.0–5.0 mm

Rear brake pedal Check/AdjustFree travel: 20–30 mm

Oiling points All necessary pointsBattery Filling electrolyteWiring and cable Routing/OperationWiring connectors Clean/TightSuspensions CheckTighten all nuts and bolts

Torque those listed in this manual

Cotter pins, circlip and fasteners

Check

Paint and chromeInspect/Wash and polish

Warning label(For E-17)

Select/Stick

TIRE PRESSUREFRONT REAR32.5 kPa

0.325 kgf/cm2

4.7 psi

30 kPa0.30 kgf/cm2

4.4 psi

ITEM CHECK FORLight

Lighting/AdjustHeadlight high/low beamTail/Brake light

LightingBack lamp (For E–17)

Instrument Lights

Lighting

Speedometer displayReverse indicator lightNeutral indicator lightOil temperature indicator lightHigh beam indicator light(For E-17)Fuel injection system indicator light

Switch Operations

Operation

Ignition switchDimmer switchEngine stop switchStarter buttonBrake light switchBrake switchParking brake switchHorn switch(For E-17, 24)Emergency stop switch(For E-17)

ITEM CHECK FOR

EngineStarting/Acceleration/Smoothness/Noise

Transmission Operation/NoiseDrive shaft Smoothness/NoiseRange lever OperationBrake Operation/NoiseSteering StabilitySuspension OperationControl cables Operation/Proper returnLeakage Fuel/Oil/ExhaustSpeedometer display OperationFunctional change button OperationSelection lever (For LT-A400F) Operation