Suzuki LT-A400 User guide

L2
© COPYRIGHT SUZUKI MANUFACTURING OF AMERICA CORPORATION Aug. ’11 (CLA) 28
99505-01042-01E
EN
FOREWORD
This vehicle has been designed and produced utilizing Suzuki’s most modern tech-
nology. The finest product, however, cannot perform properly unless it is correctly
assembled and serviced. This set-up manual has been produced to aid you in prop-
erly assembling and servicing this vehicle.
Please read this manual and follow its instructions carefully. To emphasize special
information, the symbol and the words WARNING, CAUTION, NOTICE and
NOTE have special meanings. Pay particular attention to messages highlighted by
these 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
PREPARATION
WORKSHOP
A: Packed vehicle
B: Working space
SELF PROTECTION
CAUTION
Assembling the vehicle in poor working condi-
tion can be hazardous.
Place the packed vehicle on a level floor where
it is clean and spacious.
CAUTION
Assembling the vehicle without proper clothes
and protective gear can be hazardous. You can
be injured if you do not wear proper clothes
and protective gear.
Be sure to wear proper clothes and shoes for
assembling and wear protective glasses, mask
or gloves as necessary.

2
UNCRATING THE VEHICLE
Use a cutter to separate the top part of the crate along
the 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 splinters
that 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 perforated
line.
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 vehicle
stopper.
A: J hook
B: Nut
C: Washer
D: Cardboard
E: Rubber
Carefully remove a component parts package from the
crate.
Remove the battery electrolyte container stored in the
front grip.
A: Component parts box
B: 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 rubber
are not necessary to assemble the machine.

5
LOCATION OF PARTS
Check 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 Left
Fastener 10
Screw 2 5 ×25 mm
Washer 2 OD:20.0 ID:5.5
Rubber cushion (with nut) 2 5 mm L:21.0
BBattery holder 1
Flange bolt 2 6 ×16 mm
C
Mud guard rear fender 2 Right and Left
Fastener 10
Screw 2 5 ×20 mm
Screw 2 5 ×25 mm
Washer 4 OD:20.0 ID:5.5
Rubber cushion (with nut) 4 5 mm L:21.0
Item Part Name Q’ty Remarks
DReflex reflector 2 For E-17
Flange nut 2 5 mm
E Warning label set 1 For E-17
F DVD 1 For E-17
GBattery electrolyte
container 1
HOwner’smanual 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.
AC
D

6
COMPONENT PARTS
Check that the component parts are in the box.
A: Owner’s manual (For E-24, 28)
B: Battery holder kit
C: Box

7
Before assembling the vehicle, thoroughly under-
stand the “Safety Check Out” described on
page 32.
After completion of assembly, carefully check the
vehicle referring to the “Safety Check Out”, then
deliver the vehicle to the customer.
ASSEMBLY
REMOVING THE WRAP FILM
Remove 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 fender
B: Front fender
NOTE:
The screws, washers and rubber cushions (with
nuts) are not necessary to assemble the vehicle.

8
Secure the mud guard front fender using fasteners.
A: Mud guard front fender
B: Fastener
Align the parts and secure them with the screw E.
E: 5 x 25 mm screw
F: Washer OD:20.0 mm ID:5.5 mm
G: Rubber cushion (with nut) 5 mm L:21.0 mm
H: Foot board
I: Front fender
J: Mud guard front fender
REFLEX REFLECTOR (FOR E-17)
Align the boss of reflex reflector to the hole of mud
guard rear fender.
Install 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
MUD GUARD REAR FENDER (FOR E-17, E-24)
Align the mud guard rear fender to the rear fender.
A: Mud guard rear fender
B: Rear fender
NOTE:
• To install the fastener, pull the center pin as C
and fix the fastener by pushing the center pin as
D.
• Arrows show direction of fasteners.

9
Secure the mud guard rear fender using fasteners.
A: Mud guard rear fender
B: Fastener
Align the parts and secure them with the screw E.
E: 5 x 25 mm screw
F: Washer OD:20.0 mm ID:5.5 mm
G: Rubber cushion (with nut) 5 mm L:21.0 mm
H: Foot board
I: Rear fender
J: Mud guard rear fender
Align the parts and secure them with the screw A.
A: 5 x 20 mm screw
B: Washer OD:20.0 mm ID:5.5 mm
C: Rubber cushion (with nut) 5 mm L:21.0 mm
D: Mud guard rear fender
E: 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 as
D.
• Arrows show direction of fasteners.
NOTE:
Six kind of labels: French, Finnish, Danish, Span-
ish, Portuguese, Swedish.