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.

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 only
E: 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 PARTS
The owner’s manual and component parts are located
in the box under the seat.
Pull the seat lock lever, and remove the seat.
A: Seat
B: Seat lock lever
Pull the clips up and remove the cover.
A: Cover
B: Clip
C: 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 kit
F: Box

12
A: Throttle cable
B: Front brake hose
C: Rear brake lever cable
D: Choke cable
E: Left switch wiring harness
F: 2WD/4WD selection cable (For LT-A400F)
G: Rear brake switch lead wire
H: Parking brake switch lead wire
I: Front brake switch lead wire
J: 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
SERVICING
BATTERY
Remove the battery from the vehicle.
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 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 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
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.

15
After confirming that the electrolyte has entered the
battery completely, remove the electrolyte containers
from the battery.
Wait for around 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
Charge the battery with a battery charger.
After charging the battery, install the battery in the
vehicle 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 in
shortened 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 connecting
or disconnecting the battery lead wires.
Observe the battery lead wire polarity before
connecting the lead wires to the battery termi-
nal.
NOTICE
Reversing the battery lead wires can damage
the 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: + lead
B: - lead
C: Rubber boot
Install the battery holder.
A: Battery holder
B: 6 × 16 mm flange bolt
Reinstall the seat.
Insert the seat hook into the seat hook retainer and
push the seat down firmly.
A: Seat assembly
B: Seat hook
C: Seat hook retainer
D: Boss
E: Hole

17
BRAKE FLUID
Place the vehicle on the level ground and keep the
handlebars straight.
Check the brake fluid level in the front master cylinder
reservoir.
If the fluid level is below the “LOWER” level, add the
correct type of brake fluid.
Refer to the chart below for the proper selection.
BRAKE AIR BLEEDING
Any air which may have been trapped in the brake fluid
circuit must be bled completely.
If the brake lever feels spongy or weak, then most
likely 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 and
run 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 into
the circuit during the air bleeding servicing.
3. Close the valve, pump and squeeze the lever, and
open the valve while squeezing brake lever.
4. Repeat this process until the 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
Specification and Classification
DOT 4
NOTICE
Spilled brake fluid can damage painted sur-
faces and plastic parts.
Be careful not to spill any fluid when filling the
brake fluid reservoir. Wipe spilled fluid up
immediately.
NOTE:
Do not drop brake fluid level below lower level line
while bleeding air.

18
THROTTLE CABLE
Check 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 Ato obtain the correct play.
4. Tighten the lock nut Bwhile holding the adjuster A.
5. Place the rubber boot C.
CHOKE CABLE
Check 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 Band turn the adjuster Ato
obtain the correct play.
3. Move the cable back and forth firmly to ensure that
the correct amount of free play is available and that
the cable housing is properly seated in the adjuster
A.
4. Tighten the lock nut Bwhile holding the adjuster A.
5. Place the rubber boot C.
REAR/PARKING BRAKE
Adjust the rear brake by adjusting the brake pedal first
and then adjust the brake lever.
WARNING
Inadequate throttle cable play can cause engine
speed 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 idle
speed does not rise due to handlebar move-
ment.
WARNING
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 inadequate
braking performance.
Adjust both the brake pedal and brake lever
within the specified range.

19
Brake Pedal
Check the rear brake pedal free travel.
Rear brake pedal free travel: 20–30 mm
If adjustment is necessary, adjust the free travel by
turning the adjuster A.
Brake Lever (Parking Brake)
Check the brake lever play at the lever holder when
squeezing 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 Band turn
in the adjuster Aas far as possible.
2. Turn the adjuster Cto obtain the correct play.
3. Minor adjustments can now be made with the brake
lever adjuster A.
4. Tighten the lock nut Bwhile 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 rear
wheels are locked by trying to move the vehicle
back and forth while it is in neutral.
8. 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).