Suzuki LT-A700XK5 User guide

K5
September ’04 Printed in Japan (TK) 28
99505-01125-01E
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 review this set-up 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 injury.

Indicates a potential hazard that could result in vehicle damage.
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
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.

2
LOCATION OF PARTS
Check off each of the components as shown in the photograph.
AABBCC
DD
EE
II
FF
JJ
GG
HH
KK
LL
MM

3
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Headlight assembly 1
Flange bolt 2 8 × 12 mm
Spacer 1 L:11
Allen bolt 1 5 × 20 mm
B
Headlight cover (Upper) 1
Headlight cover (Lower) 1
Fastener (Small) 2
Fastener (Medium) 1
C
Meter cover 1
Meter rubber cushion 1
Fastener (Medium) 1
Tapping screw 2 5 × 16 mm
DBattery holder 1
Flange bolt 2 6 × 16 mm
E
Trailer tow bracket 1
Flange bolt 3 10 × 30 mm
Warning label 1
Warning label (French) 1 For limited market
Item Part Name Q’ty Remarks
F Wheel center cap 4
GMud guard rear fender 2 Right and Left
Fastener (Large) 6
HReflex reflector 2
Flange nut 2 5 mm
I Warning label set
3For E-17 CG
selection
2For E-17 CH
selection
3For E-17 CI
selection
J Fuel label 1 For limited market
K
Battery 1
Battery electrolyte
container 1
L Owner’s manual 1
M Safety video 1 For limited market
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
TL
OD ID
NOTE:
The parts shown as Item E, G, H, I, J and M in the above table are supplied for limited markets.
EA B C D, K J
FFFG, H F
II

4
The photograph shown indicates the parts dismounted
from the model in addition to the items shown in the
preceding page.
A: Handlebar assembly
B: Front brake master cylinder
C: Ignition switch
D: Meter assembly
E: Front brake switch lead wire
F: Wiring harness
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
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 handlebars with the
mating surface of the front side of left clamp.

5
Tighten the handlebar clamp bolts to the specified torque.

"
""
"Handlebar clamp bolt: 26 N·m (2.6 kgf-m)
A: Flange bolt
B: Flange bolt
C: Dot mark
FRONT BRAKE MASTER CYLINDER
Remove the bolts and holder from the front brake mas-
ter cylinder.
A: Master cylinder
B: Bolt
C: Holder
Install the front brake master cylinder onto the handle-
bars.
Align the dot mark on the handlebars with the master
cylinder-to-holder fitting surface.
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
AA
Aof the front side with specified torque
and then tighten the bolt B
BB
Bof the rear side.
Make sure that the clamp has no clearance at
the front side as shown in the illustration.
FORWARD
NOTE:
To install the holder correctly, first tighten the
bolt B
BB
Bof the upper side with specified torque
and then tighten the bolt C
CC
Cof the lower side.

6

A: Bolt
B: Holder
C: Master cylinder
D: Handlebars
Connect the front brake light switch lead wires coupler
to the brake light switch.
A: Front brake 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.

7
#
A: Throttle cable
B: Front brake hose
C: Front brake switch lead wire
D: 2WD/4WD DIFF LOCK selection switch wiring harness
E: Rear brake lever cable
F: Rear 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)
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 them in addition to following the
instructions carefully.
NOTE:
Pass the throttle cable inside the boss.

8
Install the meter assembly to the headlight brace.
A: Meter assembly
B: Boss
C: Rubber grommet
D: Meter wiring harness
E: 5 × 20 mm allen bolt
F: Spacer L:11 mm
HEADLIGHT 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.

9
Align the meter cover to the headlight brace.
A: Headlight brace
B: Meter cover

A: Meter assembly
B: Meter rubber cushion
Fix the meter cover using fastener.
A: Fastener (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
BB
B
and fix the fastener by pushing the center pin
as C
CC
C.