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.

10
Align the boss and hook of headlight cover to the hole
of headlight brace.
A: Headlight cover
B: Boss
C: Hook
D: Meter cover
E: Hole
Fit the headlight 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
CC
C
and fix the fastener by pushing the center pin
as D
DD
D.

11
Fix the headlight cover using fasteners.
A: Headlight cover
B: Fastener (Medium)
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
CC
C
and fix the fastener by pushing the center pin
as D
DD
D.

12
WHEEL CENTER CAP
Attach the wheel center cap.
A: Wheel center cap
B: Wheel
C: Hub nut
D: Washer
TRAILER TOW BRACKET
Install the trailer 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.
UPUP
NOTE: (Limited market)
Stick the warning label both A
AA
Aand B
BB
B.

13
MUD GUARD REAR FENDER
(FOR E-17, 24 MARKET)
Check that the cushion is stuck to the correct position.
A: Cushion
B: Mud guard rear fender
Reflex Reflector (For E-17 market)
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
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
CC
C
and fix the fastener by pushing the center pin
as D
DD
D.

14
WARNING LABEL
(FOR E-17 MARKET)
Select the appropriate language label for your country.
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: 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

15
REAR (LEFT)
FUEL LABEL
(FOR LIMITED MARKET)
Stick the label on the rear fender.
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

16
SERVICING
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
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
NOTE:
Use the removed caps as the sealed caps of
battery filler holes.
Do not remove or pierce the sealed areas of the
electrolyte container.

17
Make sure air bubbles are coming up in each electro-
lyte container, and leave in this position for about 20
minutes.
A: Air bubbles
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

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 sealing cap has been installed in the
battery, do not remove the sealing cap.

18
Charge the battery with a battery charger.

After charging the battery, install the battery in the
vehicle as follows.

Pull the seat lock lever and remove the seat.
A: Seat
B: Seat lock lever
1. Set the battery to the 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
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
leads to the battery terminals, observe the cor-
rect polarity.
NOTE:
The terminal bolts and nuts are attached to the
battery.

19
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
BRAKE FLUID
Keep 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 components as they will be
damaged.