lt-a450xk7 text 01t r14

28
Sep. ’06 Printed in United States (CLA) 28 99505-01017-01E SUZUKI MANUFACTURING OF AMERICA CORPORATION 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.

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Page 1: LT-A450XK7 text 01T r14

Sep. ’06 Printed in United States (CLA) 28

99505-01017-01E

SUZUKI MANUFACTURING OF AMERICA CORPORATION

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 review this set-up manual carefully before performing any work. Take specialcare to properly perform the required assembly and servicing marked by either aWarning or a Caution. Failure to follow the directions in either of these two (2) cate-gories could lead to serious problems. and areas aredenoted 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.

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PREPARATIONWORKSHOP

A: Packed vehicleB: Working space

SELF PROTECTION

A: Safety gearB: Appropriate clothing

UNCRATING THE VEHICLEFor Canada onlyApply a knife to cut the carton as indicated on the car-ton to separate it from the crate base.

A: Perforate line

Except for Canada1. Remove the screws and cut the tie straps.2. Remove the carton and the plastic cover.

A: ScrewsB: Tie StrapsC: CartonD: Plastic cover

The workshop where the machine is assembledshould be clean, spacious, and have a levelfloor.

The operators should wear appropriate cloth-ing, including long sleeve shirt, long pants, andsafety gear, as shown in the illustration, forhandling crates.

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1. Remove the bolts to take off the center pole.

2. Remove the top frame first, and then vertical frames.

A: BoltsB: Center poleC: Top frameD: Vertical frame

Remove the battery electrolyte stored in the front grip.

A: Battery electrolyte container

Remove the nuts and take off the J hook of the vehiclestopper.

A: J hookB: NutsC: WasherD: CardboardE: Rubber

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.

Remove the bolts carefully while holing thecenter pole as it may fall. Be careful not toscratch the ATV.

NOTE: The J hook, nuts, cardboard, washer,and rubber are no longer needed and may bediscarded.

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LOCATION OF PARTSCheck the components as shown.

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

Item Part Name Q’ty Remarks

ABattery holder 1Flange bolt 2 6 × 16 mm

B

Trailer tow bracket 1Flange bolt 3 10 × 30 mmWarning label 1Warning label (French) 1 For limited market

C Battery electrolyte container 1

D Owner’s manual set 1

Item Part Name Q’ty RemarksE Warning label set 1 For E-17 market

FMud guard front fender 2 Right and LeftFastener 8

GMud guard rear fender 2 Right and LeftFastener 6

HReflex reflector 2 For E-17 marketFlange nut 2 5 mm

I DVD 1 For E-17 market

OD : Outside diameter (mm)ID : Inside diameter (mm)L : Length (mm)T : Thickness (mm)

T L

OD ID

NOTE: The small parts of item A, B, D, E and I are in the tail box.The parts shown as Item E, F, G, H and I in the table are supplied for limited markets.Please hand over the parts shown as Item D and I in the table to your customer together with vehicle.

BA, C

H, G F

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COMPONENT PARTS

Check the component parts stored in the tail box.

A: Tail boxB: Owner’s manual

Trailer tow kitWarning label set (Limited market) DVD (Limited market)

E

G

H

IF

BB

CC DD

C: Battery holder kit

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Before assembling the vehicle, thoroughly under-stand the “Safety Check Out” described on page 27. After completion of assembly, carefully check the vehicle referring to the “Safety Check Out”, then deliver the vehicle to the customer.

ASSEMBLY

TRAILER TOW BRACKETInstall the trailer tow bracket.

Trailer tow bracket mounting bolt: 60 N·m (6.0 kgf-m)

A: Trailer tow bracketB: 10 × 30 mm flange boltC: Mark (UP)

Stick the warning label.

A: Warning label B: Warning label (French) .....For limited market

REMOVING THE TAPERemove the tapes from the front and rear fenders.

A: Tape

UPUP

NOTE:Install the bracket placing its UP mark facedupward.

NOTE: (Limited market)Stick the warning label both A and B.

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MUD GUARD FRONT FENDER(FOR E-17, E-24 MARKET)Align the mud guard front fender to the front fender.

A: Mud guard front fenderB: Front fender

Fix the mud guard front fender using fasteners.

A: Mud guard front fenderB: Fastener

NOTE:To install the fastener, pull the center pin as Cand fix the fastener by pushing the center pinas D.

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MUD GUARD REAR FENDER(FOR E-17, E-24 MARKET)Check that the cushion is stuck to the correct position.

A: CushionB: Mud guard rear fender

REFLEX REFLECTOR (FOR E-17 MARKET)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

Align the mud guard rear fender to the rear fender.

A: Mud guard rear fenderB: Rear fender

Fix the mud guard rear fender using fasteners.

A: Mud guard rear fenderB: Fastener

NOTE: Stick the cushion on the end of radius.

NOTE:To install the fastener, pull the center pin as Cand fix the fastener by pushing the center pinas D.

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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 onlyE: Front fender (Right)F: Rear fender (Right)

REAR (RIGHT)

FRONT (RIGHT)

NOTE:Eight kind of labels: French, Finnish, Danish,German, Spanish, Dutch, Portuguese, Swedish.

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CHECK

A: Throttle cableB: Front brake hoseC: Front brake switch lead wireD: 2WD/4WD DIFF LOCK selection switch wiring harnessE: Rear brake lever cableF: Rear brake switch lead wireG: Left switch wiring harnessH: Parking brake switch lead wireI: Horn switch lead wire (For E-17, 24 market)J: Emergency switch lead wire (For E-17 market)K: Starter Cable

The line drawings on page 23, 24, 25 and 26show the proper routing of the control cables,hose and wirings.Refer to them in addition to following theinstructions carefully.

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SERVICING

BATTERY

Battery is located under the seat.Pull the seat lock lever and remove the seat.

A: Seat B: Seat lock lever

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 sealed caps ofbattery filler holes.Do not remove or pierce the sealed areas of theelectrolyte container.

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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 fillerport, tap the bottom of the container two orthree times.Never remove the container from the battery.

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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.

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: + leadB: - leadC: Rubber boot

Never use anything except the specified batteryelectrolyte. Once the sealing cap has been installed in thebattery, do not remove the sealing cap.

For charging the battery, make sure to use thecharger specially designed for MF battery. Otherwise, the battery may be overchargedresulting in shortened service life.Do not remove the cap during charging.Position the battery with the cap facing upwardduring charging.

When attaching the wiring harness batteryleads to the battery terminals, observe the cor-rect polarity.

NOTE:The terminal bolts and nuts are attached to thebattery.

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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 retainer

BRAKE FLUIDKeep the vehicle upright and place the handlebarsstraight.Check the brake fluid level in the front master cylinderreservoir.If the fluid level is below the lower level indicated in thefigure, add the correct type of brake fluid.Refer to the chart below for the proper selection

A: Lower level line

Specification and ClassificationDOT 4

Be careful not to spill any brake fluid on thepaint or plastic components as they will bedamaged.

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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 hydraulic circuit.To bleed the air from the front brake, use the followingprocedure:

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

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 procedurebelow:

1. Loosen the throttle cable adjuster lock nut B.2. Turn the adjuster A to obtain the correct play.3. Tighten the lock nut B while holding the adjuster A.

Place the rubber boot C.

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

After the adjustment is completed, check thathandlebar movement does not raise the engineidle speed and that the throttle lever returnssmoothly and automatically.

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

Brake pedalCheck the rear brake pedal height.

Rear brake pedal height: 12–22 mm

If the rear brake pedal height is not correct, adjust inthe following manner:

1. Loosen the lock nut A.2. Adjust the brake pedal height by turning the brake

pedal stopper bolt B to locate the pedal to the cor-rect height above the top face of the footrest C.

3. Tighten the lock nut A.

Check the brake pedal free travel.

Rear brake pedal free travel: 20–30 mm

If adjustment is necessary, turn the adjuster A toobtain the correct free travel.

The rear brake lever and rear brake pedal oper-ate the rear brake in a complementary manner. When one of these is misadjusted, the brakesystem as a whole will not operate properly. This could cause brake dragging or inadequatebraking performance. Be sure to adjust both the brake pedal andbrake lever within the specified ranges.

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Brake Lever (Parking Brake)Check the brake lever play at the lever holder when thelever is lightly pulled in towards the grip.

Rear brake (Parking brake) lever play: 6.0–8.0 mm

If adjustment is necessary, carry out the procedurebelow:

1. Loosen the lock nut B and turn in the adjuster A asfar as it will go.

2. Turn the adjuster C clockwise or counterclockwiseto obtain the specified play.

3. Minor adjustments can now be made with the brakelever adjuster A. Tighten the lock nut B. Set the lever cover D.

4. After adjusting the play, check that the rear wheelsroll freely with the brake disengaged, the transmis-sion in neutral, and the rear wheels off the ground.

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

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

FRONT

FRONT AND REAR SUSPENSION ADJUSTMENTCheck for the spring setting of front and rear suspen-sion.This vehicle is delivered from the factory with itsadjusters set to the following positions.

A: AdjusterREAR

Standard setting

FRONT REAR2 2

When adjusting either of the suspensions, besure to adjust both the right and left springs tothe same preload setting.

1 2 3 4 5

1 2 3 4 5

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

COLD INFLATION TIRE PRESSURE

HEADLIGHT BEAM ADJUSTMENT (RIGHT AND LEFT)The headlight beam can be adjusted vertically if nec-essary.

To adjust the beam vertically:Turn the adjuster screw clockwise or counterclockwise.

A: Adjuster screw

ENGINE COOLANTThe engine coolant level should be kept between the“FULL” and “LOW” level lines as shown in the photo-graph. Inspect the level with the vehicle held upright on levelground.

A: Engine coolant reservoirB: “FULL” level lineC: “LOW” level lineD: Radiator

LOADTIRE PRESSURE

FRONT REAR

Up to 172 kg380 lbs

35 kPa0.35 kgf/cm2

5.1 psi

30 kPa0.30 kgf/cm2

4.4 psi

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1. Remove the radiator cap lid.

A: Radiator cap lidB: Boss

2. Remove the filler cap and add 50 : 50 mixture ofengine coolant and distilled water to the “FULL” levelline from the engine coolant filler hole.

3. Reinstall the filler cap and the lid.

C: Filler cap

FRONT DIFFERENTIAL GEAR OILPlace 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 tightenthem securely.

A: Oil filler plug B: Oil level bolt

NOTE:Use hypoid gear oil SAE 90, API grade GL-5. If the vehicle is ridden where the ambient tem-perature is below 0°C or 32°F, use the hypoidgear oil SAE 80, API grade GL-5.

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FINAL GEAR OILPlace the vehicle on a level ground.Check the final gear oil levels as follows. Remove the oil filler plug. If the oil level does not reach the bottom of the fillerhole, add the gear oil through the filler hole until the oillevel reaches the bottom of the oil filler hole.Reinstall the oil filler plug and tighten it securely.

A: Oil filler plug

ENGINE OIL

Remove the fasteners to take off the footrest guard lid.

A: Footrest guard lidB: Fastener

Check the engine oil level with the engine oil dipstick.1. Place the vehicle on level ground.2. Start the engine and allow it to run for a few minutes

at idling speed.Stop the engine and wait about three minutes.

3. 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.

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

5. Draw out the dipstick and check the oil level.The level found on the dipstick should be between“L” (Low) and “F” (Full) line.

6. If the oil level is below the “L” line, add fresh oil fromthe filler hole until the oil level reaches to “F” line.If the level is above the “F” line, drain oil to “F” line.

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

8. Reinstall the footrest guard lid.

A: Engine oil filler plugB: Engine oil dipstick

NOTE:Use Mobil Fluid 424 or an equivalent.

This vehicle is shipped from factory with theengine filled with engine oil. Be sure to check oil level.

NOTE:To remove the fastener, pull the center pin as Cand pull out the fastener as D.

F

L

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

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 following 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 has following classification for con-firming the standard.

A: Code number of oil sales companyB: Oil classification

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 goodengine starting 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.

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Energy ConservingSuzuki does not recommend the use of “ENERGYCONSERVING” oils. Some engine oils which are API SH or greater havethe “ENERGY CONSERVING” indication in API classi-fication doughnut mark. These oils can affect engine life and clutch perfor-mance.

SPEEDOMETER

Set the meter to odometer, then press and hold but-tons, odo/trip and clock/hour for 2 seconds to switchbetween km/h and mph.Select km/h and mph properly to comply with trafficregulations.Check km/h and mph display after adjusting the instru-ment panel display.

A: Odo/Trip ButtonB: Clock/Hour ButtonC: 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.

RecommendedNot recommended

EN

ERGY CONSERVIN

G

API SERVICE SJ

SAE10W-40

API SERVICE SJ

SAE10W-40

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TIGHTENING TORQUE

For other bolts and nuts not listed, refer to this chart.

Item Part Name N·m kgf-m

STEERING, FRONT SUSPENSION AND FRONT BRAKE

A Handlebar clamp bolt 26 2.6

B Handlebar holder nut 60 6.0

C Front hub nut 110 11.0

D Front wheel set nut 60 6.0

EFront shock absorber mounting bolt (upper)

55 5.5

FFront shock absorber mounting nut (lower)

60 6.0

G Front brake caliper air bleeder 6.0 0.6

HFront brake master cylinder mounting bolt

10 1.0

I Front brake caliper mounting bolt 26 2.6

Item Part Name N·m kgf-m

REAR SUSPENSION AND REAR BRAKE

JRear shock absorber mounting nut (upper)

60 6.0

KRear shock absorber mounting nut (lower)

60 6.0

L Rear hub nut 110 11.0

M Rear wheel set nut 60 6.0

N Rear brake cam lever nut 11 1.1

O Rear brake pedal boss nut 11 1.1

OTHERS

P Front footrest bolt 55 5.5

Bolt Diameter (mm)Conventional or “4” marked bolt “7” marked boltN·m kgf-m N·m kgf-m

4 1.5 0.15 2.3 0.235 3 0.3 4.5 0.456 5.5 0.55 10 1.08 13 1.3 23 2.3

10 29 2.9 50 5.012 45 4.5 85 8.514 65 6.5 135 13.516 105 10.5 210 21.018 160 16.0 240 24.0

Conventional bolt

“4” marked bolt

“7” marked bolt

A

HH

BB

CO DML

E F

P GI

NN

KK

JJ

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CABLE ROUTING

Wiring harness

Wiring harness

Frame

Frame

Parking brake cable

Location of cable andharness: as shown

Parking brake cable Throttle cable

Parking brake cable

Stater cable

Parking brake cable

Sterter cable

Fix foot brake cableto the footrest bar

Parking brake cable guide

Handlebar

Pin

Locate throttle cable as shown.Must not locate out of pin.

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Cotter pin

Pin

Front side

Foot brake pedal

Washer

Fix foot brake cableto the footrest

Foot brake cable

Rear brake assy

Parking brake cable

Adjust nut

Parking brake cableFrame

Rear fender

Protector

Parking brake cable

Parking brake cable

Rear fender

Screw

Wiring harness

Tie protector withclamp as shown.

Frame

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HARNESS ROUTING

Clamp

Clamp

Emergency switch lead wire (E-17)

Emergency switch (E-17)

Horn switch(E-17, E-24)

Set the matting surfaceemergency switch to forward

Horn (E-17)

Clamp

DIFF-lock/transfer switch lead wire

Fix the front brake hose

Starter motor

Engine ground

DIFF-lock/transferrelay

Set the TS coupler to the rear fender hole.

Starter motor terminal

Battery ECM Fuse box

Master cylinder reservoir tank

To combination meter

Set the sag undercombination meter

Pass the combination meter wire behind the upper bracket.

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

Brake lever switch lead wire (L)

Handle switch lead wire (L)

Parking brake switch lead wire

Emergency switch lead wire (E-17)

DIFF-lock/transfer switch lead wire

Combination meter lead wire

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

Brake lever switch lead wire (L)

Brake lever switch lead wire (R)

Ignition switch lead wire

Handle switch lead wire (L)

Parking brake switch lead wire

Brake lever switch lead wire (R)

10 “ 15 mm (0.3 “ 0.6 in)

Horn (E-24)

Wiring Harness Drive Motor lead wire

Clamp Clamp

Wiring Harness

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Clamp

Wiring harness

Wiring harness

Wiring harness

60~80 mm (2.3 – 3.1 in) Clamp

Wiring harness

Clamp

Clamp

Clamp

Wiring harness

Clamp

Clamp

Brake light/taillight lead wire

Clamp

Wiring harness

Wiring harness

Generator lead wireGear position switch lead wireClamp

Clamp

Clamp

Clamp

Actuator

ClampClamp

Clamp

Clamp

Actuator lead wireFoot brake switch lead wire

Actuator lead wireFoot brake switch lead wire

To rear fender top

Speed sensor lead wire

ClampWiring harness

Injector coupler

ECT sensor coupler

Ignition coil

To power source

Clamp

Clamp

Wiring harness

Wiring harness lead wire

TP/IAP/IATsensor

Wiring harnessWiring harness

Actuator lead wire Gear position switch lead wire

Generator lead wire

Hose

Cooling fan thermo switch lead wire

Foot brake switch lead wireBrake light/taillight lead wire

Back up relay (E-17)

Back up relay (E-17)

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SAFETY CHECK OUT

ENGINE AND TRANSMISSION

CHASSIS

COLD INFLATION TIRE PRESSURE

ELECTRICALS

ROAD TEST INSPECTION

After completion of the setting-up the vehicleall the following items should be double-checked to confirm that the operation and func-tion of the vehicle are satisfactory. Now, set-ting-up the vehicle and pre-delivery inspectionhave been completed and the vehicle can bepassed to the customer.

ITEM MEASURE SPECIFICATIONSEngine oil Check/Refill 2,500 ml Fuel tank Drain/Fill 17.5 L Throttle cable Check/Adjust 3.0–5.0 mmExhaust system LeakageFuel system connection

Circlip/Leakage

Front differential gear oil

Check/Fill 500 ml

Final gear oil Check/Fill 770 mlEngine coolant Leakage/Level 2.45 L

ITEM MEASURE SPECIFICATIONSDisc brake (s) Clean/Fluid levelRear/Parking brake lever

Check/Adjust 6–8 mm

Rear brake pedal Check/Adjust

Height:12–22 mmFree travel:20–30 mm

Oiling pointsAll necessary points

Battery Filling electrolyteWiring and cable Routing/OperationWiring connectors Clean/Tight

SuspensionsFront/Rear, Operation

Front: Position 2Rear: Position 2

Tighten all nuts and bolts

Torque those listed in this manual

Cotter pins and circlip

Fasteners, Check

Paint and chromeInspect/Wash and polish

Warning label(For E-17 market)

Select/StickAppropriate language

LOADTIRE PRESSURE

FRONT REAR

Up to 172 kg380 lbs

35 kPa0.35 kgf/cm2

5.1 psi

30 kPa0.30 kgf/cm2

4.4 psi

ITEM CHECK FORLight

Lighting/AdjustTaillight/Brake lightHeadlight high/low beamBack lamp (For E-17 market)

Instrument Lights

Lighting

Reverse indicator lightSpeedometer display Neutral indicator lightCoolant temperature indicator light/Fuel injection indicator lightDifferential gear lock indicator lightHigh beam indicator light(For E-17 market)

Switch Operations

Operation

Ignition switchDimmer switchEngine stop switchStarter button2WD/4WD/DIFF LOCK Selection switchBrake light switchBrake switchParking brake switchOverride switchHorn switch(For E-17, 24 market)Emergency stop switch(For E-17 market)

ITEM CHECK FOR

EngineStarting/Acceleration/Smoothness/Noise

Transmission Operation/NoiseDrive shaft Smoothness/NoiseShift lever OperationBrake Front/Rear, Operation/NoiseSteering StabilitySuspension OperationControl cables Operation/Proper returnLeakage Fuel/Oil/Exhaust/CoolantOdometer and trip meter OperationSpeedometer OperationCooling fan Operation

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