Suzuki LT-A500XP Owner's Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Utility Vehicle
  5. LT-A500XP
  6. Owner's manual
Suzuki LT-A500XP Owner's Manual

Suzuki LT-A500XP Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
LT-A500XP
OWNER'S MANUAL
This owner's manual contains
important safety information.
Please read it carefully.
Never allow anyone under 16
years old to ride this ATV.

Advertisement

Table of Contents
loading

Related Manuals for Suzuki LT-A500XP

Summary of Contents for Suzuki LT-A500XP

  • Page 1 LT-A500XP OWNER’S MANUAL This owner’s manual contains important safety information. Please read it carefully. Never allow anyone under 16 years old to ride this ATV.
  • Page 2 California Proposition 65 Warning WARNING Engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. This manual should be considered a permanent part of the ve- hicle and should remain with the vehicle when resold or other- wise transferred to a new owner or operator.
  • Page 3 • WARNINGs and CAUTIONs IMPORTANT are arranged like this:  WARNING /CAUTION /NOTE WARNING-or-CAUTION Please read this manual and fol- low its instructions carefully. To This first part will identify a emphasize special information, POTENTIAL HAZARD.  the symbol and the words WARNING, CAUTION and NOTE This second part will describe have special meanings.
  • Page 4 • In the USA, anyone who pur- available at the time of publica- chases a new Suzuki ATV, and tion. Due to improvements or everyone in the purchaser’s other changes, there may be immediate family who is old...
  • Page 5 • Read this manual and all emission compliance. Your labels carefully and follow the authorized Suzuki dealer has operating procedures experienced technicians that described. are trained to provide your • Never operate an ATV without machine with the best possible proper instruction.
  • Page 6 • Never operate on excessively • Always avoid operating an ATV rough, slippery or loose terrain on paved surfaces, including until you have learned and sidewalks, paths, parking lots, practiced the skills necessary drive ways, and streets. to control the ATV on such ter- •...
  • Page 7 • Always check for obstacles • Always follow proper proce- before operating in a new dures for going down hills and area. Never attempt to operate braking hills over large obstacles, such as described this manual. large rocks or fallen trees. Check the terrain carefully Always follow proper proce- before you start down any hill.
  • Page 8 • Never exceed the stated load capacity for an ATV. Cargo should be properly distributed securely attached. Reduce speed follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. MORE INFORMATION ABOUT ATV SAFETY, Owners in the USA can call the Consumer Product Safety Commission at 1- 800-638-2772, or the ATV Distrib-...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS RIDING YOUR ATV ACCESSORY USE AND VEHICLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING PREPARATION FOR WINTER RIDING TRANSPORTING CLEANING PROCEDURE AND STORAGE PROCEDURE CONSUMER INFORMATION SPECIFICATIONS INDEX...

  • Page 11: Fuel, Oil And Engine Coolant Recommendations

    FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS FUEL ........................1-2 ENGINE OIL ......................1-3 ENGINE COOLANT SOLUTION ................. 1-5 FRONT DIFFERENTIAL GEAR OIL ..............1-6 FINAL GEAR OIL ....................1-6...

  • Page 12: Recommendations

    ATV performance are oxygenated fuels. problems resulting from the use of such fuels are not the responsibil- ity of Suzuki and may not be cov- Oxygenated fuels which meet the minimum octane requirement and ered under the New Vehicle...

  • Page 13: Engine Oil

    • Be sure that any oxygenated engine oil. Suzuki recommends fuel you use has octane rat- the use of SUZUKI PERFOR- ings of at least 87 pump MANCE 4 MOTOR OIL or equiva- octane ((R+M)/2 method). lent engine oil. Use oil with an API •...
  • Page 14 JASO T903 Energy Conserving The JASO T903 standard is an Suzuki does not recommend the index to select engine oils for 4- use of “ENERGY CONSERVING” stroke motorcycle oils. Some engine oils which have engines. Motorcycle and ATV an API classification of SH or...

  • Page 15: Engine Coolant Solution

    ENGINE COOLANT SOLUTION WARNING Use engine coolant that is com- patible with an aluminum radiator, Engine coolant is harmful or mixed with distilled water at a fatal if swallowed or inhaled. 50:50 mixture ratio for engine coolant solution. An engine cool- Do not drink antifreeze or cool- ant mixture other than 50:50 can ant solution.

  • Page 16: Front Differential Gear Oil

    Water for Mixing Use distilled water only. Water other than distilled water can cor- rode and clog the aluminum radia- tor. Required amount of engine cool- ant/water solution capacity (total): 2500 ml (2.6 US qt) 1250 ml Engine coolant (1.3 US qt) 1250 ml Water (1.3 US qt)

  • Page 17: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..................2-2 KEY ........................2-5 IGNITION SWITCH ....................2-6 INSTRUMENT PANEL ..................2-7 SHIFT LEVER ....................2-12 SELECTION SWITCH ..................2-14 LEFT HANDLEBAR ................... 2-16 RIGHT HANDLEBAR ..................2-19 THROTTLE LIMITER ..................2-19 REAR BRAKE PEDAL ..................

  • Page 18: Location Of Parts

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1 Rear brake lever 2 Left handlebar switches 3 Speedometer and indicator lights 4 Ignition switch 5 Front brake fluid reservoir 6 Front brake lever 7 Shift lever 8 Throttle lever 9 2WD/4WD/DIFF LOCK selection switch...
  • Page 19 0 Battery A Fuel tank cap B Seat lock C Footrests...
  • Page 20 D Rear brake pedal...

  • Page 21: Key

    WARNING Indicates a potential hazard that could result in injury or death. Two keys come with this vehicle. Keep the spare key in a safe place. An identifying number is stamped on the keys. Use this number when making a replace- ment key.

  • Page 22: Ignition Switch

    IGNITION SWITCH CAUTION Leaving the ignition switch in  the “ ” position without the engine running for a long time can damage the ATV’s battery. The battery will run down if the lights are on for a long time when the engine is not run- The ignition switch has three posi- ning.

  • Page 23: Instrument Panel

    Neutral Indicator “N” 4 INSTRUMENT PANEL A green light comes on when the shift lever is in neutral position. The shift position display 9 also shows “N”. Coolant Temperature Indicator “” 5 When the coolant temperature is higher than 120°C, the display ”...
  • Page 24 Have chronization mechanism. the system inspected by your indicator will go off just after ATV Suzuki dealer. starts moving. NOTE: If the power steering sys- tem does not work properly, you will feel heavier to steer but you...
  • Page 25 Shift Position Indicator 9 Odometer/Trip meter A The shift position indicator indi- cates shift lever positions: R, N, H TRIP A TRIP B ODOMETER and L R: Shift lever is in “R” (Reverse) position. The reverse indicator 3 also comes on. N: Shift lever is in “N”...
  • Page 26 3. Push the button 1 to adjust hour display. Hour display starts blinking and is to adjust. 4. Push the button 7 to adjust hour display. 5. Push the button 1 to set hour display. Hour meter “ ” The hour meter indicators total time that the vehicle is used.
  • Page 27 Suzuki dealer. If the engine stalls, try restarting the engine after turning the ignition switch off. Wait more than 3 seconds before turning on the ignition switch.

  • Page 28: Shift Lever

    SHIFT LEVER WARNING Operating the shift lever from Neutral without applying the brake can be hazardous. If you shift without applying the brake, vehicle can move unex- pectedly. This vehicle has an automatic Always apply the brake before transmission. Select gear posi- changing from Neutral to High tions according to how you intend or Reverse, to help prevent the...
  • Page 29 NOTE: Shift the shift lever into WARNING neutral before turning off the engine when parking the vehicle Operating the shift lever when on an incline. If you parked on an the ATV is moving can be haz- incline with shift lever in H, L or R ardous.

  • Page 30: Selection Switch

    SELECTION SWITCH 2WD: Engine power is supplied only to the rear wheels. Use this position for normal riding on dry, hard surfaces. DIFF LOCK The selection switch is used for changing the manner in which engine power is supplied to the wheels.
  • Page 31 NOTE: The selection lever can only be shifted into the DIFFER- ENTIAL LOCK position if the switch is in the 4WD position. NOTE: • When the switch is set to “DIFF LOCK”, the differential gear lock indicator will blink until the differential gear is locked.

  • Page 32: Left Handlebar

    Dimmer Switch 3 LEFT HANDLEBAR Use the dimmer switch to select the high or low headlight beam when the ignition switch is in the “” position. When you move the dimmer switch to the “” posi- tion, the high beam will light. When you move the dimmer switch to the “”...
  • Page 33 Override Switch 5 CAUTION The override switch allows the rider to increase the power avail- Sticking some tape or placing able by overriding the normal objects in front of the headlight speed limiter in forward Differen- can damage the headlight. tial Lock or Reverse.
  • Page 34 CAUTION Engaging the starter motor for more than five seconds at a time can damage the ATV. The starter motor and wiring harness may overheat. If the engine does not start Electric Starter Button “” 6 after several attempts, check Use this button to turn the starter the fuel supply and ignition motor.

  • Page 35: Right Handlebar

    RIGHT HANDLEBAR THROTTLE LIMITER Use the throttle limiter to restrict Front Brake Lever 1 maximum engine power by limit- Apply the front brake by squeez- ing throttle lever travel. Adjust this ing the front brake lever towards limiter according to the rider’s skill the grip.

  • Page 36: Rear Brake Pedal

    REAR BRAKE PEDAL FUEL TANK CAP Pressing the rear brake pedal will To open the fuel tank cap. Turn apply the rear brake. the fuel tank cap counterclock- wise. To close the fuel tank cap, NOTE: The rear brake may also turn it clockwise and tighten it be applied by squeezing the rear securely until it clicks.
  • Page 37 WARNING Fuel level Filler neck Improper fueling of the ATV can be hazardous. Failure to follow safety precau- tions when refueling could result in a fire or cause you to breathe toxic fumes. WARNING Refuel in a well ventilated area. Overfilling the fuel tank can be Make sure the engine is off and hazardous.

  • Page 38: Seat Lock

    SEAT LOCK WARNING Improperly installing the seat can be hazardous. Failure to install the seat prop- erly could allow the seat to move and cause loss of rider control. Make sure to properly position and securely attach the seat when you install it. To remove the seat, pull the seat lock lever upward.

  • Page 39: Box

    FRONT FENDER BOX Small and light articles such as Small and light articles such as the owner’s manual, rain gear or a gloves, maps, or sealed food wind breaker can be placed in the packages can be placed in the box.

  • Page 40: Front And Rear Suspension Adjustment

    FRONT AND REAR SUSPENSION ADJUSTMENT Front: Position 2 Rear: Position 2 FRONT WARNING Unevenly adjusting the right and left front and rear suspen- sions can be hazardous. Making one spring stiffer than the other will result in handling problems that may cause an accident.

  • Page 41: Flag Bracket

    FLAG BRACKET A bracket is provided so you can mount a flag on your vehicle. 2-25...

  • Page 43: Riding Your Atv

    RIDING YOUR ATV WHAT YOU SHOULD KNOW BEFORE RIDING ..........3-2 INSPECTION BEFORE RIDING ................3-4 WHAT TO WEAR ....................3-6 BREAK-IN ......................3-7 STARTING THE ENGINE ..................3-8 STARTING OFF AND SHIFTING ..............3-10 BRAKING ......................3-14 TURNING ......................3-15 SKIDDING OR SLIDING ..................

  • Page 44: What You Should Know Before Riding

    Suzuki. You should regularly practice the skills learned in the course and the operating techniques described in this owner’s man- ual. For more information...
  • Page 45 Before you begin riding, you WARNING should find a good place to prac- tice the skills you need to ride Operation of this ATV by chil- safely. Find a flat, open area with dren under age 16 can be haz- enough space to practice new ardous.

  • Page 46: Inspection Before Riding

    INSPECTION BEFORE RIDING WARNING WARNING Operating this with improper tires, with Failure to inspect the ATV improper or uneven tire pres- before operating it can be haz- sure can be hazardous. ardous. Failure to perform proper maintenance can also If you use improper tires or be hazardous.
  • Page 47 WARNING WARNING Overloading this ATV can be Checking maintenance items hazardous. when the engine is running can be hazardous. Overloading could cause changes in vehicle handling You could be severely injured if which could lead to an acci- your hands or clothing gets dent.

  • Page 48: What To Wear

    WHAT TO WEAR WHAT TO CHECK FOR: CHECK WARNING Steering 1. Smoothness 2. No restriction of movement Operating this ATV without 3. No play or looseness wearing an approved motorcy- Brakes 1. Proper pedal and lever cle helmet, eye protection and operation 2.

  • Page 49: Break-In

    A helmet is the most important BREAK-IN piece of gear you should wear. A The first month is the most impor- helmet can help prevent a serious tant in the life of your vehicle. head injury. Choose a helmet that Proper operation during...

  • Page 50: Starting The Engine

    Allow the Engine Oil to STARTING THE ENGINE Circulate Before Riding Before attempting to start the Allow enough idling time after engine, make sure to follow these warm or cold engine starting steps. before revving the engine or plac- ing the transmission in gear. This 1.
  • Page 51 WARNING CAUTION Engaging the starter motor for Running your ATV indoors more than five seconds at a where there is little or no venti- time can damage the ATV. lation can be hazardous. The starter motor and wiring When breathed in, exhaust harness may overheat.

  • Page 52: Starting Off And Shifting

    STARTING OFF AND SHIFTING WARNING WARNING Operating this ATV on paved surfaces, including sidewalks, Carrying a passenger on this paths, parking lots, driveways, ATV can be hazardous. and streets can be hazardous. Carrying a passenger can ATV tires are designed for off- greatly reduce your ability to road use.
  • Page 53 WARNING WARNING Operating this ATV on public Operating this ATV at exces- streets, roads or highways can sive speeds can be hazardous. be hazardous. Riding at excessive speeds You can collide with another increases your chances of los- vehicle if you ride on public ing control of the ATV, which roads.
  • Page 54 WARNING WARNING Removing your hands from the Failure to use extra care when handlebars or feet from the operating excessively footrests during operation can rough, slippery, or loose terrain be hazardous. can be hazardous. If you remove even one hand or Failure to use extra care can foot from the ATV, you can cause loss of traction or vehi-...
  • Page 55 Place your feet on the footrests. WARNING Placing a foot on the footrest board area can interfere with rear Failure to use extra care when brake pedal operation and weight operating this ATV on unfamil- shifting. iar terrain can be hazardous. After making sure that the engine You can come upon hidden is warm, apply the rear brake and...

  • Page 56: Braking

    BRAKING WARNING To stop the vehicle, first release the throttle lever. Next, apply the Braking on hills when in 4WD front and rear brakes evenly and can be hazardous. at the same time. When in 4WD, using either the WARNING front brake alone or the rear brake alone will actually brake Braking while turning the ATV...

  • Page 57: Turning

    TURNING To turn the vehicle, use the follow- ing technique: WARNING • Move your body weight for- ward and to the inside of the turn. Turning the ATV improperly • Turn the handlebars while can be hazardous. looking in the direction of the turn.

  • Page 58: Skidding Or Sliding

    SKIDDING OR SLIDING OPERATION ON HILLS WARNING WARNING Skidding or sliding improperly Operating this ATV on exces- can be hazardous. sively steep hills can be haz- ardous. You may lose control of your ATV, or regain traction unex- The ATV can overturn more pectedly, which may cause the easily on extremely steep hills ATV to overturn.
  • Page 59 Climbing a Hill WARNING WARNING Braking on hills when in 4WD can be hazardous. Climbing hills improperly can be hazardous. When in 4WD, using either the front brake alone or the rear Climbing hills improperly can brake alone will actually brake cause loss of control or cause all four wheels.
  • Page 60 2. Once you have turned around, WARNING ride down the hill as described in the DESCENDING A HILL Stalling, rolling backwards or section. improperly dismounting the ATV while climbing a hill can be If you lose forward movement, or hazardous. begin to roll backwards, follow these instructions.
  • Page 61 6. Remount the vehicle, apply the WARNING brakes, release the parking brake and ride down the hill as Braking on hills when in 4WD instructed in the DESCEND- can be hazardous. ING A HILL section. When in 4WD, using either the If the front brake does not slow front brake alone or the rear the vehicle, dismount to the side...

  • Page 62: Riding Over Obstacles

    Traversing a Slope RIDING OVER OBSTACLES WARNING WARNING Crossing hills or turning on Improperly operating this ATV hills improperly can be hazard- over obstacles can be hazard- ous. ous. Crossing hills or turning on Improperly crossing obstacles hills improperly can cause loss can cause loss of control or a of control or cause the ATV to collision.

  • Page 63: Riding Through Water

    After repeated operation of the ability. Test your brakes after ATV in these conditions, bring leaving the water. If neces- it to your Suzuki dealer to have sary, apply them several times to let friction dry out brakes inspected the linings.

  • Page 64: Riding In Cold Weather

    If the brakes are frozen, bring the the brakes do not regain full stop- ATV to a warmer area to thaw out ping power, have your local the brakes. Suzuki dealer check them before you continue riding your ATV. 3-22...
  • Page 65 Dressing for Cold Weather WARNING Riding Operating the ATV without a WARNING properly functioning brake sys- tem can be hazardous. Operating your ATV in cold weather without proper cloth- Wet or frozen brakes will ing can be hazardous. increase stopping distance. This will increase your chance Continued exposure to cold of having an accident.
  • Page 66 Continued exposure to cold tem- Riding your ATV on Snow and peratures can also lead to hypoth- ermia. Hypothermia occurs when WARNING your body’s inner temperature drops. Symptoms include numb- Riding on snow-covered terrain ness in the extremities (hands, feet, arms, and legs), and shiver- without care can be hazardous.
  • Page 67 Your eyes may be sensitive to WARNING sunlight when you ride over snow or ice on a bright, sunny day. Failure to use extra care when Snow or ice reflects more light operating on slippery surfaces into your eyes than dirt or grass such as hard-packed snow and does.

  • Page 68: Riding In Reverse

    RIDING IN REVERSE WARNING WARNING Sudden application of the throttle or making abrupt turns Improperly riding this ATV in in reverse gear can be hazard- reverse can be hazardous. ous. You could hit an obstacle or Throttle surges or abrupt turns person behind you, resulting in could cause you to lose control injury.

  • Page 69: Accessory Use And Vehicle Loading

    ACCESSORY USE AND VEHICLE LOADING ATV WINCH LEAD WIRES ................. 4-4...
  • Page 70 Operating this with There are many types of accesso- improper modifications can be ries for sale. However, Suzuki can hazardous. not have direct control over the quality or suitability of non-Suzuki Improper installation of acces- accessories. Suzuki can not test sories or modification of the each accessory that is available.
  • Page 71 Suzuki dealers offer a variety of genuine Suzuki accessories for your ATV. Please contact your Suzuki dealer for details. Accessory Use and Vehicle Load- ing Guidelines. 1. The combined weight of the rider, gear, trailer tongue weight and any accessories or cargo must never exceed the vehicle’s load capacity of 172...
  • Page 72 Suzuki genuine acces- sory ATV winch, rated line pull: 1134 kg (2500 lbs). The part num- ber of the Suzuki ATV winch for this vehicle is 99000-990YW-016. Consult your Suzuki dealer for details about attaching the acces-...

  • Page 73: Inspection And Maintenance

    INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE ................5-2 NOTICE ........................ 5-4 TOOLS ......................... 5-6 BATTERY ......................5-6 SPARK PLUG ...................... 5-9 THROTTLE CABLE ADJUSTMENT ..............5-12 FUEL HOSE ....................... 5-13 ENGINE OIL ....................... 5-13 ENGINE OIL AND FILTER CHANGE ..............5-14 AIR CLEANER ....................

  • Page 74: Maintenance Schedule

    INSPECTION AND MAINTENANCE WARNING Indicates a potential hazard that could result in injury or death. MAINTENANCE SCHEDULE Perform maintenance according to odometer reading or time interval, whichever comes first. Interval Initial 200 Every 1000 Every 2000 miles Initial 100 Every 600 Every 1200 Item months...
  • Page 75 Interval Initial 200 Every 1000 Every 2000 miles Initial 100 Every 600 Every 1200 Item months Initial 1 Every 3 Every 6 Tires – * Steering * Suspensions – – * Chassis nuts and bolts * General lubrication – I= Inspect and clean, adjust, lubricate or replace, as necessary, T= Tighten, R= Replace, C= Clean, L= Lubricate.

  • Page 76: Notice

    SIONS IN THE CLEAN AIR ACT Sec. 207 (a)(2). Keep your ATV in good condi- tion. Ask your Suzuki dealer or It is very important to inspect and a qualified mechanic to do the maintain your vehicle regularly. maintenance...
  • Page 77 When replacing parts on your frequent full throttle, or in vehicle, use only genuine dusty, wet, sandy, or muddy Suzuki replacement parts or areas. These conditions can their equivalent. cause the ATV to wear more quickly.

  • Page 78: Tools

    TOOLS BATTERY The battery is located under the seat. This battery is a sealed type battery and requires no mainte- nance. Have your dealer check the battery’s state of charge peri- odically. If the battery is discharged, recharge the battery. The stan- dard charging rate is 1.8A ×...
  • Page 79 2. Remove the bolts 1 and Keep flames and sparks away bracket 2. from the battery. Never smoke when working near the battery. NOTE: Apply a drop of SUZUKI THREAD LOCK “1342” to the bat- tery bracket bolts 1. CAUTION Exceeding...
  • Page 80 Used battery must be disposed ing or recycling of the used bat- or recycled according to the tery, consult your Suzuki dealer. local law and must not be dis- carded with ordinary house- hold waste. Make sure not to tip over the battery when you remove it from the vehicle.

  • Page 81: Spark Plug

    A white or dark insulator indicates that the engine may need adjust- ment, or another plug type may be needed. Consult your Suzuki dealer if your plug insulator is not 2. Remove fasteners. a light brown color.
  • Page 82 Use one of the spark plugs the cylinder head. listed below or equivalent. Consult your Suzuki dealer if Carefully turn the spark plug by you are not sure which spark hand into the threads. If the...
  • Page 83 CAUTION Dirt can damage your ATV if it enters an open spark plug hole. Dirt can damage engine parts 0.7 – 0.8 mm that move. (0.028 – 0.031 in) To maintain a hot, strong spark, Cover the spark plug hole keep the plug free from carbon.

  • Page 84: Throttle Cable Adjustment

    THROTTLE CABLE WARNING ADJUSTMENT Operating the vehicle with an inadequate throttle cable play can be hazardous. Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the 3.0 – 5.0 mm handlebars. This can lead to (0.12 –...

  • Page 85: Fuel Hose

    FUEL HOSE ENGINE OIL 1. Remove the seat by referring Long engine life depends much to the SEAT LOCK section. on the selection of a quality oil and the periodic changing of the oil. Daily oil level checks and peri- odic changes are two of the most important maintenance items to be performed.

  • Page 86: Engine Oil And Filter Change

    The oil level inspection should be ENGINE OIL AND FILTER performed under the following CHANGE conditions: Change the engine oil and oil filter • Park the vehicle on level at the scheduled times. The ground. engine should always be warm •...
  • Page 87 WARNING New and used oil can be haz- ardous. Children and pets may be harmed by swallowing new or used oil. Repeated, prolonged contact with used engine oil 3. Remove the oil filler cap 1. may cause skin cancer. Brief contact with used oil may irri- tate skin.
  • Page 88 6. Turn the oil filter 3 counter- clockwise with a Suzuki “cap Be sure to use a genuine type” oil filter wrench or a SUZUKI oil filter or an equiva- “strap type” filter wrench of the lent one designed for your ATV. proper size.
  • Page 89 ATV. the mounting surface. Engine damage may occur if you use oil that does not meet Suzuki’s specifications. Be sure to use the oil specified in the FUEL, OIL AND ENGINE COOLANT RECOMMENDA- Tighten the filter 2 turns or to specified torque.

  • Page 90: Air Cleaner

    AIR CLEANER CAUTION The air cleaner element must be kept clean to provide good engine Failure to inspect the air power and gas mileage. If you use cleaner element frequently if your vehicle under normal, low- the vehicle is used in dusty, stress conditions, you should ser- wet, or muddy conditions can vice the air cleaner at the intervals...
  • Page 91 Removing the Element 1. Remove the seat. 5. Carefully use an air hose to blow the dust from the air cleaner element. 2. Remove the fasteners and cover 1. NOTE: Always apply air pressure to the inside of the air cleaner ele- ment only.

  • Page 92: Air Cleaner Drain Tube

    6. Reinstall the cleaned element AIR CLEANER DRAIN TUBE or new air cleaner element in Remove the right side frame reverse order of removal. Be cover by referring to the SPARK absolutely sure that the ele- PLUG section. ment is securely in position and is sealing properly.

  • Page 93: Engine Coolant

    ENGINE COOLANT Engine Coolant Level engine coolant solution should be between “F” (full) and “L” (low) level lines on the engine coolant reservoir. If the level is lower than “L” (low) level line, bring it up to “F” (full) level by add- ing 50:50 mixture of distilled water and engine coolant.

  • Page 94: Gear Oil Change

    GEAR OIL CHANGE Inspect and change the gear oil according to the MAINTENANCE SCHEDULE. When changing the gear oil, use specified gear oil described in FUEL, OIL AND ENGINE COOLANT RECOM- MENDATIONS section. The pro- cedure for changing the front and rear differential gear oil is as fol- Front differential gear oil lows:...

  • Page 95: Tires

    6. Tighten oil filler caps securely. TIRES 7. Reinstall the covers under the This vehicle is equipped with low case. pressure tubeless tires of the size and type listed below: Front differential gear oil: 500 ml (16.9 US oz) Front Rear ...
  • Page 96 Tire Tread Condition Tire Pressure A low pressure gauge is provided in the tool kit, so you can measure the air pressure in your vehicle’s tires. Check the air pressure in all tires before each use of the vehi- 4.0 mm cle.
  • Page 97 Have this work done by your Suzuki dealer or a qualified tire repair station. When breaking the tire bead loose from...

  • Page 98: Front Brake

    FRONT BRAKE Brake Fluid WARNING Failure to properly inspect and maintain your ATV’s brake sys- tems can be hazardous. Improper maintenance of the brakes increases your chances of having an accident. Be sure to check the brake fluid Be sure to inspect the brakes level in the front brake fluid reser- before each use of the vehicle voir and inspect for brake pad...
  • Page 99 The brakes may not work cor- rectly without proper amount of brake fluid. This could lead to an accident. Inspect the brake fluid level before each use. If there is fre- quent loss of fluid, take your vehicle to a SUZUKI dealer for inspection. 5-27...
  • Page 100 Riding with unevenly worn brake pads will increase your chances of having an accident. If you need to replace brake pads, have your Suzuki dealer do this work. Inspect and main- tain the brake pads as recom- Grooved wear mended.

  • Page 101: Rear Brake

    REAR BRAKE WARNING Adjust the rear brake by adjusting the brake pedal first and then Replacing only one of the two adjust the brake lever. brake pads can be hazardous. WARNING Replacing only one brake pad can result in uneven braking Misadjusting the rear brake action.
  • Page 102 Brake Pedal The rear brake pedal should be adjusted to the range between 12 – 22 mm (0.5 – 0.9 in) above the extended line of the top surface of the footrest and should have 20 – 30 mm (0.8 – 1.2 in) of free travel. The pedal can be adjusted by adjusting the pedal height first and then adjusting the amount of...
  • Page 103 12 – 22 mm 20 – 30 mm (0.5 – 0.9 in) (0.8 – 1.2 in) 2. Loosen the lock nut 1. 5. Turn the adjuster 3 clockwise 3. Turn the adjuster 2 clockwise or counterclockwise so that or counterclockwise so that the there is 20 –...
  • Page 104 Brake lever (Parking Brake) The rear brake lever play as mea- sured at the lever holder should be 6 – 8 mm (0.2 – 0.3 in) when the lever is lightly pulled in toward the grip. This adjustment is nec- essary for proper operation of the rear brake lever and the parking brake.

  • Page 105: Rear Brake Lining Wear Limit

    (Fig.A). 3. If the extension line is out of the limit (Fig.B), have the brake plates replaced by your Suzuki dealer to insure safe operation. 5-33...

  • Page 106: Front And Rear Wheel Removal

    FRONT AND REAR WHEEL WARNING REMOVAL Failure to check brake lining wear and replace brake shoes as recommended can be haz- ardous. Riding with worn brake shoes brake shoes that unevenly worn will increase your chances of having an accident. 1.

  • Page 107: Spark Arrester

    Be sure to tighten the wheel nuts to the specified torque. If you do not have a torque wrench or do not know how to use one, ask your authorized Suzuki dealer to check the nuts. 5-35...

  • Page 108: Drive Shaft Boots

    Ask arrester screen. Be careful not your Suzuki dealer if replacement to damage the spark arrester is necessary. screen. Check that the screen has no holes or tears. Replace the screen if necessary.

  • Page 109: Light Bulb Replacement

    LIGHT BULB REPLACEMENT HEADLIGHT To replace the headlight bulb, use The wattage rating of each bulb is the following procedure: shown in the following chart. When replacing a burned-out bulb, always use the same watt- age rating. Headlight 12V 35/35W × 2 (HS1) Brake/Taillight 12V 21/5W CAUTION...
  • Page 110 BRAKE/TAILLIGHT Replace the brake/taillight bulb as follow: 4. Unhook the bulb holder spring 4 and pull out the bulb 5. 5. To replace the headlight bulb, reverse the above sequence. 1. Remove fasteners. Remove the rear cover. CAUTION Touching the headlight bulb glass with a bare hand may damage the bulb.

  • Page 111: Fuses

    FUSES The fuses are located under the seat. One 40A spare fuse is pro- The main fuse is located under vided inside the fuse box. the seat. One 30A spare fuse is located inside the fuse box cover. The fuses are designed to open when a circuit overload exists in individual electrical system cir- cuits.
  • Page 112 If the new fuse speedometer light and brake blows in a short time, consult light. your Suzuki dealer immedi- • 15A FAN fuse protects the ately. cooling fan. •...

  • Page 113: Output Terminal

    OUTPUT TERMINAL CAUTION Using improper electrical accessories can damage your ATV. Exceeding 120W or using other than 12V accessory can seri- ously damage the electrical system and accessory. This vehicle has an output termi- nal for attaching 12V electrical Check voltage and wattage accessories.

  • Page 114: General Lubrication

    Be sure that all lubrication is performed during periodic maintenance on the vehi- cle. Increase intervals when you use your ATV in severe condi- tions. Your authorized Suzuki dealer should do general lubrica- tion as shown in the MAINTE- NANCE SCHEDULE. CAUTION Lubricating switches can dam- age your ATV.

  • Page 115: Trailer Towing

    We strongly advise you to use a genuine Suzuki trailer or an equivalent ATV trailer. 5-43...
  • Page 116 WARNING WARNING Overloading your trailer can be Riding your ATV without extra hazardous. caution when towing a trailer can be hazardous. An overloaded trailer can affect the handling of the ATV. Trailer towing can affect the handling and braking of your Never overload your trailer.

  • Page 117: Troubleshooting

    TROUBLESHOOTING FUEL SUPPLY CHECK ..................6-2 IGNITION SYSTEM CHECK ................6-3...
  • Page 118 Suzuki dealer. Refer to the “INSTRUMENT PANEL” section CAUTION for an explanation of fuel injection Failure to troubleshoot a prob- system indicator.
  • Page 119 2. Check to see that the spark spark plug gap. If there is no plug is not fouled. Remove the spark, take your machine to plug and clean it. Replace it, if your authorized Suzuki dealer. necessary.

  • Page 121: Preparation For Winter Riding

    PREPARATION FOR WINTER RIDING ENGINE OIL CHANGE ..................7-2 SPARK PLUG CHANGE ..................7-2 BATTERY CHECK ....................7-2...
  • Page 122 Recharge the battery before start- ing the engine or replace with bat- ENGINE OIL CHANGE tery with a new one. Ask Suzuki Use of improper viscosity engine dealer or a qualified mechanic to oil can result in hard engine start- inspect battery condition before ing at the cold temperature.

  • Page 123: Transporting

    TRANSPORTING TRANSPORTING ....................8-2...
  • Page 124 TRANSPORTING CAUTION TRANSPORTING Failure to properly secure the It is best to transport the vehicle in ATV when transporting it can the normal position. It may also be hazardous. be transported on its back wheels, but this is not as stable as the nor- Failure to properly secure the mal position.

  • Page 125: Cleaning Procedure And Storage Procedure

    CLEANING PROCEDURE AND STORAGE PROCEDURE PREPARATION FOR CLEANING ............... 9-2 WASHING YOUR ATV ..................9-3 INSPECTION AFTER CLEANING ............... 9-4 STORAGE PROCEDURE ..................9-4 MAINTENANCE DURING STORAGE ..............9-5 PROCEDURE FOR RETURNING TO SERVICE ..........9-5...

  • Page 126: Preparation For Cleaning

    PREPARATION FOR CLEANING CLEANING PROCEDURE Wash the ATV before any mud AND STORAGE dries on the ATV. PROCEDURE Block or seal the end of the A thorough cleaning of your ATV exhaust pipe (muffler) using a is a necessary part of mainte- piece of plastic wrap, cloth rag or nance and will help keep your another method to prevent water...

  • Page 127: Washing Your Atv

    WASHING YOUR ATV CAUTION With some care, your ATV can be washed in a similar manner to Improper cleaning can damage washing an automobile. the radiator. NOTE: Avoid spraying or allowing Radiator fins can be damaged water to flow over the following by spraying high pressure places: water on them.

  • Page 128: Inspection After Cleaning

    For skill. For this reason, Suzuki rec- extended life of your ATV, lubri- ommends that you trust this main- cate it according to the “GEN- tenance work to your dealer.

  • Page 129: Maintenance During Storage

    ENGINE PROCEDURE FOR RETURNING Remove the spark plug and pour TO SERVICE one tablespoon of motor oil into • Clean the entire vehicle. the spark plug hole. Reinstall the • Drain all the engine oil. Install spark plug and crank the engine a a new oil filter and fill the few times to spread the oil in the engine with fresh oil as out-...

  • Page 131: Consumer Information

    CONSUMER INFORMATION WARRANTIES ....................10-2 ON-BOARD VEHICLE COMPUTER DATA INFORMATION ......10-2 SERIAL NUMBER LOCATION ................10-3 LOCATION OF LABELS ................... 10-4 10-1...

  • Page 132: Warranties

    In addition, once SUZUKI collects or receives data, SUZUKI may use the data research conducted SUZUKI, make the data available for outside research if need is...

  • Page 133: Serial Number Location

    Others, such as law enforcement SERIAL NUMBER LOCATION personnel, may have access to You need to know the frame and the special equipment that can engine serial numbers to get title read the information if they have documents for your ATV. You also access to the vehicle or storage need these numbers to help your device.

  • Page 134: Location Of Labels

    Suzuki dealer. WARNING Ke e p h a n d s, h a i r, c l o t h i n g , e t c . , away f r o m fa n .
  • Page 135 WARNING WARNING Improper tire pressure or overloading can cause loss of control. UNDER UNDER Loss of control can result in severe injury or death. ALWAYS maintain proper tire pressure Operating this ATV if you are under the as shown below. age of 16 increases your chance of severe •...
  • Page 136 If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance. CAUTION Accessory must not exceed 120W rating and must be 12V type.

  • Page 138: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2115 mm (83.3 in) Overall width............1210 mm (47.6 in) Overall height ..........1215 mm (47.8 in) Wheelbase ............1285 mm (50.6 in) Ground clearance..........280 mm (11.0 in) Front track ............940 mm (37.0 in) Rear track ............
  • Page 139 CHASSIS Front suspension ..........Independent, double wishbone, coil spring, oil damped Rear suspension ..........Independent, double wishbone, coil spring, oil damped Front wheel travel ..........170 mm (6.7 in) Rear wheel travel..........195 mm (7.7 in) Caster..............3.7° Trail..............18.4 mm (0.72 in) Toe-out ............5 mm (0.19 in) Camber............–1.3°...
  • Page 140 INDEX AIR CLEANER ..... 5-18 FINAL GEAR OIL ....1-6 AIR CLEANER DRAIN FLAG BRACKET ....2-25 TUBE........5-20 FRONT AND REAR ATV WINCH LEAD SUSPENSION WIRES........4-4 ADJUSTMENT .....2-24 FRONT AND REAR WHEEL REMOVAL ......5-34 BATTERY....... 5-6 FRONT BRAKE ....5-26 BATTERY CHECK ....7-2 FRONT DIFFERENTIAL BOX........
  • Page 141 IGNITION SWITCH ....2-6 NOTICE ........5-4 IGNITION SYSTEM CHECK........6-3 INSPECTION AFTER ON-BOARD VEHICLE CLEANING ......9-4 COMPUTER DATA INSPECTION BEFORE INFORMATION ....10-2 RIDING........3-4 OPERATION ON HILLS ..3-16 INSTRUMENT PANEL ... 2-7 OUTPUT TERMINAL....5-41 KEY ........2-5 PREPARATION FOR CLEANING ......9-2 PROCEDURE FOR RETURNING LEFT HANDLEBAR....
  • Page 142 SEAT LOCK ......2-22 WARRANTIES......10-2 SELECTION SWITCH..2-14 WASHING YOUR ATV ...9-3 SERIAL NUMBER WHAT TO WEAR ....3-6 LOCATION ......10-3 WHAT YOU SHOULD KNOW SHIFT LEVER ...... 2-12 BEFORE RIDING ....3-2 SKIDDING OR SLIDING ..3-16 SPARK ARRESTER..... 5-35 SPARK PLUG ......
  • Page 143 WARNING Indicates a potential hazard that could result in injury or death.
  • Page 147 This ATV is for RECREATIONAL or UTILITY USE, NO OPERATOR UNDER AGE OPERATOR ONLY-NO PASSENGERS This category G (GENERAL USE) ATV is for off road use only, for recreation and utility purposes. Training courses to teach ATV riding are available. For information contact your dealer.
  • Page 148 WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate : • without proper training or instruction •...

Table of Contents