Table of Contents
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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 spe-
cial 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) cat-
egories 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.
K6
99505-01046-01E
December '05 Printed in Japan (TK) 19
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Table of Contents
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Summary of Contents for Suzuki LT-R450K6
- Page 1 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.
- Page 2 PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed vehicle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates.
- Page 3 FRONT REAR Remove the bolts and brackets. NOTE: The brackets, bolts and vinyl tube are no longer needed and these may be discarded. A: Bolt B: Bracket C: Vinyl tube Loosen the front brake master cylinder mounting bolts. Remove the master cylinder from the bracket. Keep the position of front brake master cylin- der with its cap facing upwards until it is installed.
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Page 4: Location Of Parts
LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Headlight cover Fuel label For limited market Tapping screw 5 × 16 mm Safety DVD For E-19 market Steering head cover... - Page 5 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: Indicator light D: Front brake switch lead wire...
- Page 6 Before assembling the vehicle, thoroughly under- stand the “Safety Check Out” described on page 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 NOTE: Align the dot mark on the handlebars with the...
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Page 7: Front Brake Master Cylinder
Tighten the handlebar clamp bolts to the specified torque. Handlebar clamp bolt: 26 N·m (2.6 kgf-m) NOTE: To install the handlebars correctly, first tighten the bolt A of the front side with specified torque and then tighten the bolt B of the rear FORWARD side. - Page 8 Connect the front brake light switch lead wires coupler to the brake light switch. A: Front brake light switch B: Lead wire coupler CLUTCH LEVER HOLDER Loosen the bolts. Move the lever holder at the correct position. Align the dot mark on the handlebars with the clutch lever holder fitting surface.
- Page 9 STEERING HEAD COVER Remove the indicator light lens from the socket boot. A: Indicator light lens B: Socket boot Install the socket boot to the steering head cover. A: Steering head cover B: Socket boot C: Yellow with black tracer lead D: Blue with black tracer lead E: Red with black tracer lead Confirm that the socket boots are all installed in the...
- Page 10 Align the recess of steering head cover on the handle- bars. Push down the steering head cover firmly. A: Recess B: Steering head cover CLAMP Clamp the wiring harness of handlebar left switch, clutch lever position switch and choke cable with straps.
- Page 11 HEADLIGHT COVER Remove the rubber boot. Disconnect the headlight coupler. A: Rubber boot B: Headlight coupler Remove the headlight assembly. A: Headlight assembly B: Flange stepped bolt C: Boss Install the headlight cover to the headlight assembly. A: Headlight cover B: Headlight assembly C: 5 ×...
- Page 12 RIGHT LEFT Attach a hoist band onto the vehicle. Put a suitable pad between the vehicle body and hoist band to prevent the body from being damaged. Pass the hoist band through inside the brake pedal. A: Hoist band B: Pad C: Frame D: Brake pedal 1 Lift the vehicle with a hoist, then balance the vehi-...
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Page 13: Warning Label
Reinstall the seat. Insert the boss into the guide. Push the seat down firmly. A: Seat assembly B: Guide C: Boss WARNING LABEL (FOR E-19 MARKET) Select the appropriate language label for your country. NOTE: For E-19 CG selection: German, Spanish, Portuguese For E-19 CH selection: French, Dutch For E-19 CI selection: Swedish, Finnish, Danish Stick the label selected for your country. - Page 14 SERVICING BATTERY Remove the screw to take off battery cover. Remove the battery from the vehicle. A: Battery cover B: Screw C: Hook 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.
- Page 15 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...
- Page 16 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.
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Page 17: Brake Fluid
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. 5. - Page 18 BRAKE AIR BLEEDING Any air which may have been trapped in the brake fluid circuit must be bled completely. If the brake lever or brake pedal feels spongy or weak, then most likely there is air in the hydraulic circuit. To bleed the air from the front brake, use the following procedure.
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Page 19: Throttle Cable
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 procedure below: 1. Loosen the throttle cable adjuster lock nut A. 2. Turn the adjuster B in or out until the correct play. 3. -
Page 20: Brake Pedal
BRAKE PEDAL Check the rear brake pedal height. Brake pedal height: 0–10 mm If the rear brake pedal height is not correct, adjust in the following manner: 1. Loosen the lock nut A. 2. Rotate the push rod B to locate the pedal to the correct height below the top face of the footrest C. -
Page 21: Drive Chain
DRIVE CHAIN Check the drive chain slack. Drive chain slack: 45–55 mm If it is too tight or too loose, follow these procedures. 1. Loosen the rear axle housing nuts A. 2. Adjust the slack in the drive chain by turning adjuster C. -
Page 22: Front Suspension
FRONT SUSPENSION Rebound Damping Force Adjustment Adjust the setting of the rebound damping force to the standard position. To adjust, turn the adjuster A clockwise until it stops and then turn it counterclockwise until approximately 1-1/2 turns are felt and the two punch marks align. Do not force the adjuster screw A past the stopped position or you may damage the adjuster. -
Page 23: Rear Suspension
REAR SUSPENSION Low Speed Compression Damping Force Adjustment Adjust the setting of the low speed compression damp- ing force to the standard position. To adjust, turn the adjuster A clockwise until it stops and then turn it counterclockwise until 8 clicks are felt. Do not force the adjuster screw A past the stopped position or you may damage the adjuster. -
Page 24: Engine Coolant
ENGINE COOLANT The 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 level ground. A: Engine coolant reservoir B: “FULL” level line C: “LOW”... -
Page 25: Headlight Beam Adjustment
HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted vertically if nec- essary. To adjust the beam vertically: Loosen the headlight fitting bolts and move the head- light up or down as required. Tighten the bolts. A: Bolt ENGINE OIL This vehicle is shipped from factory with the engine filled with engine oil. - Page 26 API: American Petroleum Institute JASO: Japanese Automobile Standards Organization ENGINE OIL VISCOSITY RATING SELECTION CHART SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine 20W - 50 oil. If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the following chart.
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Page 27: Idle Speed Adjustment
Energy Conserving Suzuki does not recommend the use of “ENERGY CONSERVING” oils. Some engine oils which is API SH or greater has “ENERGY CONSERVING” indication in API classifica- tion doughnut mark. 10W-40 10W-40 These oils can affect engine life and clutch perfor- mance. -
Page 28: Tightening Torque
TIGHTENING TORQUE Item Part Name N·m kgf-m Item Part Name N·m kgf-m STEERING, FRONT SUSPENSION AND FRONT BRAKE Rear brake caliper mounting bolt Handlebar clamp bolt Rear brake push rod lock nut Handlebar holder nut Brake caliper air bleeder 0.60 Front hub nut REAR SUSPENSION Front wheel set nut... -
Page 29: Cable Routing
CABLE ROUTING Clutch cable Pass the throttle and clutch cables through downside of the high-tension cord. Guide Throttle cable Parking brake cable Pass the choke cable between the frame and wiring harness. Parking brake cable Pass the choke cable through upside of the wiring harness. Starter cable Parking brake cable Clutch cable... - Page 30 Clamp Parking brake cable Wiring harness Frame Choke cable Choke cable Wiring harness Breather hose Fuel hose Parking brake cable Guide Parking brake cable Wiring harness Pass the throttle and clutch cables through upside of the breather hose. Pass the clutch cable through forward of the throttle body and inside of the ignition coil.
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Page 31: Harness Routing
HARNESS ROUTING Front brake switch lead wire Handlebar switch wiring harness (L) Clamp Clutch lever position switch lead wire Clamp Clamp Handlebar switch wiring harness (L) Meter panel indicator light lead wire Clamp Wiring harness Clamp Generator lead wire Wiring harness Gear position switch lead wire Clamp Clamp... - Page 32 Set the ignition coil coupler to the downside of the hose. Wiring harness Clamp Wiring harness Clamp Clamp Clamp Clamp Clamp Clamp Rear brake switch lead wire Wiring harness Clamp Rear brake switch lead wire Clamp Rear brake switch lead wire Rear brake switch lead wire...
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Page 33: Safety Check-Out
SAFETY CHECK OUT COLD INFLATION TIRE PRESSURE TIRE PRESSURE After completion of the setting-up the vehicle LOAD FRONT REAR all the following items should be double- 45 kPa 45 kPa Up to 110 kg checked to confirm that the operation and func- 0.45 kgf/cm 0.45 kgf/cm (243 lbs)