Suzuki LT-A50 Service Manual
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Suzuki LT-A50 Service Manual

Suzuki LT-A50 Service Manual

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LT-A50
9 9 5 0 0 - 2 0 2 1 2 - 0 1 E

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Summary of Contents for Suzuki LT-A50

  • Page 1 LT-A50 9 9 5 0 0 - 2 0 2 1 2 - 0 1 E...

  • Page 2: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI LT-A50 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa-...
  • Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
  • Page 4 Apply oil. Use engine oil unless Measure in voltage range. otherwise specified. Apply molybdenum oil solution. Measure in current range. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in diode test range. 99000-25030 Apply SUZUKI MOLY PASTE.
  • Page 5 Apply THREAD LOCK SUPER otherwise specified. “1360”. 99000-32130 Apply molybdenum oil solution. Measure in voltage range. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in current range. 99000-25010 Apply SUZUKI MOLY PASTE.

  • Page 6: Table Of Contents

    GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ............. 1- 2 GENERAL PRECAUTIONS .............. 1- 2 SUZUKI LT-A50K2 (2002-MODEL) ........... 1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL AND OIL RECOMMENDATIONS ........... 1- 4 FUEL....................1- 5 ENGINE OIL .................. 1- 5 TRANSMISSION OIL ..............

  • Page 7: Warning/Caution/Note

    1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 8 GENERAL INFORMATION 1-3 " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order.

  • Page 9: Suzuki Lt-A50K2 (2002-Model)

    ) method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10 % ethanol.

  • Page 10: Fuel

    Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. ENGINE OIL (For USA) Use SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT or an equivalent good quality synthetic based 2-stroke engine oil rated FC under the JASO classification.

  • Page 11: Information Labels

    1-6 GENERAL INFORMATION INFORMATION LABELS APPLIED SPECIFICATION LABEL or PLATE NAME Certification plate Compliance label Manual notice label Parking brake label E Parking brake label F Tire pressure label E Tire pressure label F General warning label E General warning label F No-passenger label Age.

  • Page 12: Specifications

    GENERAL INFORMATION 1-7 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............1 260 mm (49.6 in) Overall width ..............760 mm (29.9 in) Overall height ..............745 mm (29.3 in) Wheelbase ............... 825 mm (32.5 in) Ground clearance ............120 mm (4.7 in) Seat height ...............

  • Page 13: Country Or Area Codes

    1-8 GENERAL INFORMATION COUNTRY OR AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA P-02 P-03 P-28 Canada...

  • Page 14: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ......... 2- 2 PERIODIC MAINTENANCE CHART ..........2- 2 LUBRICATION POINTS ..............2- 3 MAINTENANCE AND TUNE-UP PROCEDURE ....... 2- 4 AIR CLEANER ................2- 4 CYLINDER HEAD AND CYLINDER ..........2- 5 SPARK PLUG ................

  • Page 15: Periodic Maintenance Schedule

    2-2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on vehicle that are used under severe conditions.

  • Page 16: Lubrication Points

    PERIODIC MAINTENANCE 2-3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. Trottle cable Trottle lever Brake cable Steering shaft holder Drive chain NOTE: * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

  • Page 17: Maintenance And Tune-Up Procedure

    2-4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance chart. AIR CLEANER Clean every 3 months. If the air cleaner is clogged with dust, intake resistance will be increase, resulting in a decrease in engine output and an increase in fuel consumption.

  • Page 18: Cylinder Head And Cylinder

    PERIODIC MAINTENANCE 2-5 • Reinstall the cleaned air cleaner element in the reverse order of removal. * Be sure to position the element snugly and correctly, so that no incoming air will by-pass it. Remember, the rapid wear of piston rings and the cylinder bore is of- ten caused by a defective or poorly fitted element.

  • Page 19: Spark Plug

    2-6 PERIODIC MAINTENANCE SPARK PLUG Clean every 3 months. Replace every 6 months. Neglecting the spark plug maintenance will eventually leads to difficult starting and poor engine performance. If the spark plug is used for a long period, the electrode gradually burns away and carbon builds up along the inside part of the spark plug.

  • Page 20: Throttle Cable Play

    PERIODIC MAINTENANCE 2-7 THROTTLE CABLE PLAY Inspect initially at 1 month and every 3 months thereaf- ter. Throttle cable play A should be 3 – 5 mm (0.12 – 0.20 in) as measured at throttle when turning the throttle lightly. If the play A is incorrect, adjust it as follows: •...

  • Page 21: Transmission Oil

    * Rusted links * Kinked or binding links If any defects are found, the drive chain must be replaced. The standard drive chain is DID420. SUZUKI recommends to use this standard drive chain as a replacement. CHECKING • Loosen the bolts 1.
  • Page 22 PERIODIC MAINTENANCE 2-9 • Count out 21 pins (20-pitch) on the chain measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. $ Drive chain 20-pitch length: 259.0 mm (10.20 in) NOTE: When replacing the drive chain, replace the drive chain and sprock- ets as a set.

  • Page 23: Brakes

    2-10 PERIODIC MAINTENANCE BRAKES Inspect initially at 1 month and every 3 months thereaf- ter. FRONT BRAKE LEVER PLAY • Turn the adjusting nuts 1 so that the brake lever play A is within specification. $ Front brake lever play A: 3 – 7 mm (0.12 – 0.28 in) REAR BRAKE LEVER PLAY •...

  • Page 24: Tires

    PERIODIC MAINTENANCE 2-11 RECOIL STARTER ADJUSTMENT NOTE: Check the rear brake cable play. • Loosen the adjuster lock nut 4 and turn the recoil adjuster 3 clockwise as far as it will go. • Set the parking brake 2 and make sure that the rear wheels and locked.

  • Page 25: Suspension

    2-12 PERIODIC MAINTENANCE TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification. $ Tire depth limit Front and Rear: 4.0 mm (0.16 in) # 09900-20805: Tire depth gauge...

  • Page 26: Exhaust Pipe Bolt And Muffler Bolt

    PERIODIC MAINTENANCE 2-13 EXHAUST PIPE BOLT AND MUFFLER BOLT Tighten initial 1 month and every 3 months thereafter. • Remove the frame cover. ("5-2) • Tighten the exhaust pipe bolts 1 and muffler mounting bolt 2 to the specified torque. &...

  • Page 27: Chassis Bolts And Nuts

    2-14 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 month and every 3 months thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-15 for the locations of the following bolts and nuts on the motorcycle.) N .
  • Page 28 PERIODIC MAINTENANCE 2-15...

  • Page 29: Initial Engagement And Clutch Lock-Up Inspection

    2-16 PERIODIC MAINTENANCE INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION The LT-A50 is equipped with a centrifugal type automatic clutch. To insure proper performance and longevity of the clutch assem- blies it is essential that the clutches engage smoothly and gradu- ally.

  • Page 30: Clutch Lock-Up Inspection

    PERIODIC MAINTENANCE 2-17 CLUTCH LOCK-UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping. • Connect a tachometer onto the spark plug lead. • Start the engine. • Apply the front and rear brakes as firmly as possible. •...
  • Page 31 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE ....................3- 2 ENGINE REMOVAL AND REMOUNTING ..........3- 3 ENGINE REMOVAL ................3- 3 ENGINE REMOUNTING ..............3- 6 POWER REDUCTION PLATE ............3- 8 ENGINE DISASSEMBLY ..............3- 9 ENGINE COMPONENTS INSPECTION AND SERVICE ......3-13 CYLINDER HEAD ................3-13 CYLINDER ..................3-13 PISTON .....................3-14...

  • Page 32: Engine Components Removable With The Engine In Place

    ENGINE ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the pages listed in each section for removal and reinstallation instructions. ENGINE LEFT SIDE Engine sprocket ......

  • Page 33: Engine Removal And Remounting

    ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. • Drain the transmission oil. (!2-8) • Remove the seat. (!5-2) •...
  • Page 34 ENGINE • Remove the clamp. • Remove the recoil starter bolt. • Loosen the screw. • Remove the carburetor assembly. • Remove the oil tank 1. • Disconnect the generator lead wire and remove the spark plug cap 2.
  • Page 35 ENGINE • Remove the engine sprcket cover 1. • Remove the drive chain 2. • Remove the engine mounting bolts.

  • Page 36: Engine Remounting

    ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of engine removal. N . m kgf . m ITEM lb-ft A Engine mounting nut 22.5 B Engine mounting nut 29.5 C Engine mounting nut 22.5 • Apply a small quantity of THREAD LOCK “1342” to the threasds of engine mounting nut B and C.
  • Page 37 ENGINE • Install the drive chain. The drive chain joint clip should attached in the way that the slit end will face opposite the direction of travel. Direction of travel • Pour the specified amount of transmission oil in to the crank- case.

  • Page 38: Power Reduction Plate

    N . m kgf . m ITEM lb-ft A Exhoust pipe bolts & Do not remove the power reduction plate until the rider develops sufficient skills to operate LT-A50 safety at the maximum speed with the power reduction system in place.

  • Page 39: Engine Disassembly

    ENGINE ENGINE DISASSEMBLY • Remove the rear brake cable guide 1. • Remove the cylinder head and cylinder. • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase. • Remove the piston pin circlip 2. •...
  • Page 40 3-10 ENGINE • Remove the clutch cover. • Hold the generator rotor using the special tool. • Remove the clutch sleeve nut. ' 09930-40113: Rotor holder • Remove the thrust washer 1, wave washer 2 and clutch guide plate 3. •...
  • Page 41 ENGINE 3-11 • Remove the oil guide bearing retainer plate. • Remove the spacer 1 and washer 2. • Hold the generator rotor using the special tool. • Remove the generator rotor nut. ' 09930-40113: Rotor holder • Remove the generator rotor using the special tools. ' 09930-30104: Sliding shaft 09930-30161: Attachment “C”...
  • Page 42 3-12 ENGINE • Separate the crankcase using the special tool. ' 09920-13120: Crankcase separator • Remove the countershaft and driveshaft. • Remove the crankshaft using the special tool. ' 09920-13120: Crankcase separator...

  • Page 43: Engine Components Inspection And Service

    ENGINE 3-13 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD Remove carbon from the combustion chamber and clean the cyl- inder head. Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places.

  • Page 44: Piston

    3-14 ENGINE PISTON PISTON DIAMETER Measure the piston diameter with a micrometer at 23 mm (0.9 in) from the skirt end. If the piston diameter is less than the service limit, replace the piston. ' 09900-20202: Micrometer (25 – 50 mm) 23 mm (0.9 in) % Piston diameter...
  • Page 45 ENGINE 3-15 PISTON PIN AND PIN BORE Measure the piston pin bore inside diameter using the caliper gauge and measure the piston pin outside diameter using the micrometer. If either is out of specification or the different between these two measurements is more than the limits, replace both the piston and piston pin.

  • Page 46: Crankshaft

    3-16 ENGINE CRANKSHAFT 1 Bearing (R) 2 Oil seal (R) 3 Crank web (R) 4 Crank web (L) 5 Bearing (L) 6 Oil seal (L) 7 Conrod 8 Conrod bearing 9 Crankpin bearing 0 Crankpin CRANKSHAFT RUNOUT Support the crankshaft using the V-blocks as shown. Position the dial gauge, as shown, and rotate the crankshaft slowly to read the runout.

  • Page 47: Clutch

    ENGINE 3-17 CONROD SMALL END I.D. Measure the conrod small end inside diameter using the dial cali- pers. If the conrod small end inside diameter exceeds the service limit, replace the conrod. % Conrod small end I.D. Service Limit: 16.040 mm (0.6315 in) ' 09900-20605: Dial calipers •...

  • Page 48: Oil Seals And Bearings

    3-18 ENGINE OIL SEALS AND BEARINGS INSPECTION Damage to the lip of the oil seal may result in leakage of the fuel- air mixture or transmission oil. Inspect the oil seal and if it is dam- aged, replace it with a new one. Wash the bearing with a cleaning solvent and lubricate it with Play motor oil before inspection.
  • Page 49 3-19 REASSEMBLY • Apply grease to the lip of the oil seals. For U.S.A. ( 99000-25030: SUZUKI SUPER GREASE “A” For the others ( 99000-25010: SUZUKI SUPER GREASE “A” • Install the oil seals using the special tool. ' 09913-70210: Bearing installer set •...

  • Page 50: Engine Reassembly

    • Install the countershaft and driveshaft. • Install the dowel pins 1. • Before assembling the crankcase, apply the engine oil to each gear and bearing. • Apply sealant to the crankcase. * 09900-31140: SUZUKI BOND “1207B” • Tighten the crankcase screws diagonally.

  • Page 51: Generator Rotor

    ENGINE 3-21 • After the crankcase screws have been tightened, make sure that the crankshaft, countershaft and driveshaft rotate smoothly. • If their shafts do not rotate smoothly, try to free it by tapping with plastic hammer. GENERATOR ROTOR • Install the generator stator 1. NOTE: Apply a small quantity of THREAD LOCK “1342”...

  • Page 52: Clutch

    3-22 ENGINE CLUTCH 1 Oil seal 2 Thrust washer 3 Wave washer 4 Wave washer 5 Wave washer guide plate 6 Clutch shoe 7 Trust washer 8 Key 9 Clutch drum/primary drive gear 0 Spacer A Thrust washer A Clutch shoe nut N .
  • Page 53 ENGINE 3-23 • Install the clutch drum 1, washer 2 and key 3. • Install the key into the key groove and mount the clutch shoe on the key. • Install the wave washer. • Install the guide plate, wave washer and thrust washer. •...

  • Page 54: Piston Ring And Piston

    • Before installing the piston pin, apply SUZUKI CCI SUPER oil onto its surface. • Apply SUZUKI CCI SUPER oil to the big and small ends of the conrod. • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.

  • Page 55: Cylinder

    ENGINE 3-25 CYLINDER • Install the new cylinder base gasket 1. • Apply SUZUKI CCI SUPER oil onto the piston and cylinder wall surfaces and then carefully install the cylinder 2 over the piston. CYLINDER HEAD • Install the new cylinder head gasket 1.
  • Page 56 • Hitch the one end 6 of the spring to the reel as shown in the figure and install the spring in the reel. • Apply SUZUKI SUPER GREASE “A” to the spiral spring. For USA ( 99000-25030: SUZUKI SUPER GREASE “A”...
  • Page 57 • Install the reel in the cover. • Install the return spring to the cover so that the rachet is pushed inward. • Apply SUZUKI SUPER GREASE “A” to the return spring 2. For USA ( 99000-25030: SUZUKI SUPER GREASE “A”...
  • Page 58 3-28 ENGINE • Tie a knot at the end of rope. • Pull the rope and check that the rachet is pushed out. • After remounting the recoil starter, the following adjustment or necessary. *Rear brake lever play ......!2-10 *Recoil starter adjustment .....
  • Page 59 FUEL AND LUBRICATION SYSTEM FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK AND FUEL VALVE ............4- 2 REMOVAL..................4- 2 FUEL FILTER INSPECTION AND CLEANING ........4- 3 REMOUNTING .................4- 3 CARBURETOR ..................4- 4 SPECIFICATIONS ................4- 5 I.D. NO. LOCATION ................4- 5 REMOVAL..................4- 6 DISASSEMBLY ................4- 7 CLEANING ..................4- 7 INSPECTION AND ADJUSTMENT ..........4- 8...

  • Page 60: Fuel Tank And Fuel Valve

    FUEL AND LUBRICATION SYSTEM FUEL TANK AND FUEL VALVE 1 Breather hose 2 Fuel tank cap 3 Fuel tank 4 Fuel valve REMOVAL Gasoline is very explosive. Extrem care must be taken. • Turn the fuel valve “OFF” position. • Remove the frame cover. ("5-2) •...

  • Page 61: Fuel Filter Inspection And Cleaning

    FUEL AND LUBRICATION SYSTEM • Disconnect the fuel hose 1, and vacuum hose 2. • Remove the fuel tank. • Remove the fuel valve assembly. FUEL FILTER INSPECTION AND CREANING If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result.

  • Page 62: Carburetor

    FUEL AND LUBRICATION SYSTEM CARBURETOR 1 Jet needle 2 Throttle valve 3 Starter valve 4 Needle valve 5 Pilot air screw 6 Throttle stop screw 7 Float 8 Needle jet 9 Main jet 0 Pilot jet No.1 A Pilot jet No.2 B Drain plug C Starter lever...

  • Page 63: Specifications

    FUEL AND LUBRICATION SYSTEM SPECIFICATIONS ITEM SPECIFICATION Carburetor type MIKUNI VM12SC Bore size 12 mm I.D. No 43F0 Idle r/min. 1 800 ± 100 r/min. Float height 24.5 – 25.0 mm (0.96 – 0.98 in) Main jet (M.J.) # 55 Jet needle (J.N.) 3E3-4th...

  • Page 64: Removal

    FUEL AND LUBRICATION SYSTEM REMOVAL • Remove the right frame cover. ("5-2) • Remove the clamp. • Turn the fuel valve to “OFF” position. • Disconnect the fuel hose 1. • Lossen the carburetor clamp bolt 2. • Remove the screws 3 with throttle valve. •...

  • Page 65: Disassembly

    FUEL AND LUBRICATION SYSTEM DISASSEMBLY • Disconnect the throttle cable and remove the throttle valve 1 and spring 2. • Remove the jet needle 3. • Remove the screws and float chamber. • Remove the main jet 4, needle jet 5, pilot jet No.1 6 and pilot jet No.2 7.

  • Page 66: Inspection And Adjustment

    FUEL AND LUBRICATION SYSTEM • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. • Clean all circuits of the carburetor thoroughly - not just the per- ceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soak, if nec- essary, to loosen dirt and varnish.

  • Page 67: Reassembly And Remounting

    FUEL AND LUBRICATION SYSTEM FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Mea- sure the float height A while the float arm is just contacting the needle valve using vernier calipers. Bend the tongue 1 as nec- essary to bring the float height A to the specified value.

  • Page 68: Carburetion

    4-10 FUEL AND LUBRICATION SYSTEM CARBURETION Proper carburetion is determined by several interrelated factors (i.e. engine power, fuel consumption, fuel cooling ability, jet settings etc.). Therefore, the jet size and the positions of any adjustable parts should not be changed from the original settings. Changes should only be made when adjusting for differences in altitude or other climatic conditions.

  • Page 69: Oil Pump

    FUEL AND LUBRICATION SYSTEM 4-11 OIL PUMP 1 Stopper screw 2 Gasket 3 Oil hose 4 Oil pump cam 5 Plunger 6 Plunger spring 7 Oil pump valve 8 Oil pump driven gear 9 Oil seal 0 Air bleeder screw A O-ring B Check valve A Union bolt...

  • Page 70: Reassembly

    4-12 FUEL AND LUBRICATION SYSTEM • Remove the oil pump cam. NOTE: When removing the oil pump cam, the plunger and its spring will pop out. Do not miss there two parts. Inspect the oil pump valve wall and clutch cover bore wall for nick, scratches or other damage.

  • Page 71: Air Bleeding

    • Remove the drive chain and engine sprocket from the drive shaft. ("3-5) • Fill the CCI oil gauge 1 with SUZUKI CCI SUPER OIL. Con- nect the oil gauge to the suction side of the oil pump. • Run the engine at 2 000 r/min.
  • Page 72 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS................5- 1 REMOVAL..................5- 2 REMOUNTING .................5- 3 FRONT AND REAR WHEEL ..............5- 4 REMOVAL..................5- 4 REMOUNTING .................5- 4 TIRES ....................5- 5 TIRE REPLACEMENT ..............5- 5 FRONT BRAKE ..................5- 7 REMOVAL AND DISASSEMBLY .............5- 7 INSPECTION ..................5- 9 REASSEMBLY AND REMOUNTING ..........5- 9 STEERING AND FRONT SUSPENSION ..........5-12 REMOVAL AND DISASSEMBLY .............5-14...

  • Page 73: Exterior Parts

    CHASSIS EXTERIOR PARTS REMOVAL SEAT • Remove the seat. STEERING COVER • Remove the screws. • Disconnect the ignition switch lead wires, and than remove the steering cover. FRAME COVER • Remove the frame cover. NOTE: Replace the fuel tank cap 1 after removing the frame cover. •...

  • Page 74: Remounting

    CHASSIS NOTE: To remove the fastener, dapress the head A of fastener core and pull out the fastener. REMOUNTING Remount the exterior parts in the reverse order of removal. Pay attention following point: FRAME COVER • Install the frame cover using the fastner. •...

  • Page 75: Front And Rear Wheel

    CHASSIS FRONT AND REAR WHEELS REAR 1 Oil seal 2 Bearing 3 Spacer 4 Front wheel hub 5 Bearing 6 Oil seal 7 Front wheel 8 Front wheel center cap FRONT 9 Rear wheel hub N . m kgf . m ITEM lb-ft 0 Rear wheel...

  • Page 76: Tires

    CHASSIS TIRES TIRE REPLACEMENT • Remove the front and rear wheels. ("5-4) • After removing the air valve cap, release the tire pressure by depressing the valve. • Dismount the bead from the rim completely as shown. • Separate the tire from the rim by using a set of tire levers and rim protectors.
  • Page 77 CHASSIS • Inflate the tire to seat the tire bead. $ Maximum tire bead seat pressure Front : 250 kPa (2.5 kgf/cm , 36 psi) Rear : 250 kPa (2.5 kgf/cm , 36 psi) Place the tire under a protective tire cage or similar pro- tective covering device before inflating the tire.

  • Page 78: Front Brake

    CHASSIS FRONT BRAKE 1 Front brake shoe 2 Spring 3 Front brake cam shaft 4 O-ring 5 Dust seal 6 Front brake panel 7 Cam lever A Front brake cam lever nut N . m kgf . m ITEM lb-ft REMOVAL AND DISASSEMBLY •...
  • Page 79 CHASSIS • Remove the spring 1. • Remove the front brake adjusting nut 2. • Remove the front brake cam lever nut and bolt. • Remove the brake cam lever and front brake camshaft 3. • Remove the brake panel. •...

  • Page 80: Inspection

    Replace the brake shoes as a set, otherwise braking per- formance will be adversely attected. REASSEMBLY AND REMOUNTING • Apply SUZUKI SUPER GREASE “A” to the bearing before in- stalling. For USA & 99000-25030: SUZUKI SUPER GREASE “A”...
  • Page 81 • When installing the brake cam lever on the camshaft align the panch mark 1 of the cam lever with the slit 2 of the camshaft. • Apply SUZUKI SUPER GREASE “A” to the brake cam and pin, and install the brake shoes.
  • Page 82 CHASSIS 5-11 • Tighten the front hub nut 1 to the specified torque. ! Front hub nut: 65 N . m (6.5 kgf . m, 47.9 lb-ft) • Install the new cotter pin. • Install the front wheel. ("5-4) • After installing the front brake, adjust the following items. * Front brake lever play.

  • Page 83: Steering And Front Suspension

    5-12 CHASSIS STEERING AND FRONT SUSPENSION 1 Tie-rod 2 Inner tie-rod end 3 knuckle arm bolt 4 Dust seal 5 Bushing 6 Knuckle arm (L) 7 Outer tie-rod end 8 Spacer 9 Knuckle arm (R) A Tie-rod lock nut B Tie-rod end nut C Kunckle arm nut N .
  • Page 84 CHASSIS 5-13 1 Clamp 2 Handlebar 3 Steering shaft 4 Dust seal 5 Steering shaft holder 6 Steering shaft lower dust seal 7 Bushing 8 O-ring A Handleber clamp bolt B Steering shaft holder bolt C Steering shaft lower nut N .

  • Page 85: Removal And Disassembly

    5-14 CHASSIS REMOVAL AND DISASSEMBLY FRONT SUSPENSION • Remove the front wheel. ("5-4) • Remove the front brake. ("5-7) • Remove the front brake cable 1. • Remove the cotter pin and remove the tie-rod end nut 2. • Remove the front suspensions arm nuts. •...

  • Page 86: Steering

    CHASSIS 5-15 • Remove the knuckle arm bushings using the special tools. % 09923-73210: Bearing remover 09930-30104: Sliding shaft STEERING • Remove the front suspension. ("5-12) • Remove the front and rear brake cable. • Remove the throttle case cover screws. •...
  • Page 87 5-16 CHASSIS • Remove the cotter pin and steering shaft lower nut 1 and tie- rod end nut 2. • Remove the tie-rods. • Remove the handlebar clamp bolts. • Remove the cotter pin. • Remove the steering shaft holder bolts. •...

  • Page 88: Inspection

    CHASSIS 5-17 • Remove the dust seals 1 and 2. • Separate the tie rod ends 3, nuts 4, 5 and tie rods 6. The lock nuts 4 have left hand threads. INSPECTION Inspect the removed parts for the following abnormallities. * Handlebar distortion.
  • Page 89 5-18 CHASSIS FRONT SHOCK ABSORBER • Inspect the shock absorber for oil leakage or damage. If any damage are found, replace the front shock absorber with a new one. Do not attempt to disassemble the front shock absorber. It is unserviceable. TIE-ROD/TIE-ROD END •...
  • Page 90 • Install the steering shaft bushing using the special tool. % 09924-84510: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the new dust seal 1, steering shaft holders 2 and new dust seals 3 before remount- ing the steering shaft.
  • Page 91 5-20 CHASSIS • Tighten the steering shaft nut to the specified torque and new cotter pin. ! Steering shaft lower nut: 29 N . m (2.9 kgf . m, 2.1 lb-ft) • Tighten the steering shaft holder bolts to the specified torque and new cotter pins.
  • Page 92 FRONT SUSPENSION • Install the knuckle arm bushing using the special tool. % 09924-84510: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the knuckle arm dust seals. • Apply SUZUKI SUPER GREASE “A” to the knuckle arm bush- ings and install the spacer and the dust seals.
  • Page 93 5-22 CHASSIS • Tighten the front suspension arm bolts to the specified torque. ! Front suspension arm bolt: 50 N . m (5.0 kgf . m, 36 lb-ft) • Tighten the front shock absorber upper bolt to the specified torque. ! Front shock absorber upper bolt: 29 N .

  • Page 94: Toe-In Adjustment

    CHASSIS 5-23 TOE-IN ADJUSTMENT Adjust the toe-in as follows: • Place the vehicle on level ground and set the handlebars straight. Make sure all the tires are inflated to the standard pressure. ("2-11) • Place 30 kg (66 lbs) of weight on the seat. •...

  • Page 95: Rear Brake And Rear Axle Housing

    5-24 CHASSIS REAR BRAKE AND REAR AXLE HOUSING 1 Spacer (R) 2 Rear brake cover 3 Rear brake drum 4 Rear brake shoe 5 Rear brake cam 6 O-ring 7 Rear brake anchor panel 8 Brake cam lever spring 9 Rear brake cam lever 0 Spacer (L) A Rear axle shaft B Oil seal...

  • Page 96: Removal And Disassembly

    CHASSIS 5-25 REMOVAL AND DISASSEMBLY • Remove the cotter pin 1. • Remove the rear axle nut by applying the rear brake. • Remove the rear wheels. • Remove the spacer, 2, 3. • Remove the rear brake drum cover. •...
  • Page 97 5-26 CHASSIS • Disconnect the rear brake cables. • Remove the rear brake panel. • Remove the rear brake cam lever bolt and cam lever. • Remove the rear brake cam 1, brake lining indicator plate 2, spring 3, and O-rings 4. •...

  • Page 98: Inspection

    CHASSIS 5-27 • Remove the rear axle bearings using the special tool. % 09921-20240: Bearing remover set • Remove the spacer 1. INSPECTION DUST SEAL Inspect the dust seals for wear or damage. If any damages are found, replace the tie rod with a new one. BEARING Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection.

  • Page 99: Reassembly And Remounting

    Reassemble and remount the rear suspension in the reverse or- der of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the rear axle bearings and the rip of the dust seals before installing them. For USA &...
  • Page 100 3. Make sure the sealed side of the bearing face out- ward. Right Left • Tighten the rear axle housing bolts to the securely. • Apply SUZUKI SUPER GREASE “A” to the rear brake cam shaft and new O-rings. For USA & 99000-25030: SUZUKI SUPER GREASE “A” For the others &...
  • Page 101 • Tighten the rear brake panel nut to the specified torque. ! Rear brake panel nut: 28 N . m (2.8 kgf . m, 20.5 lb-ft) • Apply SUZUKI SUPER GREASE “A” to the brake cam and pin. • Install the brake shoes.
  • Page 102 CHASSIS 5-31 • Install the brake drum 1, and circrip 2. • Install the rear sprocket and rear axle. • Install the chain cover. • Install the rear brake drum cover. • Install the spacer right 3 and left 4.
  • Page 103 5-32 CHASSIS • Tighten the rear hub nut to the specified torque. ! Rear hub nut: 75 N . m (7.5 kgf . m, 55 lb-ft) • Install the new cotter pin. • After installing the rear brake and drive chain, adjust the follow- ing items.

  • Page 104: Rear Suspension

    CHASSIS 5-33 REAR SUSPENSION 1 Rear shock absorber 2 Chain case 3 Rear shock absorber lower bolt 4 Swingarm pivot bolt 5 Bushing 6 Spacer 7 Swingarm A Rear shock absorber upper bolt B Rear shock absorber lower nut C Swingarm pivot nut N .

  • Page 105: Removal And Disassembly

    5-34 CHASSIS REMOVAL AND DISASSEMBLY • Remove the rear brake and rear axle housing. ("5-23) • Remove the rear shock absorber upper bolt 1. • Remove the swingarm pivot nut 2. • Remove the swingarm 3. • Remove the rear shock absorber lower bolt 4. INSPECTION REAR SHOCK ABSORBER •...

  • Page 106: Reassembly And Remounting

    CHASSIS 5-35 BUSHING • Inspect the bushing for wear or damage. If any dameges found, replace the bushing with a new one. REASSEMBLY AND REMOUNTING • Reasembl and remount the rear suspension in the reverse or- der of removal and disassembly. Pay attention to the following points: •...
  • Page 107 5-36 CHASSIS • Install the rear axle housing and rear brake. ("5-27) • After installing the rear suspension adjust the following items. * Rear brake lever play ........... "2-10 * Drive chain slack .........."2-8...
  • Page 108 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ..............6- 2 IGNITION SYSTEM ................6- 3 DESCRIPTION .................6- 3 TROUBLESHOOTING ..............6- 3 INSPECTION ..................6- 4 SWITCH ....................6- 5...

  • Page 109: Cautions In Servicing

    ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.

  • Page 110: Ignition System

    ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION The ignition system is shown in the diagram below: namely the generator, CDI/Ignition coil unit and spark plug. CDI/Ignition coil unit Generator Spark plug TROUBLESHOOTING...

  • Page 111: Inspection

    ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the seat. (!5-2) • Remove the frame cover. (!5-2) • Remove the spark plug cap. • Connect a new spark plug to the spark plug cap on the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected.

  • Page 112: Switch

    ELECTRICAL SYSTEM IGNITION COIL RESISTANCE Measure the ignition coil resistance in the secondary winding. If the winding is in sound condition, the resistance should be close to the specified value. & Ignition coil resistance Secondary: 13 – 20 kΩ Ω Ω Ω Ω (Spark plug cap – Ground) GENERATOR COIL RESISTANCE •...
  • Page 113 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ................7- 2 WIRING DIAGRAM ................7- 6 WIRE AND CABLE ROUTING ..............7- 7 SPECIAL TOOLS ..................7-11 TIGHTENING TORQUE .................7-13 SERVICE DATA ..................7-15...

  • Page 114: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard to 1. Worn cylinder. Rebore or replace. start. 2. Worn piston ring. Replace. 3. Stiff piston ring. Repair or replace. 4.
  • Page 115 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Worn cylinder. Replace. 2. Worn piston rings. Replace. 3. Stiff piston ring. Replace. 4. Gas leaks from crankshaft oil seal. Replace. 5. Excessive spark plug gap. Adjust or replace. 6.

  • Page 116: System

    SERVICING INFORMATION CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. 1. Clogged fuel pipe. Clean. 2. Air leaking from joint between starter body and Tighten, adjust or replace carburetor. gasket. 3. Air leaking from carburetor joint. Tighten or replace defective parts.
  • Page 117 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Suspension too stiff. 1. Worn suspension arms and related bushings. Replace. Suspension too noisy. 1. Loose suspension system bolts. Tighten. 2. Worn suspension arms and related bushings. Replace. Rear wheels wobble. 1. Distorted rear wheel rims. Replace.

  • Page 118: Wiring Diagram

    SERVICING INFORMATION WIRING DIAGRAM CDI UNIT/IGNITION COIL EMERGENCY STOP SWITCH ENGINE STOP SWITCH PULL FREE WIRE COLOR ..Black with White tracer ..Black with Yellow tracer IGNITION SWITCH MAGNETO...

  • Page 119: Wire And Cable Routing

    SERVICING INFORMATION WIRE AND CABLE ROUTING WIRE ROUTING Engine stop switch lead wire Clamp Ignition lead wire Clamp Clamp Emergency switch lead wire Generator lead wire Clamp Clamp To engine stop switch CDI/Ignition coil Wiring harness Ignition lead wire Clamp Generator lead wire Clamp...

  • Page 120: Cable Routing

    SERVICING INFORMATION CABLE ROUTING Engine stop switch lead wire Rear brake cable Throttle cable Rear brake cable Front brake cable (R) Front brake cable (L) Cable guide Fit claw of bracket Rear brake cable Throttle cable Rear brake cable...
  • Page 121 SERVICING INFORMATION Rear brake cable Throttle cable Engine stop switch lead wire Throttle cable Rear brake cable Cable guide Engine stop switch lead wire Front brake cable (L) Front brake cable (R) Throttle cable Front brake cable (L) Front brake cable (R) Engine stop switch lead wire Front brake cable (L) Rear brake cable...
  • Page 122 7-10 SERVICING INFORMATION BREATHER AND AIR VENT HOSE ROUTING Air vent hose Breather hose Drain hose Clamp Drain hose...

  • Page 123: Special Tools

    SERVICING INFORMATION 7-11 SPECIAL TOOLS 09900-00401 09900-00410 “L” type hexagon 09900-06107 09900-06108 09900-09004 Hexagon wrench set wrench set Snap ring pliers Snap ring pliers Impact driver set 09900-20205 09900-20101 09900-20202 Micrometer 09900-20508 Vernier calipers Micrometer 09900-20605 (0 – 25 mm) Cylinder gauge set (150 mm) (25 –...
  • Page 124 7-12 SERVICING INFORMATION 09941-50111 Bearing remover NOTE: When ordering a special tool, please confirm whether it is available or not.

  • Page 125: Tightening Torque

    SERVICING INFORMATION 7-13 TIGHTENING TORQUE ENGINE N . m kgf . m ITEM lb-ft Exhaust pipe clamp nut Engine mounting bolt (lower) 22.5 Engine mounting bolt 29.5 Cylinder head nut Generator rotor nut 36.0 Clutch shoe nut 61.5 CHASSIS N . m kgf .
  • Page 126 7-14 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolts and nuts listed in the preceding page, refer to this chart: Conventional or “4” marked bolt “7” marked bolt Bolt Diameter A (mm) N . m kgf . m N . m kgf .

  • Page 127: Service Data

    SERVICING INFORMATION 7-15 SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.065 – 0.075 0.120 (0.0026 – 0.0030) (0.0047) Cylinder bore 41.000 – 41.015 41.065 (1.6142 – 1.6148) (1.6167) Measure at 20 mm (0.8 in) from the top surface. Piston diam.
  • Page 128 7-16 SERVICING INFORMATION CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch wheel I.D. 87.00 – 87.15 87.50 (3.425 – 3.431) (3.445) Clutch shoe thickness No groove ——— at any part Clutch engagement 2 200 – 2 600 r/min. ——— Clutch lock-up 2 500 –...
  • Page 129 SERVICING INFORMATION 7-17 ITEM SPECIFICATION NOTE Ignition coil resistance Plug cap – Secondary 13 – 20 kΩ Terminal 100 – 160 Ω Generator coil resistance Primary B/Y – Ground Ignition coil primary peak voltage : B/Y More than 100 V : Ground BRAKE + WHEEL Unit: mm (in)
  • Page 130 BRICANT or an equivalent good quality synthetic P-03 based 2-stroke engine oil rated FC under the JASO classification. Use SUZUKI CCI SUPER OIL. If they are not avail- For the others able, use a good quality 2-stroke engine oil rated FC under the JASO classification.
  • Page 131 LT-A50K3/K4 (’03, 04-MODELS) LT-A50K3/K4 (’03, ’04-MODELS) CONTENTS SPECIFICATIONS .................8- 2 SERVICE DATA ..................8- 3...
  • Page 132 LT-A50K3/K4 (’03, 04-MODELS) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............1 260 mm (49.6 in) Overall width ..............760 mm (29.9 in) Overall height ..............745 mm (29.3 in) Wheelbase ............... 825 mm (32.5 in) Ground clearance ............120 mm (4.7 in) Seat height ...............
  • Page 133 LT-A50K3/K4 (’03, 04-MODELS) SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.065 – 0.075 0.120 (0.0026 – 0.0030) (0.0047) Cylinder bore 41.000 – 41.015 41.065 (1.6142 – 1.6148) (1.6167) Measure at 20 mm (0.8 in) from the top surface. Piston diam.
  • Page 134 LT-A50K3/K4 (’03, 04-MODELS) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch wheel I.D. 87.00 – 87.15 87.50 (3.425 – 3.431) (3.445) Clutch shoe thickness No groove ——— at any part Clutch engagement 2 200 – 2 600 r/min. ——— Clutch lock-up 2 500 –...
  • Page 135 LT-A50K3/K4 (’03, 04-MODELS) ITEM SPECIFICATION NOTE Ignition coil resistance Plug cap – Secondary 13 – 20 kΩ Terminal 100 – 160 Ω Generator coil resistance Primary B/Y – Ground Ignition coil primary peak voltage : B/Y More than 100 V : Ground BRAKE + WHEEL Unit: mm (in)
  • Page 136 BRICANT or an equivalent good quality synthetic P-03 based 2-stroke engine oil rated FC under the JASO classification. Use SUZUKI CCI SUPER OIL. If they are not avail- For the others able, use a good quality 2-stroke engine oil rated FC under the JASO classification.

  • Page 137: Lt-A50K5 ('05-Model)

    LT-A50K5 (’05-MODEL) LT-A50K5 (’05-MODEL) This chapter describes specifications, service data and servicing information which differ from those of the LT-A50K3/K4 (’03, ’04-MODELS). NOTE: * Any differences between the LT-A50K3/K4 (’03, ’04-MODELS) and LT-A50K5 (’05-MODEL) in specifications and service data are indicated with an asterisk mark (*). * Please refer to the chapters 1 through 8 for details which are not given in this chapter.

  • Page 138: Specifications

    LT-A50K5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................1 260 mm (49.6 in) Overall width ..................760 mm (29.9 in) Overall height ..................745 mm (29.3 in) Wheelbase ..................825 mm (32.5 in) Ground clearance................120 mm ( 4.7 in) Seat height ..................

  • Page 139: Service Data

    LT-A50K5 (’05-MODEL) SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.065 – 0.075 0.120 (0.0026 – 0.0030) (0.0047) Cylinder bore 41.000 – 41.015 41.065 (1.6142 – 1.6148) (1.6167) Measure at 20 mm (0.8 in) from the top surface. Piston diam.
  • Page 140 LT-A50K5 (’05-MODEL) OIL PUMP ITEM SPECIFICATION Oil pump reduction ratio 60.95 (53/20 × 23/1) Oil pump discharge rate 0.6 – 0.8 ml (0.020/0.021 – 0.027/0.030 US/lmp oz) for 5 minutes at 2 000 r/min CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch wheel I.D.
  • Page 141 LT-A50K5 (’05-MODEL) ELECTRICAL ITEM SPECIFICATION NOTE Spark plug Type NGK: BPR4H 0.50 – 0.60 (0.020 – 0.024) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Plug cap – Secondary 13 – 20 kΩ - Terminal 100 – 160 Ω Generator coil resistance Primary B/Y –...
  • Page 142 LUBRICANT or an equivalent good quality syn- P-03 thetic based 2-stroke engine oil rated FC under the JASO classification. Use SUZUKI CCI SUPER OIL. If they are not avail- able, use a good quality 2-stroke engine oil rated For the others FC under the JASO classification.

  • Page 143: Tightening Torque

    LT-A50K5 (’05-MODEL) TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Exhaust pipe clamp nut Engine mounting bolt (lower) 22.5 Engine mounting bolt 29.5 Cylinder head nut Generator rotor nut 36.0 Clutch shoe nut 61.5 CHASSIS ITEM N·m kgf-m lb-ft Handlebar clamp bolt Wheel nut (Front and Rear) 20.5 Front hub nut...

  • Page 144: Rear Brake And Rear Axle Housing

    LT-A50K5 (’05-MODEL) REAR BRAKE AND REAR AXLE HOUSING Spacer (R) Rear brake cover " Rear brake drum Rear brake shoe Rear brake cam O-ring & Rear brake anchor panel Brake cam lever spring Rear brake cam lever Spacer (L) Rear axle shaft Oil seal Bearing Rear axle housing...
  • Page 145 Prepared by 3rd Ed. March, 2004 1st Ed. March, 2001 Part No. 99500-20212-01E Printed in Japan...
  • Page 146 Printed in Japan K2 K3 K4 K5...

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