Suzuki LT-Z90K7 Setup Manual
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Suzuki LT-Z90K7 Setup Manual

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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.
K7
99505-01027-01E
August '06 Printed in Japan (TK) 28

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Summary of Contents for Suzuki LT-Z90K7

  • 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 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 Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate.

  • 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 Steering head cover Fuel label Fuel tank vent hose Battery electrolyte container Front grip Owner’s manual Flange bolt 8 ×...
  • 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: Throttle cable C: Front brake cable D: Rear brake cable E: Tool set...
  • 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 Align the dot mark on the handlebars with the mating surface of the front side of right clamp.

  • Page 7: Throttle Cable

    The line drawings on page 26, 27 and 28 show the proper routing of the control cables and wiring. Refer to drawings in addition to follow- ing the instructions carefully. A: Front brake cable B: Throttle cable C: Left switch wiring harness D: Parking brake switch lead wire E: Rear brake cable THROTTLE CABLE...

  • Page 8: Rear Brake Cable

    REAR BRAKE CABLE Turn the brake cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess of brake lever, then pull on the outer cable housing and insert it into the adjuster.

  • Page 9: Front Brake Cable

    FRONT BRAKE CABLE Pass the front brake cable through the hole of steering head cover. A: Front brake cable B: Steering head cover C: Hole Turn the brake cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess of brake cable equalizer, then pull on the outer cable housing and insert it into the adjuster.

  • Page 10: Front Wheel

    Remove the bolts holding the front part of the vehicle. Before removing bolts, lift the front of the vehi- cle a little by using a hoist to prevent the dam- age to the bolt threads. NOTE: The bolts are no longer needed and may be dis- carded.
  • Page 11 Properly position the wheel on the axle stud bolts. NOTE: Be sure to install the front wheels with the air valves facing outwards. Temporarily finger-tighten the wheel set nuts. A: Stud bolt B: Air valve C: Washer OD:20.0 mm ID:10.5 mm D: 10 mm flange nut (Wheel set nut) Remove the hoist used to lift the vehicle and then place the vehicle in place.
  • Page 12 FRONT GRIP AND REFLEX REFLECTOR FRONT SIDE (FOR LIMITED MARKET) Install the reflex reflector to the bracket. A: Reflex reflector B: Bracket C: 5 mm flange nut Install the front grip with four bolts together with the reflector assembly. A: Front grip B: Frame C: 8 ×...

  • Page 13: Warning Label

    OWNER’S MANUAL Pull the seat release lever toward the rear and remove the seat. A: Seat release lever Store the owner’s manual in place. A: Owner’s manual WARNING LABEL (FOR E-19 MARKET) Select the appropriate language label for your country. AVERTISSEMENT AVERTISSEMENT AVERTISSEMENT...
  • Page 14 Stick the label selected for your country. FRONT A: Warning label (General warning) B: Warning label (Tire information) C: Warning label (Age 12) D: Front fender (Right) E: Rear fender (Right) FUEL LABEL (FOR LIMITED MARKET) Stick the label on the fuel tank. A: Fuel tank B: Fuel label...
  • Page 15 SERVICING BATTERY The battery is located under the seat. Pull the seat release lever toward the rear and remove the seat. A: Seat release lever Unhook the clamp to take off the CDI wiring harness. Remove the rubber band. Remove the battery from the vehicle. A: Clamp B: Rubber band Filling electrolyte...
  • Page 16 Remove the caps from the electrolyte container. NOTE: Use the removed caps as the sealed caps of battery filler holes. Do not remove or pierce the sealed areas of the electrolyte container. A: Caps B: Sealed area With just enough force to break the nozzle seal of elec- trolyte container, push each nozzle of the electrolyte container into the battery’s electrolyte filler ports and hold the container firmly so that it does not fall.
  • Page 17 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.
  • Page 18 Check the rubber cushions are installed in the correct position before installing the battery. A: Rubber cushion 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.
  • Page 19 THROTTLE CABLE Check the throttle cable play at the throttle lever end. Throttle cable play: 3.0–5.0 mm 3.0–5.0 mm 3.0–5.0 mm If adjustment is necessary, carry out the procedure below: 1. Remove the steering head cover. 2. Loosen the throttle cable adjuster lock nut A. 3.

  • Page 20: Front Brake

    FRONT BRAKE Check the brake lever play. The brake lever play A measured at the lever holder when the lever is squeezed, and the brake cable holder B is in the straight up position as shown in the photograph. Front brake lever play: 3–7 mm 3–7 mm 3–7 mm If adjustment is necessary, carry out the procedure...

  • Page 21: Drive Chain

    DRIVE CHAIN Check the drive chain slack through the inspection window. Drive chain slack: 15–25 mm If it is too tight or too loose, follow these procedures. 1. Remove the bolt to take off the chain case cover. A: Chain case cover B: Bolt C: Hook D: Inspection window...
  • Page 22 REAR/PARKING BRAKE Check the brake lever play. The brake lever play measured at the lever holder when the lever is squeezed. Rear brake lever play: 3–5 mm 3–5 mm 3–5 mm If adjustment is necessary, carry out the procedure below: 1.

  • Page 23: Engine Oil

    ENGINE OIL This vehicle is shipped from factory with the engine filled with engine oil. Be sure to check oil level. Check the engine oil level with the engine oil dipstick. 1. Place the vehicle on level ground. 2. Start the engine and allow it to run for a few minutes at idling speed.
  • Page 24 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.

  • Page 25: Tire Pressure

    TIRE PRESSURE Using an accurate air gauge, check the air pressure of the front and rear tires. The pressure should be as shown. COLD INFLATION TIRE PRESSURE TIRE PRESSURE FRONT REAR 22.5 kPa 20 kPa 0.225 kgf/cm 0.20 kgf/cm 3.3 psi 2.9 psi IDLE SPEED ADJUSTMENT After completing all of the servicing procedures, adjust...

  • Page 26: 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 SUSPENSION AND REAR BRAKE Handlebar set bolt Rear wheel nut Front wheel nut Rear axle nut Front axle nut Rear shock absorber bolt (Upper) Front shock absorber bolt Rear brake cam lever nut 0.77...

  • Page 27: Harness Routing

    HARNESS ROUTING Rear brake cable Clamp Wiring harness CDI unit Battery Handlebar switch lead wire (L) Rear brake switch lead wire Clamp Starter relay Starter motor lead wire Battery - terminal Battery + terminal Generator lead wire Clamp Handlebar switch lead wire (L) Starter motor Starter motor Wiring harness...

  • Page 28: Cable Routing

    CABLE ROUTING Clamp Rear brake cable Throttle cable Front brake cable (R) Pass the rear brake cable through downside of the frame. Rear brake cable Front brake cable (L) Pass the brake cable through downside of the frame. Front brake cable (L) Front brake cable (R) Throttle cable Rear brake cable...
  • Page 29 Clamp Throttle cable Bracket Front brake cable Fix the boot of the front brake cable. Adjuster nut Front brake cable (L) Front brake cable (R) Rear brake cable Pass the rear brake cable through outside of the rear belt cooling duct. Wiring harness Pass the rear brake cable through inside of the rear fender.

  • Page 30: Safety Check-Out

    SAFETY CHECK OUT COLD INFLATION TIRE PRESSURE TIRE PRESSURE After completion of the setting-up the vehicle FRONT REAR all the following items should be double- 22.5 kPa 20 kPa 0.225 kgf/cm 0.20 kgf/cm checked to confirm that the operation and func- 3.3 psi 2.9 psi tion of the vehicle are satisfactory.

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