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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 special
care to properly perform the required assembly and servicing marked by either a
Warning or a Caution. Failure to follow the directions in either of these two (2) cate-
gories could lead to serious problems.
and
areas are
denoted to emphasize certain areas and carry the following meanings:
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in vehicle damage.
This set-up manual is based on a vehicle of standard specification. Some minor dif-
ferences from this manual may be found in other specifications.
K6
99505-01006-01E
June '05 Printed in Japan (TK) 28
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Table of Contents
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Summary of Contents for Suzuki LT-Z50K6
- 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. Remove the straps holding the handlebar assembly. NOTE: The brackets, bolts and vinyl tube are no longer needed and these may be discarded. A: Bolt B: Bracket C: Vinyl tube D: Strap Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate.
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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 Handlebar clamp(Upper) Fuel label Handlebar clamp(Lower) Battery electrolyte container Flange bolt 8 × 45 mm Owner’s manual Handlebar pad Manual bag... - 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: Tool set C: Emergency stop switch lanyard D: Rear wheel assembly...
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Page 6: Removing The Bracket
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 REMOVING THE BRACKET Remove the bracket from the handlebar mounting position. - Page 7 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 A of the front side with specified the bolt FRONT B of the rear torque and then tighten the bolt side.
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Page 8: Rear Wheel
REAR WHEEL Remove the rear wheels. NOTE: The wheels are fixed inside out when they are packed. The paper is no longer needed and may be dis- carded. A: Rear wheel assembly B: 8 mm flange self-lock nut (Wheel set nut) C: Paper When installing the rear wheels onto the axles, special attention must be paid to the arrow of the rotational... - Page 9 A: 8 mm flange self-lock nut (Wheel set nut) HANDLEBAR PAD Install the handlebar pad to the handlebar reinforcing bar. NOTE: The “SUZUKI” logo should face the backward. A: Handlebar pad B: Strap L:180 mm C: “SUZUKI” logo FRONT FUEL TANK VENT HOSE Install the fuel tank vent hose into the cable guide as shown in the photograph.
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Page 10: Air Gauge
AIR GAUGE Pull the seat release lever toward the rear and remove the seat. A: Seat release lever Store the air gauge with tool set in place. A: Air gauge (Tool set) OWNER’S MANUAL Store the owner’s manual in place. A: Owner’s manual EMERGENCY STOP SWITCH LANYARD Pass the emergency stop switch lanyard through the... -
Page 11: Warning Label
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 RÉGLER LE FREIN DE STATIONNEMENT AVANT LE DÉMARRAGE DU MOTEUR Stick the label selected for your country. - Page 12 SERVICING BATTERY The battery is located under the seat. Pull the seat release lever toward the rear and remove the seat. Remove the battery from the vehicle. A: Seat release lever Filling electrolyte Remove the aluminium tape sealing the battery elec- trolyte filler holes.
- Page 13 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 14 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 15 1. Set the battery to the box. + lead to the + positive terminal 2. First connect the of the battery. + terminal with rubber boot. 3. Cover - lead to the - negative terminal of 4.
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Page 16: 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 B in or out until the correct play. 2. -
Page 17: Front Brake
FRONT BRAKE Check the brake lever play. A measured at the lever holder The brake lever play when the lever is squeezed, and the brake cable B is in the straight up position as shown in the holder photograph. -
Page 18: Drive Chain
DRIVE CHAIN Check the drive chain slack. Drive chain slack: 20–30 mm If it is too tight or too loose, follow these procedures. A and 1. Loosen bolts 2. Adjust the slack in the drive chain by turning the right and left chain adjuster nuts. - Page 19 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: 4–6 mm If adjustment is necessary, carry out the procedure below: 1.
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Page 20: Engine Oil
ENGINE OIL This vehicle is shipped from factory with the engine filled with engine oil. Be sure to check oil level. Remove the fastener to take off the engine oil mainte- nance lid. NOTE: To remove the fastener, push in the center pin and pull out the fastener. - Page 21 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 22: Tire Pressure
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 23: 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 holder bolt Rear wheel nut Front wheel nut Rear axle nut Front axle nut Rear shock absorber bolt and nut (Upper and Lower) Front shock absorber bolt (Upper and Lower) -
Page 24: Cable Routing
CABLE ROUTING Front brake cable (R) Throttle cable Rear brake cable Cable guide Front brake cable (L) Front brake cable (R) Front brake cable (L) SECT: D – D Throttle cable Rear brake cable Front brake cable (L) Rear brake cable Clamp Front brake cable (R) Wiring harness... -
Page 25: Harness Routing
HARNESS ROUTING Handlebar switch wiring harness (L) Clamp CDI unit Starter relay Battery + terminal Fuse box Clamp Clamp Wiring harness Clamp Wiring harness Emergency switch lead wire Magneto lead wire Starter motor lead wire Case Clamp Wiring harness Ignition switch lead wire Handlebar switch lead wire (L) Clamp Clamp... -
Page 26: 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- 20 kPa 20 kPa 0.20 kgf/cm 0.20 kgf/cm checked to confirm that the operation and func- 2.9 psi 2.9 psi tion of the vehicle are satisfactory.