Suzuki 2009 LT-R450 Service Manual
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Suzuki 2009 LT-R450 Service Manual

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  • Page 2: Table Of Contents

    THROTTLE BODY....................21 CONSTRUCTION ..................21 REMOVAL ....................22 FRONT SUSPENSION CONSTRUCTION ............24 SWINGARM CONSTRUCTION ................25 BRAKE PEDAL ....................26 REMOVAL ....................26 INSTALLATION..................26 REAR SHOCK ABSORBER ................27 REMOVAL ....................27 © COPYRIGHT SUZUKI MOTOR CORPORATION 2008...
  • Page 3 2 LT-R450/ZK9 (’09-MODEL) LT-R450/ZK9 (’09-MODEL) CONTENTS CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER INFORMATION ....................28 WIRING HARNESS ROUTING ................29 OIL HOSE ROUTING..................31 FRONT BRAKE HOSE ROUTING..............32 THROTTLE BODY INSTALLATION..............33 BRAKE PEDAL INSTALLATION ..............34 HANDLEBAR INSTALLATION .................

  • Page 4: Specifications

    LT-R450/ZK9 (’09-MODEL) 3 SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................1 845 mm (72.6 in) Overall width..................1 245 mm (49.0 in) Overall height ..................1 085 mm (42.7 in) Wheelbase ..................1 285 mm (50.6 in) Front track ..................1 045 mm (41.1 in) Rear track ...................

  • Page 5: Maintenance And Tune-Up Procedures

    4 LT-R450/ZK9 (’09-MODEL) MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each Periodic Maintenance item which differ from those of the LT-R450/ZK8 (’08-MODEL). For details other than the following items, refer to the LT-R450 Service Manual. BRAKES Inspect initially at 1 month and every 3 months there- after.
  • Page 6 LT-R450/ZK9 (’09-MODEL) 5 • Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. PARKING BRAKE LT-R450K8 2-19...

  • Page 7: Oil Jet

    6 LT-R450/ZK9 (’09-MODEL) OIL JET REMOVAL • Separate the left and right crankcase. (LT-R450K8 3-22) • Remove the piston cooling oil jet 1 from the right crankcase. INSPECTION AND CLEANING • Check the oil jet for clogging. • If they are clogged, clean their oil passage with a proper wire and compressed air.

  • Page 8: Engine Lubrication System Chart

    LT-R450/ZK9 (’09-MODEL) 7 ENGINE LUBRICATION SYSTEM CHART CONROD BIG CAM FACE (IN & EX) END BEARING CAMSHAFT JOURNAL CAM CHAIN CRANK PIN (IN & EX) ORIFICE CYLINDER HEAD RIGHT CRANKSHAFT PISTON PIN LEFT CRANKSHAFT PISTON CYLINDER CRANKSHAFT CYLINDER WALL RIGHT END STARTER CLUTCH OIL NOZZLE RIGHT CRANKCASE...

  • Page 9: Fi System Diagnosis

    8 LT-R450/ZK9 (’09-MODEL) FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM...

  • Page 10: Ecm Terminal

    LT-R450/ZK9 (’09-MODEL) 9 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT Power source — TO sensor signal (TOS) — CKP sensor signal (CKP+) FI/ECT indicator GP switch signal (GP) ECT sensor signal (ECT) TP sensor signal (TP) — IAP sensor signal (IAP) Sensors ground (E2) —...

  • Page 11: Dtc Table And Defective Condition

    10 LT-R450/ZK9 (’09-MODEL) DTC TABLE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM CKP sensor The signal does not reach ECM for 1 CKP sensor wiring and mechan- sec. or more, after receiving the IAP ical parts sensor input signal.
  • Page 12 LT-R450/ZK9 (’09-MODEL) 11 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <...

  • Page 13: Fi System Troubleshooting

    12 LT-R450/ZK9 (’09-MODEL) FI SYSTEM TROUBLESHOOTING “C17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.2 V Sensor voltage < 4.1 V •...
  • Page 14 LT-R450/ZK9 (’09-MODEL) 13 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then measure the IAP sensor input voltage. 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire and ground. 7) If OK, then measure the voltage at the Red wire and B/Br wire.
  • Page 15 14 LT-R450/ZK9 (’09-MODEL) 6) Remove the front fender. (LT-R450K8 7-6) 7) Disconnect the ECM coupler. 8) Check the continuity between G/B wire B and terminal 6. 9) If OK, then check the continuity between B/Br wire C and ter- minal N. ...
  • Page 16 LT-R450/ZK9 (’09-MODEL) 15 7) Remove the front fender. (LT-R450K8 7-6) 8) Disconnect the ECM coupler. 9) Check the continuity between Red wire A and terminal C. 10)Also, check the continuity between G/B wire B and terminal  IAPS lead wire continuity: Continuity () ...
  • Page 17 16 LT-R450/ZK9 (’09-MODEL) Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. (Page 20) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total - voltage is 4.5 –...
  • Page 18 LT-R450/ZK9 (’09-MODEL) 17 Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE ATMOSPHERIC OUTPUT (Reference) PRESSURE VOLTAGE (ft) (mmHg) 3.1 – 3.6 2 000 2 001 2.8 – 3.4 5 000 1 524 5 001 1 525...
  • Page 19 18 LT-R450/ZK9 (’09-MODEL) “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although FP relay • FP relay circuit open or short. is turned ON. • FP relay (ECM) malfunction. ngine stop switch Ignition switch...
  • Page 20 LT-R450/ZK9 (’09-MODEL) 19 Is the voltage OK? ECM coupler (Harness side) • FP relay (ECM) malfunction. • O/W or O/G wire open or shorted, or poor ter- minal D or E connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM.

  • Page 21: Cooling Fan Relay

    20 LT-R450/ZK9 (’09-MODEL) COOLING FAN RELAY ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4) Click “Operate”...

  • Page 22: Throttle Body

    LT-R450/ZK9 (’09-MODEL) 21 THROTTLE BODY CONSTRUCTION 1 TP sensor 7 Starter valve  2 Throttle body 8 Throttle cable cover 3 Fuel delivery pipe 9 IAP sensor ITEM N·m kgf-m lbf-ft 4 O-ring A Fuel delivery pipe mounting screw 0.35 5 Fuel injector B Fuel injector mounting screw 0.35...

  • Page 23: Removal

    22 LT-R450/ZK9 (’09-MODEL) REMOVAL • Remove the front fender. (LT-R450K8 7-6) • Remove the fuel tank and fuel tank lower cover. (LT-R450K8 5-4) • Remove the rubber cap 1. • Disconnect the fuel injector coupler 2, IAP sensor coupler 3 and TP sensor coupler 4.
  • Page 24 LT-R450/ZK9 (’09-MODEL) 23 • Remove the starter valve 6 and spring 7 from the starter cable. NOTE: Remove the IAP sensor 8 as shown in the IAP sensor removal and installation. (Page 20) INSTALLATION (LT-R450K8 5-18)

  • Page 25: Front Suspension Construction

    24 LT-R450/ZK9 (’09-MODEL) FRONT SUSPENSION CONSTRUCTION 1 Front shock absorber B Lower wishbone arm Spring washer A eliminated 2 Collar C Steering knuckle as K9 model 3 Dust seal D Spring washer 4 Bearing E Cotter pin  5 Collar F Tie rod 6 Upper wishbone arm G Tie rod end...

  • Page 26: Swingarm Construction

    LT-R450/ZK9 (’09-MODEL) 25 SWINGARM CONSTRUCTION 1 Swingarm 9 Inner dust seal 2 Rear brake disc cover 0 Bearing 3 Chain guide A Outer spacer 4 Chain guide plate B Thrust bearing  5 Sprocket guard C Thrust washer 6 Chain adjuster rubber seal D Outer dust seal ITEM N·m...

  • Page 27: Brake Pedal

    Install the brake pedal in the reverse order of removal. Pay attention to the following points: • Apply grease to the oil seal and brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the brake pedal pivot bolt 1 to the specified torque.

  • Page 28: Rear Shock Absorber

    LT-R450/ZK9 (’09-MODEL) 27 REAR SHOCK ABSORBER REMOVAL • Raise the rear wheel off the ground and support the vehicle with jack or wooden block. • Remove the cushion rod lower bolt/nut. • Remove the rear shock absorber mounting bolts/nuts. NOTE: If it is difficult to remove the mounting bolt of the upper side, remove the exhaust pipe.

  • Page 29: Cushion Rod, Cushion Lever And Rear Shock Absorber Information

    28 LT-R450/ZK9 (’09-MODEL) CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER INFORMATION 4 mm (0.6 in) 5.75 mm (0.23 in) 1 mm (0.04 in) 15.75 mm (0.62 in) 5.75 mm (0.23 in) 1 Spacer 60 N·m (6.0 kgf-m, 43.5 lbf-ft) 2 Washer 60 N·m (6.0 kgf-m, 43.5 lbf-ft) 3 Dust seal...

  • Page 30: Wiring Harness Routing

    LT-R450/ZK9 (’09-MODEL) 29 WIRING HARNESS ROUTING Handlebar switch (L) Clutch lever position switch Clamp Clamp Handlebar switch (L) Meter panel indicator light Headlight Clamp Wiring harness Clamp Starter cable Clamp Brake light/Taillight Clamp Wiring harness Wiring harness Generator Gear position switch Ignition switch Clamp...
  • Page 31 30 LT-R450/ZK9 (’09-MODEL) Wiring harness Set the ignition coil coupler to the downside of the hose. Clamp Hose Fuel level switch Clamp Clamp Cooling Clamp Clamp fan relay Clamp IAP sensor Install the spark plug Clamp cap firmly. Engine mounting upper bracket Install the wiring harness to the clamp.

  • Page 32: Oil Hose Routing

    LT-R450/ZK9 (’09-MODEL) 31 OIL HOSE ROUTING OIL HOSE (4 places) Install the oil tank cushion to the both sides of the 6 Breather hose oil tank. 1 Oil level gauge 7 Breather hose 2 Oil return tank 8 Oil hose (R) 3 Oil tank 9 Oil hose (L) 4 Breather hose...

  • Page 33: Front Brake Hose Routing

    32 LT-R450/ZK9 (’09-MODEL) FRONT BRAKE HOSE ROUTING FRONT RIGHT BRAKE HOSE LEFT BRAKE HOSE Fit the brake hose with brake hose sleeve shape *1 The black paint is forward. correctly fitted inside clamp. After the under surface of brake pipe joint has After the brake hose union has contacted the contacted the end face of hose bracket of frame, under surface of master cylinder, tighten the...

  • Page 34: Throttle Body Installation

    LT-R450/ZK9 (’09-MODEL) 33 THROTTLE BODY INSTALLATION 1.8 N·m (0.18 kgf-m, 1.3 lbf-ft) UPPER UPPER LOWER LOWER OUTLET TUBE INTAKE PIPE 12 N·m (1.2 kgf-m, 8.5 lbf-ft) 4.5 N·m (0.45 kgf-m, 3.3 lbf-ft) 4 Fuel feed hose No.2 *1 Face the clamp ends right side. *2 Pass the fuel vapor return hose through left side of the wiring harness.

  • Page 35: Brake Pedal Installation

    34 LT-R450/ZK9 (’09-MODEL) BRAKE PEDAL INSTALLATION 5.8 mm (0.22 in) 5.8 mm (0.22 in) 11.3 mm (0.45 in) 11.3 mm (0.45 in) 5 mm (0.2 in) 125.8 mm (4.95 in) 1 Cotter pin 4 Brake pedal spring 2 Brake pedal pivot bolt 5 Brake pedal 3 Rear brake switch...

  • Page 36: Handlebar Installation

    LT-R450/ZK9 (’09-MODEL) 35 HANDLEBAR INSTALLATION Align the edge of master cylinder holder with *1 Align the “ ” mark on the right grip with mark. punch mark on handlebars. Align the edge of throttle case upper with punch Align the matching surface of clutch lever holder mark on handlebars.

  • Page 37: Tightening Torque

    36 LT-R450/ZK9 (’09-MODEL) TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lbf-ft Engine mounting bolt (Lower) 54.0 CHASSIS ITEM N·m kgf-m lbf-ft Steering knuckle end nut (Upper & Lower) 21.0 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. —...
  • Page 38 LT-R450/ZK9 (’09-MODEL) 37 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 32.890 – 32.930 32.590 (1.2949 – 1.2965) (1.2831) 33.451 – 33.491 33.151 (1.3170 – 1.3185) (1.3052) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 39 38 LT-R450/ZK9 (’09-MODEL) ITEM STANDARD LIMIT Piston ring thickness 0.71 – 0.76 — (0.0280 – 0.0299) 1.08 – 1.10 — (0.0425 – 0.0433) 0.97 – 0.99 — (0.0382 – 0.0390) Piston pin bore 19.002 – 19.008 19.030 (0.7481 – 0.7483) (0.7492) Piston pin O.D.
  • Page 40 LT-R450/ZK9 (’09-MODEL) 39 DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.851 (77/27) — Final reduction ratio 2.571 (36/14) — Gear ratios 2.076 (27/13) — 1.647 (28/17) — 1.333 (28/21) — 1.095 (23/21) —...
  • Page 41 40 LT-R450/ZK9 (’09-MODEL) INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE 9 – 17 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount Approx. 83 ml (2.8/ 2.9 US/lmp oz) and more/10 sec. Fuel pressure regulator operating Approx.
  • Page 42 LT-R450/ZK9 (’09-MODEL) 41 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug Type NGK: CR8EB 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 155 – 232 Ω CKP sensor resistance CKP sensor peak voltage 0.5 V and more When cranking Ignition coil resistance...
  • Page 43 42 LT-R450/ZK9 (’09-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD/SPECIFICATION LIMIT Rear brake pedal height 0 – 10 — (0 – 0.4) Brake caliper cylinder bore 25.40 – 25.45 Front — (1.0000 – 1.0020) 33.96 – 34.01 Rear — (1.3370 –...

  • Page 44: Tire Pressure

    LT-R450/ZK9 (’09-MODEL) 43 TIRE PRESSURE COLD INFLATION kgf/cm TIRE PRESSURE FRONT 0.45 REAR 0.45 VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs) SUSPENSION ITEM STANDARD/SPECIFICATION LIMIT Front shock absorber spring pre- — set length (9.7) Front shock absorber damping Rebound * 1-3/4 turns out from stiffest position —...

  • Page 45: Wiring Diagram

    WIRING DIAGRAM Wiring diagram wire color, refer to LT-R450 service manual section “WIRE COLOR”.
  • Page 46 Prepared by October, 2008 Part No. 99501-44030-01E Printed in Japan...

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