Suzuki QuadRacer LT-R450 Manuals

Manuals and User Guides for Suzuki QuadRacer LT-R450. We have 2 Suzuki QuadRacer LT-R450 manuals available for free PDF download: Service Manual, Installation Instructions

Suzuki QuadRacer LT-R450 Service Manual

Suzuki QuadRacer LT-R450 Service Manual (444 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 45 MB

Table of Contents

General Information 1

9
- Table of Contents
  9
- Warning/Caution/Note
  10
- General Precautions
  10
- Suzuki Lt-R450K6 ('06-Model)
  12
- Serial Number Location
  12
- Fuel, Oil and Engine Coolant Recommendation
  13
  - Fuel (for Usa and Canada)
    13
  - Fuel (for Other Countries)
    13
  - Engine Oil (for Usa)
    13
  - Engine Oil (for Other Countries)
    13
  - Brake Fluid
    13
  - Engine Coolant
    14
- Break-In Procedures
  14
- Information Labels
  15
- Specifications
  16
  - Dimensions and Dry Mass
    16
  - Engine
    16
  - Drive Train
    16
  - Chassis
    17
  - Electrical
    17
  - Capacities
    17
Periodic Maintenance

18
- Periodic Maintenance Schedule
  19
  - Periodic Maintenance Chart
    19
- Maintenance and Tune-Up Procedures
  20
  - Air Cleaner
    20
  - Exhaust Pipe Nuts and Muffler Bolts
    21
  - Valve Clearance
    22
  - Spark Plug
    27
  - Fuel Line
    28
  - Fuel Filter
    28
  - Throttle Cable Play
    28
  - Engine Idle Speed
    29
  - Throttle Body
    29
  - Engine Oil and Oil Filter
    29
  - Engine Oil Hose
    31
  - Engine Coolant
    32
  - Radiator
    33
  - Radiator Hose
    33
  - Spark Arrester
    34
  - Clutch Cable Play
    35
  - Brakes
    35
  - Brake Fluid
    38
  - Brake Hose
    40
  - Tires
    40
  - Steering
    41
  - Drive Chain
    42
  - Suspensions
    45
  - Front and Rear Wheel Set Nuts
    45
  - Rear Axle Nut and Lock-Nut
    46
  - Chassis Bolts and Nuts
    47
  - General Lubrication
    50
- Compression Pressure Check
  51
  - Compression Test Procedure
    51
- Oil Pressure Check
  52
  - Oil Pressure Test Procedure
    52
- Sds Check
  53
Engine

56
- Engine Components Removable with Engine in Place
  57
  - Engine Left Side
    57
  - Engine Right Side
    57
  - Engine Center
    57
- Engine Removal and Remounting
  58
  - Engine Removal
    58
  - Engine Installation
    63
- Engine Disassembly
  66
- Engine Components Inspection and Service
  79
  - Cylinder Head
    79
  - Automatic Decomp
    88
  - Camshaft
    88
  - Cam Chain Tension Adjuster and Tensioner
    91
  - Cylinder
    91
  - Piston and Piston Ring
    92
  - Conrod
    94
  - Crankshaft
    95
  - Balancer Shaft and Balancer Driven and Drive Gear
    96
  - Starter Clutch
    96
  - Generator
    98
  - Starter Torque Limiter
    98
  - Oil Pump
    99
  - Clutch
    100
  - Gearshift Fork and Gear
    102
  - Transmission
    103
  - Oil Strainer
    106
  - Crankcase
    106
  - Right Crankcase Cover
    111
  - Gearshift Shaft
    112
- Engine Reassembly
  113
Fi System Diagnosis

135
- Precautions in Servicing
  137
  - Electrical Parts
    137
  - Fuse
    138
  - Ecm/Various Sensors
    138
  - Electrical Circuit Inspection Procedure
    140
  - Using the Multi-Circuit Tester
    143
- Fi System Technical Features
  144
  - Injection Time (Injection Volume)
    144
  - Compensation of Injection Time (Volume)
    145
  - Injection Stop Control
    145
  - Fi System Parts Location
    146
  - Fi System Wiring Diagram
    148
- Ecm Terminal
  149
- Self-Diagnosis Function
  150
  - User Mode
    150
  - Dealer Mode
    151
  - Diagnostic Trouble Code Table
    152
  - Tps Adjustment
    153
- Fail-Safe Function
  154
- Fi System Troubleshooting
  155
- Sensors
  194
  - Ckp Sensor Inspection
    194
  - Ckp Sensor Removal and Installation
    194
  - Iap Sensor Inspection
    194
  - Iap Sensor Removal and Installation
    194
  - Tp Sensor Inspection
    194
  - Tp Sensor Removal and Installation
    194
  - Tps Adjustment
    194
  - Ect Sensor Inspection
    194
  - Ect Sensor Removal and Installation
    194
  - Iat Sensor Inspection
    195
  - Iat Sensor Removal and Installation
    195
  - To Sensor Inspection
    195
  - To Sensor Removal and Installation
    195
Fuel System and Throttle Body

196
- Fuel Delivery System
  197
- Fuel System
  198
  - Fuel Tank Removal
    198
  - Fuel Tank Installation
    199
  - Fuel Pressure Inspection
    200
  - Fuel Pump Removal
    201
  - Fuel Pump Installation
    201
  - Fuel Pump Inspection
    201
  - Fuel Discharge Amount Inspection
    202
  - Fuel Pump Relay Inspection
    203
  - Fuel Valve/Fuel Filter
    204
  - Fuel Pressure Regulator
    206
- Throttle Body
  207
  - Construction
    207
  - Removal
    208
  - Disassembly
    209
  - Cleaning
    211
  - Inspection
    211
  - Reassembly
    211
  - Installation
    213
  - Fuel Injector Removal
    213
  - Fuel Injector Inspection
    213
  - Fuel Injector Installation
    213
  - Throttle Position Sensor (Tps) Setting
    213
Cooling and Lubrication System

214
- Engine Coolant
  215
- Cooling Circuit
  216
  - Cooling Circuit Inspection
    216
- Radiator and Water Hose
  217
  - Radiator Removal
    217
  - Radiator Cap Inspection
    219
  - Radiator Inspection and Cleaning
    219
  - Radiator Installation
    219
  - Water Hose Inspection
    220
  - Radiator Reservoir Tank
    220
- Cooling Fan
  221
  - Removal
    221
  - Installation
    222
  - Inspection
    222
  - Cooling Fan Relay Inspection
    223
- Ect Sensor
  223
  - Removal
    223
  - Inspection
    223
  - Installation
    224
- Thermostat
  225
  - Removal
    225
  - Inspection
    225
  - Installation
    226
- Water Pump
  227
  - Removal and Disassembly
    227
  - Inspection
    229
  - Reassembly and Installation
    230
- Oil Tank, Oil Return Tank and Hoses
  233
  - Construction
    233
  - Oil Tank
    234
  - Oil Return Tank
    236
- Lubrication System
  237
  - Oil Pressure
    237
  - Oil Filter
    237
  - Oil Strainer
    237
  - Oil Pump
    237
  - Engine Lubrication System Chart
    238
Chassis

239
- Exterior Parts
  241
  - Construction
    241
  - Fastener Removal and Reinstallation
    243
  - Removal
    244
  - Installation
    246
- Front and Rear Wheels
  247
  - Construction
    247
  - Removal
    248
  - Inspection and Disassembly
    249
  - Reassembly and Installation
    250
- Tires
  253
  - Tire Replacement
    253
- Front Brake
  256
  - Construction
    256
  - Brake Pad Replacement
    257
  - Brake Fluid Replacement
    258
  - Brake Caliper Removal and Disassembly
    258
  - Brake Caliper Inspection
    260
  - Brake Caliper Reassembly and Installation
    261
  - Brake Disc Removal and Disassembly
    262
  - Brake Disc Inspection
    262
  - Brake Disc Reassembly and Installation
    263
  - Master Cylinder Removal and Disassembly
    263
  - Master Cylinder Inspection
    264
  - Master Cylinder Reassembly and Installation
    265
- Front Suspension
  267
  - Construction
    267
  - Removal
    268
  - Inspection and Disassembly
    269
  - Reassembly and Installation
    273
  - Front Shock Absorber Disposal
    276
  - Suspension Setting
    276
- Handlebars
  278
  - Construction
    278
  - Removal
    279
  - Inspection
    279
  - Installation
    280
- Steering
  282
  - Construction
    282
  - Removal
    283
  - Inspection and Disassembly
    285
  - Reassembly and Installation
    287
  - Toe Adjustment
    290
- Rear Brake
  292
  - Construction
    292
  - Brake Pad Replacement
    293
  - Brake Fluid Replacement
    294
  - Brake Caliper Removal and Disassembly
    295
  - Brake Caliper Inspection
    297
  - Brake Caliper Reassembly and Installation
    298
  - Brake Disc Removal and Installation
    301
  - Brake Disc Inspection
    301
  - Master Cylinder Removal and Disassembly
    302
  - Master Cylinder Inspection
    303
  - Master Cylinder Reassembly and Installation
    303
- Brake Pedal
  305
  - Removal
    305
  - Installation
    305
- Rear Shock Absorber
  306
  - Construction
    306
  - Removal
    306
  - Inspection and Disassembly
    307
  - Reassembly and Installation
    309
  - Rear Shock Absorber Disposal
    310
  - Suspension Setting
    311
- Cushion Rod and Cushion Lever
  313
  - Construction
    313
  - Removal
    314
  - Inspection and Disassembly
    314
  - Reassembly and Installation
    318
- Cushion Rod, Cushion Lever and Rear Shock Absorber Information
  320
- Swingarm
  321
  - Construction
    321
  - Removal
    322
  - Inspection and Disassembly
    324
  - Reassembly
    327
  - Installation
    328
- Rear Axle
  329
  - Construction
    329
  - Removal
    330
  - Inspection and Disassembly
    332
  - Reassembly and Installation
    334
- Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm and Rear Axle Reassembling Information
  340
- Drive Chain
  341
  - Drive Chain Cutting
    341
  - Drive Chain Connecting
    342
- Drive Chain Control Roller
  345
  - Construction
    345
  - Removal
    345
  - Inspection
    345
  - Installation
    346
Electrical System

347
- Cautions in Servicing
  348
  - Connector
    348
  - Coupler
    348
  - Clamp
    348
  - Fuse
    348
  - Semi-Conductor Equipped Part
    349
  - Battery
    349
  - Connecting the Battery
    349
  - Wiring Procedure
    349
  - Using the Multi-Circuit Tester
    350
- Location of Electrical Components
  351
- Charging System
  353
  - Troubleshooting
    353
  - Inspection
    354
- Starter System and Side-Stand/Ignition Interlock System
  357
  - Troubleshooting
    357
  - Starter Motor Removal
    358
  - Starter Motor Disassembly
    359
  - Starter Motor Inspection
    359
  - Starter Motor Reassembly
    360
  - Starter Relay Inspection
    361
- Ignition System
  363
  - Troubleshooting
    363
  - Inspection
    365
- Indicator Light
  368
  - Inspection
    369
- Lamps
  372
  - Headlight, Brake Light/Taillight
    372
- Relays
  373
  - Starter Relay
    373
  - Fuel Pump Relay
    373
  - Cooling Fan Relay
    373
  - Switches Inspection
    374
- Battery
  375
  - Specifications
    375
  - Initial Charging
    375
  - Servicing
    377
  - Recharging Operation
    377
Servicing Information

378
- Troubleshooting
  379
  - Fi System Malfunction Code and Defective Condition
    379
  - Engine
    381
  - Radiator (Cooling System)
    387
  - Chassis
    387
  - Brakes
    389
  - Electrical
    390
  - Battery
    391
- Wiring Harness, Cable and Hose Routing
  392
  - Wiring Harness Routing
    392
  - Cable Routing
    395
  - Fuel System Hose Routing
    396
  - Cooling System Hose Routing
    397
  - Oil Hose Routing
    398
  - Front Brake Hose Routing
    399
  - Rear Brake Hose Routing
    400
  - Throttle Body Installation
    401
  - Fuel Tank Installation
    402
  - Brake Pedal Installation
    403
  - FRONT SIDE REFLEX REFLECTOR INSTALLATION (for E-28)
    404
  - BRAKE LIGHT/TAILLIGHT INSTALLATION (for Others)
    405
  - BRAKE LIGHT/TAILLIGHT INSTALLATION (for E-28)
    406
  - Drive Chain Roller Installation
    407
- Special Tools
  408
- Tightening Torque
  411
  - Engine
    411
  - Fi System and Intake Air System
    412
  - Cooling System
    412
  - Chassis
    413
  - Tightening Torque Chart
    414
- Service Data
  415

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Suzuki QuadRacer LT-R450 Installation Instructions

Suzuki QuadRacer LT-R450 Installation Instructions (2 pages)

FUEL INJECTION MANAGEMENT SYSTEM

Brand: Suzuki | Category: Motorcycle Accessories | Size: 0 MB

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