lt-r450/zk9 (`09

Transcription

lt-r450/zk9 (`09

LT-R450/ZK9 (’09-MODEL) 1
LT-R450/ZK9 (’09-MODEL)
This chapter describes specifications, service data and servicing procedures which differ from
those of the LT-R450/ZK8 (’08-MODEL).
NOTE:
• Any differences between the LT-R450/ZK8 (’08-MODEL) and LT-R450/ZK9 (’09-MODEL)
in specifications and service data are indicated with an asterisk mark (*).
• Please refer to the LT-R450K8 (’08-MODEL) service manual for details which are not
given in this manual.
CONTENTS
SPECIFICATIONS ..............................................................................................
MAINTENANCE AND TUNE-UP PROCEDURES .............................................
BRAKES....................................................................................................
OIL JET...............................................................................................................
REMOVAL .................................................................................................
INSPECTION AND CLEANING ................................................................
INSTALLATION.........................................................................................
ENGINE LUBRICATION SYSTEM CHART .......................................................
FI SYSTEM DIAGNOSIS ....................................................................................
FI SYSTEM WIRING DIAGRAM ...............................................................
ECM TERMINAL .......................................................................................
DTC TABLE AND DEFECTIVE CONDITION ...........................................
FI SYSTEM TROUBLESHOOTING ..........................................................
COOLING FAN RELAY.............................................................................
SENSOR .............................................................................................................
IAP SENSOR INSPECTION......................................................................
IAP SENSOR REMOVAL AND INSTALLATION......................................
THROTTLE BODY..............................................................................................
CONSTRUCTION ......................................................................................
REMOVAL .................................................................................................
FRONT SUSPENSION CONSTRUCTION .........................................................
SWINGARM CONSTRUCTION ..........................................................................
BRAKE PEDAL ..................................................................................................
REMOVAL .................................................................................................
INSTALLATION.........................................................................................
REAR SHOCK ABSORBER ..............................................................................
REMOVAL .................................................................................................
© COPYRIGHT SUZUKI MOTOR CORPORATION 2008
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2 LT-R450/ZK9 (’09-MODEL)
CONTENTS
CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER
INFORMATION ..................................................................................................
WIRING HARNESS ROUTING ..........................................................................
OIL HOSE ROUTING.........................................................................................
FRONT BRAKE HOSE ROUTING.....................................................................
THROTTLE BODY INSTALLATION..................................................................
BRAKE PEDAL INSTALLATION ......................................................................
HANDLEBAR INSTALLATION .........................................................................
TIGHTENING TORQUE .....................................................................................
SERVICE DATA.................................................................................................
WIRING DIAGRAM ............................................................................................
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45
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
MODEL
LT-R450/Z
CODE
E-19
E-28
E-33
COUNTRY or AREA
E.U.
Canada
California (U.S.A.)
EFFECTIVE FRAME NO.
JSAAL43A 92100001 –
JSAAL43A 92100001 –
JSAAL43A 92100001 –
SPECIFICATIONS
DIMENSIONS AND CURB MASS
Overall length .....................................................................................
Overall width.......................................................................................
Overall height .....................................................................................
Wheelbase .........................................................................................
Front track ..........................................................................................
Rear track ...........................................................................................
Ground clearance ...............................................................................
Seat height .........................................................................................
* Curb mass........................................................................................
1 845 mm (72.6 in)
1 245 mm (49.0 in)
1 085 mm (42.7 in)
1 285 mm (50.6 in)
1 045 mm (41.1 in)
985 mm (38.8 in)
240 mm (9.4 in)
780 mm (30.7 in)
188 kg (414 lbs)
ENGINE
Type ...................................................................................................
Number of cylinders ...........................................................................
Bore ....................................................................................................
Stroke .................................................................................................
Displacement......................................................................................
Compression ratio ..............................................................................
Fuel system ........................................................................................
Air cleaner ..........................................................................................
Starter system ....................................................................................
Lubrication system .............................................................................
Idle speed ...........................................................................................
Four stroke, liquid-cooled, DOHC
1
95.5 mm (3.760 in)
62.8 mm (2.472 in)
450 cm³ (27.5 cu. in)
11.7 : 1
Fuel injection
Polyurethane foam element
Electric
Dry sump
1 800 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................................................
Transmission ......................................................................................
Gearshift pattern.................................................................................
Primary reduction ratio .......................................................................
Gear ratios, Low ................................................................................
2nd .................................................................................
3rd..................................................................................
4th ..................................................................................
Top.................................................................................
Final reduction ratio ............................................................................
Drive chain .........................................................................................
Wet multi-plate type
5-forward
1 down, 4 up (Foot operated)
2.851 (77/27)
2.076 (27/13)
1.647 (28/17)
1.333 (28/21)
1.095 (23/21)
0.913 (21/23)
2.642 (37/14)
RK 520SMOZ10S, 96 Links
CHASSIS
Front suspension ................................................................................
Rear suspension ................................................................................
Front wheel travel ...............................................................................
Rear wheel travel ...............................................................................
Caster .................................................................................................
Trail ....................................................................................................
Toe-in .................................................................................................
Camber...............................................................................................
Steering angle ....................................................................................
Turning radius ....................................................................................
Front brake .........................................................................................
Rear brake..........................................................................................
Front tire size......................................................................................
Rear tire size ......................................................................................
Independent, double wishbone, coil spring, oil damped
Swingarm type, coil spring, oil damped
254 mm (10.0 in)
277 mm (10.9 in)
8.0°
30 mm (1.18 in)
0 mm
–3.0°
41°
3.5 m (11.5 ft)
Disc brake, twin
Disc brake
AT20 × 7 R10, tubeless
AT18 × 10 R8, tubeless
ELECTRICAL
lgnition type ........................................................................................
lgnition timing ..................................................................................... *
Spark plug ..........................................................................................
Battery ................................................................................................
Generator ...........................................................................................
Main fuse ............................................................................................
Fuse ...................................................................................................
Headlight ............................................................................................
Brake light/Taillight .............................................................................
Neutral indicator light..........................................................................
Reverse indicator light ........................................................................
Coolant tempereture indicator light ....................................................
Electronic ignition (CDI)
3° B.T.D.C. at 1 800 r/min
NGK CR8EB
12 V 21.6 kC (6 Ah)/10 HR
Three-phase A.C. generator
20 A
10/10 A
12 V 40/40 W
LED
12 V 3.4 W
12 V 3.4 W
12 V 3.4 W
CAPACITIES
Fuel tank............................................................................................. * 9.0 L (2.4/2.0 US/lmp gal)
Engine oil, oil change......................................................................... Oil tank 1 200 ml (1.3/1.1 US/Imp qt)
Engine 400 ml (0.4/0.4 US/Imp qt)
With filter change ............................................................. Oil tank 1 300 ml (1.4/1.1 US/lmp qt)
Engine 400 ml (0.4/0.4 US/lmp qt)
Overhaul .......................................................................... Oil tank 1 400 ml (1.5/1.2 US/lmp qt)
Engine 400 ml (0.4/0.4 US/lmp qt)
Coolant ...............................................................................................
1.4 L (1.5/1.2 US/lmp qt)
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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 thereafter.
BRAKE PADS
LT-R450K8 2-18
FRONT BRAKE LEVER ADJUSTMENT
Adjust the brake lever position as follows:
• Loosen the lock-nut 1.
• Turn in or out adjuster 2 to obtain the proper brake lever
position.
• The standard adjuster length A is 11 – 15 mm (0.4 – 0.6 in).
• Tighten the lock-nut 1 securely.
 Front brake lever adjuster lock-nut:
5 N·m (0.5 kgf-m, 3.5 lbf-ft)
REAR BRAKE PEDAL AND LEVER
The procedure for adjusting the rear brake pedal and brake
lever is as follows:
NOTE:
First adjust the brake pedal, and then adjust the brake lever.
Brake pedal
• Turn the adjuster 1 in or out until the pedal height A to the
specification, after loosening the lock-nut 2.
• Make sure to tighten the lock-nut 2 securely.
 Brake pedal height A: 0 – 10 mm (0 – 0.4 in)
 Rear brake master cylinder rod lock-nut:
18 N·m (1.8 kgf-m, 13.0 lbf-ft)
• 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
5
6
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.
INSTALLATION
• Apply engine oil to the O-ring 1.

Use a new O-ring to prevent oil leakage.
• Install the piston cooling oil jet 2.
• Apply a small quantity of THREAD LOCK to the piston cooling
oil jet bolt, and then tighten the bolt.
 99000-32110: THREAD LOCK SUPER “1322”
or equivalent
ENGINE LUBRICATION SYSTEM CHART
CAM FACE (IN & EX)
CONROD BIG
END BEARING
CAMSHAFT JOURNAL
(IN & EX)
CRANK PIN
CYLINDER HEAD
RIGHT CRANKSHAFT
PISTON PIN
PISTON
CYLINDER WALL
CYLINDER
CRANKSHAFT
RIGHT END
OIL NOZZLE
RIGHT CRANKCASE
CAM CHAIN
ORIFICE
LEFT CRANKSHAFT
STARTER CLUTCH
K8
OIL FILTER
BY-PASS
OIL JET
OIL PUMP (NO. 1)
K9
OIL HOSE
COUNTER GEARS
OIL TANK
SPACER
DRIVESHAFT
COUNTERSHAFT
DRIVE GEARS
LEFT CRANKCASE
GENERATOR COVER
OIL PUMP (NO. 2)
OIL PUMP (FOR RETURN)
OIL STRAINER (REAR)
OIL STRAINER (FRONT)
CLUTCH
OIL PAN
OIL HOSE
7
Tip-over sensor (TOS)
Intake air temperature
sensor (IATS)
Engine coolant
temperature sensor
(ECTS)
Intake air pressure
sensor (IAPS)
Throttle position sensor
(TPS)
Crankshaft position sensor
(CKPS)
Br/W
Dg
B/Bl
B/Br
G/B
R
Y
G/W
Bl
Fuel
pump
relay
W/Bl
P
B/W
B/W
B/W
3
5
N
Fuel indicator
light
FI light
2
1
to fuel
sensor
Ignition coil (IG COIL)
Gear
position 4
switch
Bl/B
B
Y/B
G/R
Fuel injector (FI)
Fuel
pump
O/W
O/G
O/W
Gr/W
Y/B
Neutral
indicator
light
Engine
stop
switch
Cooling fan relay
M
20A
10A
Clutch lever position
switch
Ignition
switch
Starter motor
Starter relay
Starter
switch
10A
Cooling fan
Battery
8
FI SYSTEM DIAGNOSIS
FI SYSTEM WIRING DIAGRAM
ECM TERMINAL
TERMINAL
NO.
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
CIRCUIT
Power source
TO sensor signal (TOS)
CKP sensor signal (CKP+)
GP switch signal (GP)
TP sensor signal (TP)
IAP sensor signal (IAP)
—
ECM ground (E1)
CKP sensor signal (CKP–)
Serial data for self-diagnosis
—
Neutral switch (NT)
Power source for sensors (VCC)
Fuel pump power source (FPP)
Fuel pump (FP)
Injector (#11)
Fuel indicator
Ignition coil
TERMINAL
NO.
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
CIRCUIT
—
—
FI/ECT indicator
ECT sensor signal (ECT)
—
Sensors ground (E2)
IAT sensor signal (IAT)
—
—
—
Mode select switch
Starter motor (STA)
—
—
Cooling fan relay (FAR)
—
Ground (E01)
Ground (E02)
9
10
DTC TABLE AND DEFECTIVE CONDITION
DETECTED
DETECTED FAILURE CONDITION
ITEM
CKP sensor The signal does not reach ECM for 1
sec. or more, after receiving the IAP
sensor input signal.
DTC No.
C12
P0335
TP sensor
C14
H
P0120
L
ECT sensor
C15
H
P0115
L
IAP sensor
C17
H
P0105
L
IAT sensor
C21
H
P0110
L
The sensor should produce following
voltage.
0.4 V
sensor voltage < 4.5 V
In other than the above range, C14
(P0120) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.
The sensor voltage should be the following.
0.2 V
value.
value.
The sensor should produce following
voltage.
0.2 V
value.
value.
The sensor voltage should be the following.
0.2 V
value.
value.
CHECK FOR
CKP sensor wiring and mechanical parts
CKP sensor, lead wire/coupler
connection
TP sensor, lead wire/coupler
connection
TP sensor circuit shorted to
VCC or ground circuit open
TP sensor circuit open or
shorted to ground or VCC circuit
open
ECT sensor, lead wire/coupler
connection
ECT sensor circuit open or
ground circuit open
ECT sensor circuit shorted to
ground
IAP sensor, lead wire/coupler
connection
IAP sensor circuit shorted to
IAP sensor circuit open or
open
IAT sensor, lead wire/coupler
connection
IAT sensor circuit open or
ground circuit open
IAT sensor circuit shorted to
ground
DTC No.
C23
H
P1651
L
C24
DETECTED
DETECTED FAILURE CONDITION
ITEM
TO sensor
The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.
0.2 V
In other than the above value, C23
value.
value.
Ignition signal
P0351
C31
Gear position signal
P0705
Fuel injector
C32
P0201
C41
Fuel pump
relay
P0230
C60
P0480
Cooling fan
relay
11
CHECK FOR
TO sensor, lead wire/coupler
connection
TO sensor circuit shorted to
TO sensor circuit open or
open
CKP sensor (pick-up coil) signal is pro- Ignition coil, wiring/coupler connection, power supply from the
duced, but signal from ignition coil is
battery
interrupted 5 times or more continuously. In this case, the code C24
Gear position signal voltage should be
higher than the following for 3 seconds
and more.
Gear position switch voltage
0.9 V
If lower than the above value, C31
CKP sensor (pickup coil) signal is produced, but fuel injector signal is interrupted 8 times or more continuously. In
this case, the code C32 (P0201) is
indicated.
GP switch, wiring/coupler connection, gearshift cam, etc.
Fuel injector, wiring/coupler connection, power supply to the
injector
No voltage is applied to the fuel pump, Fuel pump relay, lead wire/coualthough fuel pump relay is turned ON. pler connection, power source to
the fuel pump relay and fuel
NOTE:
The FP relay is incorporated in the injector
ECM.
Cooling fan relay signal is not input to
ECM.
Cooling fan relay, lead wire/coupler connection
12
FI SYSTEM TROUBLESHOOTING
“C17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION
C17
P0105
DETECTED CONDITION
IAP sensor voltage is not within the following range.
0.2 V
Sensor voltage < 4.1 V
NOTE:
* Note that atmospheric pressure varies
depending on weather conditions as
well as altitude.
* Take that into consideration when
inspecting voltage.
H
value.
L
value.
•
•
•
•
•
POSSIBLE CAUSE
Clogged vacuum passage between throttle body
and IAP sensor.
Air being drawn from vacuum passage between
throttle body and IAP sensor.
IAP sensor circuit open or shorted to ground.
IAP sensor malfunction.
ECM malfunction.
• IAP sensor circuit shorted to VCC or ground circuit open.
• IAP sensor circuit open or shorted to ground or
VCC circuit open.
ECM
IAP sensor
B/Br
E2
G/B
IAP
R
VCC
INSPECTION
Step 1 (When indicating C17:)
1) Turn the ignition switch OFF.
2) Remove the engine mounting left upper bracket 1 by removing the bolts 2 and washers 3. (LT-R450K8 3-6)
1
3) Check the IAP sensor coupler for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
1
4)
5)
6)
7)
1
Disconnect the IAP sensor coupler.
Turn the ignition switch ON.
Measure the voltage at the Red wire and ground.
If OK, then measure the voltage at the Red wire and B/Br
wire.
V
 IAP sensor input voltage: 4.5 – 5.5 V
(+ Red – - Ground)
(+ Red – - B/Br)
 09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
 Tester knob indication: Voltage ()
Is the voltage OK?
YES
NO
Go to Step 2.
• Loose or poor contacts on the ECM coupler
(terminal C or N).
• Open or short circuit in the Red wire or B/Br
wire.
Step 1 (When indicating P0105-H:)
If OK, then check the IAP sensor lead wire continuity.
1
4) Disconnect the IAP sensor coupler.
5) Check the continuity between Red wire A and G/B wire B.
If the sound is not heard from the tester, the circuit condition
is OK.
1
13
14
6)
7)
8)
9)
Remove the front fender. (LT-R450K8 7-6)
Disconnect the ECM coupler.
Check the continuity between G/B wire B and terminal 6.
If OK, then check the continuity between B/Br wire C and terminal N.
1
 IAPS lead wire continuity: Continuity ()
ECM coupler (Harness side)
 Tester knob indication: Continuity test ()

When using the multi-circuit tester, do not strongly
touch the terminal of the ECM coupler with a needle
pointed tester probe to prevent the terminal damage
or terminal bend.
Is the continuity OK?
YES
NO
Go to Step 2.
G/B wire shorted to VCC, or B/Br wire open.
10)After repairing the trouble, clear the DTC using SDS tool.
(LT-R450K8 4-25)
Step 1 (When indicating P0105-L:)
If OK, then check the IAP sensor lead wire continuity.
1
4) Disconnect the IAP sensor coupler.
5) Check the continuity between G/B wire B and ground.
6) Also, check the continuity between G/B wire B and B/Br wire
C. If the sound is not heard from the tester, the circuit condition is OK.
1
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
6.
1
 IAPS lead wire continuity: Continuity ()
 Tester knob indication: Continuity test ()

or terminal bend.
Is the continuity OK?
YES
NO
Go to Step 1 (Page 12) and go to Step 2.
Red wire or G/B wire open, or G/B wire shorted to
ground
11)After repairing the trouble, clear the DTC using SDS tool.
(LT-R450K8 4-25)
Step 2
1) Connect the IAP sensor coupler and ECM coupler.
2) Insert the needle pointed probes to the lead wire coupler.
3) Start the engine at idle speed and measure the IAP sensor
output voltage at the wire side coupler (between G/B and B/
Br wires).
 IAP sensor output voltage: Approx. 2.1 V at idle speed
(+ G/B – - B/Br)
Is the voltage OK?
YES
NO
Go to Step 3.
• Open or short circuit in the G/B wire
• If wire is OK, replace the IAP sensor with a new
one.
4) After repairing the trouble, clear the DTC using SDS tool.
(LT-R450K8 4-25)
2
V
15
16
Step 3
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 – 5.0 V) and connect - terminal to the ground terminal 2 and + terminal to the VCC terminal 3.
4) Check the voltage between Vout 4 and ground. Also, check
if voltage reduces when vacuum is applied up to 53 kPa (400
mmHg) by using vacuum pump gauge. (Page 17)
3
V
 09917-47011: Vacuum pump gauge
09900-25008: Multi-circuit tester set
Is the voltage OK?
YES
NO
• G/B, Red or B/Br wire open or shorted to
ground, or poor 6, C or N connection
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
If check result is not satisfactory, replace the IAP
sensor with a new one.

or terminal bend.
(LT-R450K8 4-25)
3
Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 –
30 °C, 68 – 86 °F)
ALTITUDE
(Reference)
(ft)
(m)
0
0
ATMOSPHERIC
PRESSURE
(mmHg)
kPa
760
100
OUTPUT
VOLTAGE
(V)
3.1 – 3.6
2 000
2 001
610
611
707
707
94
94
5 000
5 001
1 524
1 525
634
634
85
85
2.8 – 3.4
2.6 – 3.1
8 000
8 001
2 438
2 439
567
567
76
76
2.4 – 2.9
10 000
3 048
526
70
17
18
“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.
INSPECTION
Step 1 (When indicating C41:)
2) Remove the front fender. (LT-R450K8 7-6)
3) Check the ECM coupler for loose or poor contacts.
If OK, then check the FP relay input voltage.
1
4) Disconnect the ECM coupler.
5) Insert the needle pointed probe to the ECM coupler.
6) Measure the voltage between terminal D and ground.
1
 FP relay input voltage: Battery voltage
V
Is the voltage OK?
YES
NO
• FP relay (ECM) malfunction.
• O/W or O/G wire open or shorted, or poor terminal D or E connection.
• If wire and connection are OK, intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for
open circuit and poor connection.
• Replace the ECM with a known good one, and
inspect it again.
Open or short circuit in the O/W wire.

or terminal bend.
(LT-R450K8 4-25)
1
19
20
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” 2.
At this time, if an operation sound is heard from the cooling
fan relay and cooling fan motor is operated, the function is
normal.
NOTE:
Cooling fan relay and cooling fan motor operation can be
checked until the engine coolant temperature is less than 90 °C
(194 °F) after starting the engine.
5) Click “Stop” 3 to check the operation properly.
SENSOR
IAP SENSOR INSPECTION
The intake air pressure sensor is installed at the top side of the
throttle body. (Page 12)
IAP SENSOR REMOVAL AND INSTALLATION
• Remove the fuel tank and fuel tank lower cover.
(LT-R450K8 5-4)
• Disconnect the IAP sensor coupler 1.
• Remove the plate 2, IAP sensor 3 and O-ring 4.
• Install the IAP sensor in the reverse order of removal.

Replace the O-ring 4 with a new one.
21
THROTTLE BODY
CONSTRUCTION
1
2
3
4
5
6
TP sensor
Throttle body
Fuel delivery pipe
O-ring
Fuel injector
Injector seal
7
8
9
A
B
C
Starter valve
Throttle cable cover
IAP sensor
Fuel delivery pipe mounting screw
Fuel injector mounting screw
TP sensor mounting screw

ITEM
A
B
C
N·m
3.5
3.5
3.5
kgf-m lbf-ft
0.35
2.5
0.35
2.5
0.35
2.5
22
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.
• Remove the throttle cable cover 5.
• Disconnect the throttle cable from drum.

After disconnecting the throttle cables, do not snap
the throttle valve from full open to full close. It may
cause damage to the throttle valve and throttle body.
• Loosen the throttle body clamp screws and move the throttle
body assembly upward.
• Disconnect the starter cable from the throttle body assembly.
• 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)
23
24
FRONT SUSPENSION CONSTRUCTION
1
1
2
3
4
5
6
7
8
9
0
A
Front shock absorber
Collar
Dust seal
Bearing
Collar
Upper wishbone arm
Dust seal
Collar
Bearing
Washer
Spring washer
B
C
D
E
F
G
A
B
C
D
E
Lower wishbone arm
Steering knuckle
Spring washer
Cotter pin
Tie rod
Tie rod end
Shock absorber mounting nut
Wishbone arm pivot nut
Knuckle end nut
Tie rod end nut
Tie rod lock-nut
1
Spring washer A eliminated
as K9 model

ITEM
A
B
C
D
E
N·m
60
65
29
29
29
kgf-m
6.0
6.5
2.9
2.9
2.9
lbf-ft
43.5
47.0
21.0
21.0
21.0
SWINGARM CONSTRUCTION
1
2
3
4
5
6
7
8
Swingarm
Rear brake disc cover
Chain guide
Chain guide plate
Sprocket guard
Chain adjuster rubber seal
Chain buffer
Inner spacer
9
0
A
B
C
D
A
B
Inner dust seal
Bearing
Outer spacer
Thrust bearing
Thrust washer
Outer dust seal
Rear axle housing set nut
Swingarm pivot nut

ITEM
A
B
N·m
28
95
kgf-m
2.8
9.5
lbf-ft
20.0
68.5
25
26
BRAKE PEDAL
REMOVAL
• Remove the brake pedal cover 1 and clip 2.
• Remove the cotter pin 3 and washer 4.
• Remove the master cylinder rod pin 5.
• Remove the brake pedal pivot bolt 6.
• Remove the return spring 7 and brake pedal 8.
INSTALLATION
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.
 Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lbf-ft)
• Install the return spring 2 properly. (Page 34)
• Install cotter pins and clip.

Replace the removed cotter pin with a new one.
• Adjust the brake pedal height. (Page 4)
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.
• Remove the rear shock absorber.
INSTALLATION
(LT-R450K8 7-71)
27
28
CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER
INFORMATION
(a)
(b)
4 mm (0.6 in)
(c)
5.75 mm (0.23 in)
1 mm (0.04 in)
15.75 mm (0.62 in)
(d)
(e)
5.75 mm (0.23 in)
(a)
60 N·m (6.0 kgf-m, 43.5 lbf-ft)
1
Spacer
(b)
60 N·m (6.0 kgf-m, 43.5 lbf-ft)
2
Washer
(c)
78 N·m (7.8 kgf-m, 56.5 lbf-ft)
3
Dust seal
(d)
78 N·m (7.8 kgf-m, 56.5 lbf-ft)
(e)
78 N·m (7.8 kgf-m, 56.5 lbf-ft)
WIRING HARNESS ROUTING
Handlebar switch (L)
Clutch lever position switch
Clamp
Clamp
Handlebar switch (L)
Meter panel indicator light
Headlight
Clamp
Wiring harness
Starter cable
Clamp
Clamp
Brake light/Taillight
Clamp
Wiring harness
Wiring harness
Generator
Gear position switch
Ignition
switch
Clamp
Wiring harness
Starter lead wire
29
30
Wiring harness
Set the ignition coil coupler to the
downside of the hose.
Clamp
Hose
Fuel level
switch
Clamp
Clamp
Cooling
fan relay
Clamp
Clamp
Clamp
IAP sensor
Engine mounting
upper bracket
Install the
spark plug
cap firmly.
Clamp
Install the wiring harness
to the clamp.
Ignition coil
Clamp
Wiring harness
Clamp
Rear brake switch lead wire
Rear brake switch
Clamp
Rear brake switch lead wire
OIL HOSE ROUTING
*1
K8
OIL HOSE (4 places)
K9
*1
1
2
3
4
5
Install the oil tank cushion to the both sides of the
oil tank.
Oil level gauge
Oil return tank
Oil tank
Breather hose
Oil tank over-flow hose
6 Breather hose
7
8
9
A
Breather hose
Oil hose (R)
Oil hose (L)
Matching mark
31
32
FRONT BRAKE HOSE ROUTING
*1
*5
30
˚
*3
*2
*4
FRONT
RIGHT BRAKE HOSE
21
˚
LEFT BRAKE HOSE
14˚
21˚
21
˚
*6
Fit the brake hose with brake hose sleeve shape
correctly fitted inside clamp.
After the under surface of brake pipe joint has
After the brake hose union has contacted the
*2 contacted the end face of hose bracket of frame, *5 under surface of master cylinder, tighten the
tighten the pipe joint mounting bolt.
union bolt.
After the brake hose union has contacted the
*3 Clamp the brake hose firmly.
*6
stopper, tighten the union bolt.
*1 The black paint is forward.
*4
THROTTLE BODY INSTALLATION
1.8 N·m
(0.18 kgf-m, 1.3 lbf-ft)
*1
UPPER
UPPER
L
R
LOWER
INTAKE PIPE
R
L
LOWER
OUTLET TUBE
*4
12 N·m
(1.2 kgf-m,
8.5 lbf-ft)
*2
4.5 N·m
(0.45 kgf-m,
3.3 lbf-ft)
*3
*1 Face the clamp ends right side.
*2 Pass the fuel vapor return hose through left side of the wiring harness.
Install the fuel feed hose No.2 with the white paint side to the fuel
*3
pump.
*4 Pass the dust guard upward of the wiring harness.
1 IAT sensor
2 Fuel vapor return hose
3 Fuel feed hose No.1
4 Fuel feed hose No.2
5 Intake pipe
6 Throttle body
7
8
9
0
Air cleaner
Dust guard
Fuel pump
Wiring harness
33
34
BRAKE PEDAL INSTALLATION
36.5 mm
(1.44 in)
5.8 mm (0.22 in)
11.3 mm (0.45 in)
5 mm
(0.2 in)
1 Cotter pin
2 Brake pedal pivot bolt
3 Rear brake switch
7 mm (0.3 in)
5 mm (0.2 in)
125.8 mm (4.95 in)
4 Brake pedal spring
5 Brake pedal
35
HANDLEBAR INSTALLATION
*2
*1
*3
*4
*1 Align the “
” mark on the right grip with mark.
Align the edge of throttle case upper with punch
mark on handlebars.
*3 Align the “ ” mark on the left grip with mark.
*2
*5
Align the edge of master cylinder holder with
punch mark on handlebars.
Align the matching surface of clutch lever holder
*5
with mark.
*4
36
TIGHTENING TORQUE
ENGINE
ITEM
Engine mounting bolt (Lower)
N·m
75
kgf-m
7.5
lbf-ft
54.0
N·m
29
kgf-m
2.9
lbf-ft
21.0
CHASSIS
ITEM
Steering knuckle end nut (Upper & Lower)
SERVICE DATA
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
LIMIT
—
—
—
—
—
—
Valve stem deflection
IN. & EX.
—
0.25
(0.010)
Valve guide I.D.
IN. & EX.
—
Valve stem O.D.
IN.
EX.
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN.
—
EX.
—
0.03
(0.001)
34.0
(1.34)
33.3
(1.31)
Valve spring tension
IN.
EX.
119 – 137 N
(11.9 – 13.7 kgf, 26.2 – 30.2 lbs)
at length 30.9 mm (1.22 in)
78.5 N
(7.85 kgf, 17.3 lbs)
at length 30.9 mm (1.22 in)
—
—
—
—
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
Cam chain pin
Cylinder head distortion
Unit: mm (in)
STANDARD
32.890 – 32.930
(1.2949 – 1.2965)
33.451 – 33.491
(1.3170 – 1.3185)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8653)
15th pin
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
—
1st
2nd
R
2nd
Approx. 7.6 (0.30)
Approx. 12.3 (0.48)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
1st
—
2nd
—
1st
Piston ring groove width
1st
2nd
Oil
LIMIT
32.590
(1.2831)
33.151
(1.3052)
0.150
(0.0059)
—
—
—
0.05
(0.002)
Unit: mm (in)
STANDARD
800 kPa
(8.0 kgf/cm2, 114 psi)
0.045 – 0.055
(0.0018 – 0.0022)
95.500 – 95.515
(3.7598 – 3.7604)
95.450 – 95.465
(8.9437 – 3.7585)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion
37
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
LIMIT
—
0.120
(0.0047)
Nicks or
Scratches
95.380
(3.7551)
0.05
(0.002)
—
—
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
—
—
—
—
38
ITEM
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
STANDARD
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.97 – 0.99
(0.0382 – 0.0390)
19.002 – 19.008
(0.7481 – 0.7483)
18.994 – 19.000
(0.7478 – 0.7480)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
LIMIT
—
—
—
19.030
(0.7492)
18.980
(0.7472)
Unit: mm (in)
STANDARD
19.010 – 19.018
(0.7484 – 0.7487)
—
0.30 – 0.65
(0.012 – 0.026)
21.75 – 21.80
(0.8563 – 0.8583)
62.0 ± 0.1
(2.441 ± 0.004)
LIMIT
19.040
(0.7496)
3.0
(0.12)
1.0
(0.04)
—
—
—
0.08
(0.003)
STANDARD
10 kPa (0.1 kgf/cm2, 1.4 psi)
at 3 000 r/min
LIMIT
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
CLUTCH
ITEM
Clutch cable play
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
Clutch spring free length
—
Unit: mm (in)
STANDARD
10 – 15
(0.4 – 0.6)
3.07 – 3.23
(0.120 – 0.127)
13.85 – 13.95
(0.545 – 0.549)
—
53.06
(2.09)
LIMIT
—
2.77
(0.109)
13.35
(0.528)
0.10
(0.004)
50.4
(1.98)
DRIVE TRAIN + DRIVE CHAIN
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Drive chain slack
Gearshift lever height
No.1, No.2
& No.3
No.1, No.2
& No.3
Type
Links
20-pitch
length
STANDARD
2.851 (77/27)
2.571 (36/14)
2.076 (27/13)
1.647 (28/17)
1.333 (28/21)
1.095 (23/21)
0.913 (21/23)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.8 – 4.9
(0.189 – 0.193)
RK 520SMOZ10S
96
—
45 – 55
(1.8 – 2.2)
5 – 10
(0.2 – 0.4)
LIMIT
—
—
—
—
—
—
—
0.5
(0.020)
—
—
—
—
319.4
(12.57)
—
—
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
ECT sensor resistance
Radiator cap valve opening pressure
Cooling fan operating temperature
Engine coolant type
Engine coolant including reserve
39
STANDARD/SPECIFICATION
NOTE
Approx. 76.5 °C (169.7 °F)
—
4.5 mm (0.18 in) and over at 90 °C (194 °F)
20 °C
Approx. 2.6 kΩ
(68 °F)
50 °C
Approx. 0.772 kΩ
(122 °F)
80 °C
Approx. 0.279 kΩ
(176 °F)
110 °C
Approx. 0.118 kΩ
(230 °F)
108 – 137 kPa
(1.08 – 1.37 kgf/cm², 15.4 – 19.5 psi)
OFF → ON
Approx. 98 °C (208 °F)
ON → OFF
Approx. 93 °C (199 °F)
Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Approx. 1 400 ml
(1.5 – 1.2 US/lmp qt)
—
—
—
—
—
—
—
—
—
—
40
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
9 – 17 Ω at 20 °C (68 °F)
Approx. 83 ml (2.8/ 2.9 US/lmp oz)
and more/10 sec.
NOTE
Approx. 294 kPa (2.94 kgf/cm², 41.81 psi)
FI SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor output voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor output voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
SPECIFICATION
155 – 232 Ω
0.5 V and more
4.5 – 5.5 V
* Approx. 2.1 V at idle speed
4.5 – 5.5 V
Approx. 4.5 kΩ
Closed
Approx. 1.4 kΩ
Opened
Approx. 4.2 kΩ
Closed
Approx. 0.6 V
Opened
Approx. 3.8 V
4.5 – 5.5 V
0.2 – 4.9 V
Approx. 2.6 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
0.2 – 4.9 V
Approx. 2.6 kΩ at 20 °C (68 °F)
15.0 – 25.0 kΩ
Normal
0.4 – 1.4V
Leaning
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
* FP relay input voltage
3.7 – 4.4 V
0.9 V and more
Battery voltage
150 V and more
Battery voltage
THROTTLE BODY
ITEM
Bore size
I.D. No.
Idle r/min
Idle air screw
Throttle cable play
SPECIFICATION
43 mm
* 45G1
1 800 ± 100 r/min
* 2-1/4 turns back
3 – 5 mm
(0.12 – 0.20 in)
NOTE
When cranking
When
leaning 65°
From 1st to Top
When cranking
ELECTRICAL
Unit: mm (in)
ITEM
Spark plug
SPECIFICATION
NGK: CR8EB
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
155 – 232 Ω
0.5 V and more
Type
Gap
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When engine is cold)
Starter motor brush length
Regulated voltage
Starter relay resistance
GP switch voltage
Battery
Type
designation
Capacity
Fuse size
Ignition
Fan
Main
Primary
0.1 – 1.0 Ω
Secondary
8 – 15 kΩ
150 V and more
0.1 – 1.5 Ω
Approx. 240 W at 5 000 r/min
NOTE
When cranking
Terminal –
Terminal
Plug cap –
Terminal
When cranking
50 V (AC) and more at 5 000 r/min
Standard
Limit
7.0 (0.28)
3.5 (0.14)
13.5 – 15.0 V at 5 000 r/min
3–6Ω
0.9 V and more (From 1st to Top)
FTX7A-BS
12 V 21.6 kC (6 Ah)/10 HR
10 A
10 A
20 A
WATTAGE
Unit: W
ITEM
Headlight
41
HI
LO
Brake light/Taillight
Fuel indicator light
Neutral indicator light
Engine coolant temp. FI warning
indicator light
SPECIFICATION
40
40
LED
3.4
3.4
3.4
42
BRAKE + WHEEL
Unit: mm (in)
ITEM
Rear brake pedal height
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Brake disc thickness
Front
Rear
Brake disc runout (Front & Rear)
Master cylinder bore
—
Front
Rear
Master cylinder piston diam.
Front
Rear
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim runout
Wheel rim size
Tire size
Tire type
Tire tread depth
Wheel axle runout
0 – 10
(0 – 0.4)
25.40 – 25.45
(1.0000 – 1.0020)
33.96 – 34.01
(1.3370 – 1.3390)
25.318 – 25.368
(0.9968 – 0.9987)
33.878 – 33.928
(1.3338 – 1.3357)
DOT 4
2.8 – 3.2
(0.110 – 0.126)
3.8 – 4.2
(0.150 – 0.165)
12.700 – 12.743
(0.5000 – 0.5017)
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
12.657 – 12.684
(0.4983 – 0.4994)
3.5 m (11.5 ft)
0±4
(0 ± 0.16)
– 3.0°
8.0°
Front
—
Rear
—
Front
Rear
Front
Rear
Front
Rear
10 × 5.5 AT
8 × 8.0 AT
AT20 × 7R10 
AT18 × 10R8 
* DUNLOP: KT382
DUNLOP: KT385
Front
—
Rear
—
Rear
—
LIMIT
—
—
—
—
—
—
2.5
(0.098)
3.5
(0.138)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
6.0
(0.24)
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
45
45
0.45
0.45
6.5
6.5
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
SUSPENSION
ITEM
Front shock absorber spring preset length
Front shock absorber damping
force adjuster
274
(9.7)
Rebound * 1-3/4 turns out from stiffest position
Compression * 3-1/2 turns out from stiffest position
Rear shock absorber spring pre-set
229.75
length
(9.0)
* 11 clicks out from stiffest position
Rear shock absorber damping
Rebound
force adjuster
Compression
9 clicks out from stiffest position
(Low speed)
Compression * 1-1/6 turns out from stiffest position
(High speed)
Front wheel travel
254
(10.0)
Rear wheel travel
277
(10.9)
LIMIT
—
—
—
—
—
—
—
—
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 95 octane or
higher. An unleaded gasoline is recommended.
* 9.0 L (2.4/2.0 US/lmp gal)
SAE 10 W-40, API SF/SG or SH/SJ with JASO MA
1 200 ml
(1.3/1.1 US/lmp qt)
Change
400 ml
(0.4/0.4 US/lmp qt)
1 300 ml
(1.4/1.1 US/lmp qt)
Filter change
400 ml
(0.4/0.4 US/lmp qt)
1 400 ml
(1.5/1.2 US/lmp qt)
Overhaul
400 ml
(0.4/0.4 US/lmp qt)
NOTE
E-28, 33
Others
Oil tank side
Engine side
Oil tank side
Engine side
Oil tank side
Engine side
43
WIRING DIAGRAM
Wiring diagram wire color, refer to LT-R450 service manual section “WIRE COLOR”.
ECM
Prepared by
October, 2008
Part No. 99501-44030-01E
Printed in Japan
44

lt-r450/zk9 (`09

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