Suzuki LT-R450K6 Benutzerhandbuch

December ’05 Printed in Japan (TK) 19

99505-01046-01E

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.

PREPARATION

WORKSHOP

A: Packed vehicle

B: Working space

SELF PROTECTION

UNCRATING THE VEHICLE

Remove the carton.

A: Crate

The workshop where the machine is assembled

should be clean, spacious, and have a level

floor.

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.

Metal crates may have sharp edges and may

cause injury.

FRONT REAR

Remove the bolts and brackets.

A: Bolt

B: Bracket

C: Vinyl tube

Loosen the front brake master cylinder mounting bolts.

Remove the master cylinder from the bracket.



A: Bolt

B: Front brake master cylinder

Remove the bolts from the crate.

A: Bolt

Lift the steel frame to separate it from the base of the

crate.



A: Steel frame

B: Crate base

NOTE:

The brackets, bolts and vinyl tube are no longer

needed and these may be discarded.

Keep the position of front brake master cylin-

der with its cap facing upwards until it is

installed.

NOTE:

The bolt is no longer needed and this may be

discarded.

Handling crates requires two operators.

Be careful not to scratch the vehicle.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

AHeadlight cover 1

Tapping screw 4 5 × 16 mm

B Steering head cover 1

CStrap 2 L:120

DHolder 1 For front brake

master cylinder

Flange bolt 2 6 × 25 mm

E Fuel tank vent hose 1

F Warning label set

3For

E-19 CG selection

2For

E-19 CH selection

3For

E-19 CI selection

Item Part Name Q’ty Remarks

G Fuel label 1 For limited market

H Safety DVD 1 For E-19 market

IBattery electrolyte

container 1

J Owner’s manual 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item F, G and H in the above table are supplied for limited markets.

Please hand over the parts shown as Item H in the above table to your customer together with vehicle.

ACB G DEF F

The photograph shown indicates the parts dismounted

from the model in addition to the items shown in the

preceding page.

A: Handlebar assembly

B: Front brake master cylinder

C: Indicator light

D: Front brake switch lead wire

HHJIIJ

Before assembling the vehicle, thoroughly under-

stand the “Safety Check Out” described on page

32.

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

A: Handlebars

B: Clamp (Upper)

C: Clamp (Lower)

D: Flange bolt

E: Dot mark

NOTE:

Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

Tighten the handlebar clamp bolts to the specified

torque.

"Handlebar clamp bolt: 26 N·m (2.6 kgf-m)



A: Flange bolt

B: Flange bolt

C: Dot mark

FRONT BRAKE MASTER CYLINDER

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

"Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Front brake master cylinder

C: 6 × 25 mm flange bolt

D: 6 × 25 mm flange bolt

E: Dot mark



A: Bolt

B: Holder

C: Master cylinder

D: Handlebars

NOTE:

To install the handlebars correctly, first tighten

the bolt



Aof the front side with specified

torque and then tighten the bolt



Bof the rear

side.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

FORWARD

NOTE:

To install the holder correctly, first tighten the

bolt



Cof the upper side with specified torque

and then tighten the bolt



Dof the lower side.

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for brake fluid leakage.

Connect the front brake light switch lead wires coupler

to the brake light switch.

A: Front brake light switch

B: Lead wire coupler

CLUTCH LEVER HOLDER

Loosen the bolts.

Move the lever holder at the correct position.

Align the dot mark on the handlebars with the clutch

lever holder fitting surface.

Tighten the clutch lever holder bolts.

A: Clutch lever holder

B: Bolt

C: Dot mark

A: Throttle cable

B: Front brake hose

C: Parking brake lever cable

D: Clutch cable

E: Choke cable

F: Left switch wiring harness

G: Clutch lever position switch wiring harness

H: Front brake switch lead wire

The line drawings on page 28, 29, 30 and 31

show the proper routing of the control cables,

hose and wirings.

Refer to them in addition to following the

instructions carefully.

STEERING HEAD COVER

Remove the indicator light lens from the socket boot.

A: Indicator light lens

B: Socket boot

Install the socket boot to the steering head cover.

A: Steering head cover

B: Socket boot

C: Yellow with black tracer lead

D: Blue with black tracer lead

E: Red with black tracer lead

Confirm that the socket boots are all installed in the

correct position and angle.

Install the indicator light lens to the socket boot.

A: Neutral indicator lens

B: Fuel indicator lens

C: FI/engine coolant temperature indicator lens

D: Indicator light lens

E: Socket boot

NOTE:

Align the parting line of the indicator lens with

line of steering head cover.

Align the recess of steering head cover on the handle-

bars.

Push down the steering head cover firmly.

A: Recess

B: Steering head cover

CLAMP

Clamp the wiring harness of handlebar left switch,

clutch lever position switch and choke cable with

straps.

Clamp the brake light switch lead wire with straps.

A: Strap L:120 mm

B: Choke cable

C: Left switch wiring harness

D: Clutch lever position switch wiring harness

E: Front brake switch lead wire

FUEL TANK VENT HOSE

Install the fuel tank vent hose to the fuel tank cap.

Insert the free end of fuel tank vent hose to the hole of

steering shaft.



A: Fuel tank vent hose

B: Fuel tank cap

C: Hole

Be sure not to bend or twist the hose when

installing.

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