Suzuki LT-Z90K7 Benutzerhandbuch

August ’06 Printed in Japan (TK) 28

99505-01027-01E

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.

REAR

Remove the bolts and brackets.

A: Bolt

B: Bracket

C: Vinyl tube

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

Take out the front wheel assembly and various compo-

nent parts packaged around from the crate.

A: Front wheel assembly

B: Component parts

NOTE:

The brackets, bolts and vinyl tube are no longer

needed and these 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

A Steering head cover 1

B Fuel tank vent hose 1

CFront grip 1

Flange bolt 4 8 × 16 mm

Front wheel assembly 2 Right and Left

Flange nut 8 10 mm

Washer 8 OD:20.0 ID:10.5

EPin 1 For rear brake cable

Adjuster nut 1

Reflex reflector 2 Right and Left

Bracket 2

Flange nut 2 5 mm

G Warning label set

3For

E-19 CG selection

2For

E-19 CH selection

3For

E-19 CI selection

Item Part Name Q’ty Remarks

H Fuel label 1

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.

CF DAB E FD

The photograph shown indicates the parts dismounted

from the model in addition to the items shown in the

preceding page.

A: Handlebar assembly

B: Throttle cable

C: Front brake cable

D: Rear brake cable

E: Tool set

I J

Before assembling the vehicle, thoroughly under-

stand the “Safety Check Out” described on page

29.

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

Align the dot mark on the handlebars with the mating

surface of the front side of right 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

D: Clamp (Upper)

E: Clamp (Lower)

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.

FRONT

A: Front brake cable

B: Throttle cable

C: Left switch wiring harness

D: Parking brake switch lead wire

E: Rear brake cable

THROTTLE CABLE

Remove the screw to take off the throttle case cover.

Insert the inner cable end into the recess of throttle

cable lever correctly.

A: Throttle case cover

B: Screw

C: Cable end

D: Throttle cable lever

Pull on the outer cable and insert the outer cable cap

to the recess of throttle case correctly as shown.

A: Throttle cable

B: Outer cable cap

C: Throttle case

D: Recessed area



Reinstall the throttle case cover.

A: Gasket

The line drawings on page 26, 27 and 28 show

the proper routing of the control cables and

wiring. Refer to drawings in addition to follow-

ing the instructions carefully.

NOTE:

Before installing the cable, grease the cable

end.

Check the gasket at the correct position.

Check to ensure that the throttle operates

freely and closes automatically.

REAR BRAKE CABLE

Turn the brake cable adjuster and lock nut in as far as

possible and align the slots.

Insert the inner cable end into the recess of brake

lever, then pull on the outer cable housing and insert it

into the adjuster.

A: Brake cable

B: Adjuster

C: Lock nut

D: Cable end

Set the pin into the brake cam lever.

Insert the end of the brake cable into the pin hole.

Attach the adjuster nut on the end of the brake cable.

Do not adjust at this time.

Adjustment will be covered in the SERVICING section.

A: Brake cam lever

B: Pin

C: Adjuster nut

NOTE:

Before installing the cable, grease the cable

end.

FRONT BRAKE CABLE

Pass the front brake cable through the hole of steering

head cover.

A: Front brake cable

B: Steering head cover

C: Hole

Turn the brake cable adjuster and lock nut in as far as

possible and align the slots.

Insert the inner cable end into the recess of brake

cable equalizer, then pull on the outer cable housing

and insert it into the adjuster.

Do not adjust at this time.

Adjustment will be covered in the SERVICING section.

A: Brake cable

B: Adjuster

C: Lock nut

D: Cable end

E: Brake cable equalizer

The procedure to install the left brake cable is identical

to that of the right.

A: Brake cable

B: Adjuster

C: Lock nut

D: Cable end

E: Brake cable equalizer

NOTE:

Set the right side brake cable to the lower side

adjuster.

Before installing the cable, grease the cable

end.

NOTE:

Set the left side brake cable to the upper side

adjuster.

Before installing the cable, grease the cable

end.

Remove the bolts holding the front part of the vehicle.



A: Bolt



1. Lift the front of vehicle by using a hoist.



2. Raise the rear of vehicle.



3. Pull the crate base forward, then balance the vehi-

cle.



FRONT WHEEL

When installing the front wheel onto the axle, special

attention must be paid to the arrow of the rotational

direction on the tire sidewall.

When the tire is properly installed, the arrow must indi-

cate forward rotation of the wheel.

Carefully clean the front wheel hubs and drums with a

cloth to remove all dust.

Before removing bolts, lift the front of the vehi-

cle a little by using a hoist to prevent the dam-

age to the bolt threads.

NOTE:

The bolts are no longer needed and may be dis-

carded.

Be careful the hoist band has clearance at the

cables, guide and wiring harness.

FRONT

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