Suzuki QuadRacer LT-R450 Bedienungsanleitung

LT-R450

99500-44062-03E

GROUP INDEX

GENERAL INFORMATION 1

PERIODIC MAINTENANCE 2

ENGINE 3

FI SYSTEM DIAGNOSIS 4

FUEL SYSTEM AND

THROTTLE BODY 5

COOLING AND

LUBRICATION SYSTEM 6

CHASSIS 7

ELECTRICAL SYSTEM 8

SERVICING INFORMATION 9

EMISSION CONTROL

INFORMATION 10

LT-R450K7 (’07-MODEL) 11

LT-R450K8 (’08-MODEL) 12

WIRING DIAGRAM 13

FOREWORD

This manual contains an introductory description on

the SUZUKI LT-R450 and procedures for its inspec-

tion, service and overhaul of its main components.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the vehicle and its mainte-

nance. Use this section as well as other sections as

a guide for proper inspection and service.

This manual will help you know the vehicle better so

that you can assure your customers of fast and reli-

able service.



* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual vehicle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual vehicle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI vehicles.

If you do not have the proper knowledge and

tools, ask your authorized SUZUKI motorcy-

cle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the vehicle

unsafe for the rider.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front and rear wheels

1Front wheel

2Washer

3Cotter pin

4Air valve

5Front tire

6Front hub plate

7Spacer

8Dust seal

9Hub bearing

0Front wheel hub

ASpacer

BHub bearing

CDust seal

DCollar

EFront brake disc

FDisc cover

GAxle shaft

HRear wheel hub

IRear wheel

JRear tire

KWasher

AWheel set nut

BFront hub nut

CRear hub nut

DBrake disc bolt

ITEM N·m

kgf-m

lb-ft

A66 6.6 47.5

B65 6.5 47.0

C121 12.1 87.5

D23 2.3 16.5

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK “1342”.

99000-32050

Apply oil. Use engine oil unless

otherwise specified.

Apply THREAD LOCK SUPER “1360”.

99000-32130

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKl

MOLY PASTE in a ratio of 1 : 1)

Apply or use brake fluid.

Apply SUZUKI SUPER GREASE “A”

or equivalent grease.

99000-25010

Measure in voltage range.

Apply SUZUKI SILICONE GREASE.

99000-25100 Measure in resistance range.

Apply SUZUKI MOLY PASTE.

99000-25140 Measure in current range.

Apply SUZUKI BOND “1215”

or equivalent bond.

99000-31110

Measure in diode test range.

Apply SUZUKI BOND “1216B”.

99000-31230 Measure in continuity test range.

Apply THREAD LOCK SUPER “1303”.

99000-32030 Use special tool.

Apply THREAD LOCK SUPER “1322”

or equivalent thread lock.

99000-32110

Indicates service data.

1216B

ABBREVIATIONS USED IN THIS

MANUAL

ABDC : After Bottom Dead Center

AC : Alternating Current

ACL : Air Cleaner, Air Cleaner Box

API : American Petroleum Institute

ATDC : After Top Dead Center

A/F : Air Fuel Mixture

BBDC : Before Bottom Dead Center

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CO : Carbon Monoxide

CPU : Central Processing Unit

DC : Direct Current

DMC : Dealer Mode Coupler

DOHC : Double Over Head Camshaft

DRL : Daytime Running Light

DTC : Diagnostic Trouble Code

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

FP Relay : Fuel Pump Relay

GEN : Generator

GND : Ground

GP Switch : Gear Position Switch

HC : Hydrocarbons

IAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP Sensor)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

IG : Ignition

IAS : Idle air screw

LH : Left Hand

MAL-Code : Malfunction Code

(Diagnostic Code)

Max : Maximum

MIL : Malfunction Indicator Lamp

Min : Minimum

NOX : Nitrogen Oxides

OHC : Over Head Camshaft

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

RH : Right Hand

ROM : Read Only Memory

SAE : Society of Automotive Engineers

SDS : Suzuki Diagnosis System

TO Sensor : Tip-Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

SAE-TO-FORMER SUZUKI TERM

This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in

this manual in compliance with SAE recommendations, as well as their former SUZUKI names.

SAE TERM FORMER SUZUKI TERM

FULL TERM ABBREVIATION

Air Cleaner ACL Air Cleaner, Air Cleaner Box

Battery Positive Voltage B+ Battery Voltage, +B

Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),

Crank Angle

Data Link Connector DLC Dealer Mode Coupler

Diagnostic Test Mode DTM ––––

Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code

Electronic Ignition El ––––

Engine Control Module ECM Engine Control Module (ECM)

Fl Control Unit, Engine Control Unit (ECU)

Engine Coolant Level ECL Coolant Level

Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-

perature, Water Temperature

Engine Speed RPM Engine Speed (RPM)

Fa n C o n t r o l F C ––––

Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge

Fuel Pump FP Fuel Pump (FP)

Generator GEN Generator

Ground GND Ground (GND, GRD)

Ignition Control IC Electronic Spark Advance (ESA)

Ignition Control Module ICM ––––

Intake Air Temperature IAT Intake Air Temperature (IAT), Air Temperature

Malfunction Indicator Lamp MIL Lamp

Malfunction Indicator Lamp (MIL)

Manifold Absolute Pressure MAP Intake Air Pressure (IAP), Intake Vacuum

SAE TERM FORMER SUZUKI TERM

FULL TERM ABBREVIATION

On-Board Diagnostic OBD Self-Diagnosis Function

Diagnostic

Programmable Read Only Memory PROM ––––

Random Access Memory RAM ––––

Read Only Memory ROM ROM

Throttle Body TB Throttle Body (TB)

Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)

Throttle Position Sensor TP Sensor TP Sensor (TPS)

Voltage Regulator VR Voltage Regulator

WIRE COLOR

B : Black O : Orange

Bl : Blue P : Pink

Br : Brown R : Red

Dbr : Dark brown W : White

Dg : Dark green Y : Yellow

Gr : Gray

B/Bl : Black with Blue tracer

B/Br : Black with Brown tracer

B/O : Black with Orange tracer

B/R : Black with Red tracer

B/W : Black with White tracer

B/Y : Black with Yellow tracer

Bl/B : Blue with Black tracer

Bl/W : Blue with White tracer

Br/W : Brown with White tracer

G/B : Green with Black tracer

G/R : Green with Red tracer

G/W : Green with White tracer

Gr/W : Gray with White tracer

O/G : Orange with Green tracer

O/W : Orange with White tracer

O/Y : Orange with Yellow tracer

R/W : Red with White tracer

W/B : White with Black tracer

W/Bl : White with Blue tracer

W/R : White with Red tracer

Y/B : Yellow with Black tracer

Y/Bl : Yellow with Blue tracer

GENERAL INFORMATION 1-1

GENERAL INFORMATION

CONTENTS

WARNING/CAUTION/NOTE......................................................................... 1- 2

GENERAL PRECAUTIONS .......................................................................... 1- 2

SUZUKI LT-R450K6 (’06-MODEL) ............................................................... 1- 4

SERIAL NUMBER LOCATION ..................................................................... 1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION....................... 1- 5

FUEL (FOR USA AND CANADA).......................................................... 1- 5

FUEL (FOR OTHER COUNTRIES) ........................................................ 1- 5

ENGINE OIL (FOR USA)........................................................................ 1- 5

ENGINE OIL (FOR OTHER COUNTRIES)............................................. 1- 5

BRAKE FLUID........................................................................................ 1- 5

ENGINE COOLANT................................................................................ 1- 6

BREAK-IN PROCEDURES........................................................................... 1- 6

INFORMATION LABELS .............................................................................. 1- 7

SPECIFICATIONS......................................................................................... 1- 8

DIMENSIONS AND DRY MASS............................................................. 1- 8

ENGINE .................................................................................................. 1- 8

DRIVE TRAIN ......................................................................................... 1- 8

CHASSIS ................................................................................................ 1- 9

ELECTRICAL ......................................................................................... 1- 9

CAPACITIES .......................................................................................... 1- 9

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

E-19

E-28

E-33

E.U.

Canada

California (U.S.A.)

JSAAL41A 62100001 –

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS

and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are

unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the vehicle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well-

ventilated and that you follow all of the material manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system

until they have cooled.

After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related

to the system for leaks.

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