Suzuki LT-R450K6 Setup Manual Download Page 30

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Choke cable

Clamp

Wiring harness

Parking brake cable

Frame

Guide

Pass the throttle and clutch cables through upside of the breather hose.

Pass the clutch cable through forward of the
throttle body and inside of the ignition coil.

Breather hose

Fuel hose

Summary of Contents for LT-R450K6

Page 1: ...e 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 po...

Page 2: ...he 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 ...

Page 3: ... 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 car...

Page 4: ...E Fuel tank vent hose 1 F Warning label set 3 For E 19 CG selection 2 For E 19 CH selection 3 For 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 I Battery electrolyte container 1 J Owner s manual 1 OD Outside diameter mm ID Inside diameter mm L Length mm T Thickness mm T L OD ID NOTE The parts shown as Item F G and H in the above tabl...

Page 5: ...es 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 E E F F D D C C A A B B G G H H J I I J ...

Page 6: ...ly 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 ...

Page 7: ...r 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 A of the front side with specified torque and then tighten the bolt B of 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 fi...

Page 8: ...r 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 w...

Page 9: ... 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 ...

Page 10: ... 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 t...

Page 11: ...dlight assembly B Flange stepped bolt C Boss Install the headlight cover to the headlight assembly A Headlight cover B Headlight assembly C 5 16 mm tapping screw Reinstall the headlight assembly at the correct posi tion Connect the headlight coupler correctly Install the rubber boot A Headlight assembly B Flange stepped bolt C Headlight coupler ...

Page 12: ... base backward then balance the vehicle Place the vehicle in a clean working area and then remove the hoist hook RIGHT OWNER S MANUAL Pull the seat lock cable and remove the seat A Seat lock cable Store the owner s manual in place A Owner s manual Put a suitable pad between the vehicle body and hoist band to prevent the body from being damaged Pass the hoist band through inside the brake pedal ...

Page 13: ...he label selected for your country A Warning label General warning B Warning label Tire information C Warning label Age 16 D Front fender Right E Rear fender Right FUEL LABEL FOR LIMITED MARKET Stick the label on the fuel tank A Fuel tank B Fuel label NOTE For E 19 CG selection German Spanish Portuguese For E 19 CH selection French Dutch For E 19 CI selection Swedish Finnish Danish UNLEADED FUEL O...

Page 14: ...ing electrolyte Remove the aluminium tape sealing the battery elec trolyte filler holes A Aluminium tape B Electrolyte filler hole Remove the caps from the electrolyte container A Caps B Sealed area NOTE Use the removed caps as the sealed caps of battery filler holes Do not remove or pierce the sealed areas of the electrolyte container ...

Page 15: ...firmly so that it does not fall Take precaution not to allow any of the fluid to spill A Electrolyte containers Make sure air bubbles are coming up in each electro lyte container and leave in this position for about 20 minutes A Air bubbles NOTE If no air bubbles are coming up from a filler port tap the bottom of the container two or three times Never remove the container from the battery ...

Page 16: ...tery in the vehicle as follows Never use anything except the specified battery electrolyte Once the sealing cap has been installed in the battery do not remove the sealing cap For charging the battery make sure to use the charger specially designed for MF battery Otherwise the battery may be overcharged resulting in shortened service life Do not remove the cap during charging Position the battery ...

Page 17: ... reservoirs If the fluid level is below the lower level indicated in the figure add the correct type of brake fluid Refer to the chart below for the proper selection A Lower level line B Upper level line FRONT BRAKE LEVER Check the brake lever play at the adjuster bolt Front brake lever adjuster bolt length 11 15 mm If adjustment is necessary carry out the procedure below 1 Loosen the lock nut A 2...

Page 18: ... cannot draw any additional air back into the circuit during the air bleeding servicing 3 Close the valve pump and squeeze the lever and open the valve while squeezing brake lever 4 Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles 5 After bleeding the brake circuit tighten the bleeder valve to the specified torque Replace the rubber protective cap 6 Be...

Page 19: ...ly to ensure that the correct amount of free play is available and that the cable housing is properly seated in the adjuster A 3 Tighten the lock nut B and set the rubber boot C to correct position CLUTCH CABLE Check the clutch lever play at the clutch lever end when the lever is lightly pulled in towards the grip Clutch lever play 10 15 mm If adjustment is necessary carry out the procedure below ...

Page 20: ...E Parking brake adjustment may be required if the park ing brake does not work properly Parking brake cable length 49 53 mm 1 Loosen the lock nut A Turn out the adjuster B 2 Loosen the lock nut D Turn the adjuster C to obtain the correct cable length Tighten the lock nut D 3 Turn the adjuster B clockwise until it stops then turn the adjuster counterclockwise 1 8 1 4 turn 4 Tighten the lock nut A w...

Page 21: ...down at a point midway between the chain buffer and rear sprocket 4 After adjusting tighten the axle housing nut to the specified torque Rear axle housing nut 28 N m 2 8 kgf m NOTE Insert a proper rod D into the rear sprocket hole B and adjuster hole Turn the adjuster C by rotating the rear wheels Make sure that the rear sprocket is properly aligned with the engine sprocket Verify the reference ma...

Page 22: ...ng of the compression damping force to the standard position To adjust turn the adjuster B clockwise until it stops and then turn it counterclockwise until approximately 2 1 4 turns are felt and the two punch marks align Do not force the adjuster screw A past the stopped position or you may damage the adjuster Be sure to adjust the damping force on both front forks equally T E N H S Do not force t...

Page 23: ...s align Rebound Damping Force Adjustment Adjust the setting of the rebound damping force to the standard position To adjust turn the adjuster C clockwise until it stops and then turn it counterclockwise until 7 clicks are felt TIRE PRESSURE Using an accurate air gauge check the air pressure of the front and rear tires The pressure should be as shown COLD INFLATION TIRE PRESSURE Do not force the ad...

Page 24: ...over A Side cover B Fastener C Fastener D Fastener 2 Remove the reservoir tank cap and add 50 50 mix ture of engine coolant and distilled water to the FULL level line from the engine coolant filler hole 3 Reinstall the reservoir tank cap E Reservoir tank cap 4 Reinstall the side cover A Side cover B Fastener C Fastener D Fastener Large NOTE To remove the fastener B push in the center pin and pull ...

Page 25: ...with the oil filler plug Wipe the oil from the dipstick with a clean rag 4 Reinsert the dipstick until the threads touch the filler neck but do not screw the plug in 5 Draw out the dipstick and check the oil level The level found on the dipstick should be between L Low and F Full line 6 If the oil level is below the L line add fresh oil from the filler hole until the oil level reaches to F line If...

Page 26: ...ricate clutch and transmission gears with engine oil JASO T903 specifies performance requirements for motorcycle and ATV clutches and transmission There are two classes MA and MB The oil container has following classification for con firming the standard A Code number of oil sales company B Oil classification SAE API JASO 10W 40 SF or SG 10W 40 SH or SJ MA API American Petroleum Institute JASO Jap...

Page 27: ...laneous mounting parts to the proper torque specs Confirm that all cables and wiring harnesses are con nected and routed correctly Recommended Not recommended E N E R GY CONSER V I N G A PI SERVICE S J SAE 10W 40 A PI SERVICE S J SAE 10W 40 NOTE The engine idle should be adjusted with engine warmed up Use premium unleaded gasoline with an octane rating of 95 or higher Research method Unleaded gaso...

Page 28: ... brake caliper mounting bolt 26 2 6 K Rear brake push rod lock nut 18 1 8 L Brake caliper air bleeder 6 0 0 60 REAR SUSPENSION M Rear shock absorber bolt and nut upper 60 6 0 N Rear shock absorber bolt and nut lower 60 6 0 O Rear hub nut 121 12 1 P Rear wheel set nut 60 6 0 OTHERS Q Footrest bolt 55 5 5 R Rear swingarm pivot nut 95 9 5 S Rear axle housing set nut 28 2 8 T Rear brake pedal boss bol...

Page 29: ...e cable Parking brake cable Starter cable Pass the throttle and clutch cables through downside of the high tension cord Pass the choke cable between the frame and wiring harness Pass the choke cable through upside of the wiring harness Choke cable Pass the choke cable through rearward of the parking brake cable ...

Page 30: ...ng harness Parking brake cable Parking brake cable Parking brake cable Frame Guide Pass the throttle and clutch cables through upside of the breather hose Pass the clutch cable through forward of the throttle body and inside of the ignition coil Breather hose Fuel hose ...

Page 31: ... Handlebar switch wiring harness L Clutch lever position switch lead wire Meter panel indicator light lead wire Brake light taillight lead wire Wiring harness Wiring harness Wiring harness Wiring harness Starter motor lead wire Generator lead wire Gear position switch lead wire Front brake switch lead wire ...

Page 32: ...amp Clamp Clamp Clamp Wiring harness Wiring harness Wiring harness Set the ignition coil coupler to the downside of the hose Rear brake switch lead wire Rear brake switch lead wire Rear brake switch lead wire Rear brake switch lead wire ...

Page 33: ... electrolyte Wiring and cable Routing Operation Wiring connectors Clean Tight Front suspension Operation R DF 1 1 2 turn back C DF 2 1 4 turn back Rear suspension Operation R DF 7 clicks back C DF 3 4 turn back High C DF 8 clicks back Low Tighten all nuts and bolts Torque those listed in this manual Cotter pins and circlip Fasteners Check Paint and chrome Inspect Wash and polish Warning label For ...

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Suzuki LT-R450K6, Setup Manual

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