Suzuki LT-Z50K6 Setup Manual Download Page 10 | Manualshive

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9

AIR GAUGE

Pull the seat release lever toward the rear and remove
the seat.

A: Seat release lever

Store the air gauge with tool set in place.

A: Air gauge (Tool set)

OWNER’S MANUAL

Store the owner’s manual in place.

A: Owner’s manual

EMERGENCY STOP SWITCH LANYARD

Pass the emergency stop switch lanyard through the
case.
Clamp the case to the frame.

A: Case
B: Emergency stop switch lanyard
C: Clamp
D: Frame

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Summary of Contents for LT-Z50K6

Page 1: ... performing any work Take special 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 cate gories 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 pote...

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: ... Vinyl tube D Strap 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 Handling crates requires two operators Be careful not to scratch the vehicle ...

Page 4: ... 2 Flange bolt 4 8 45 mm B Handlebar pad 1 Strap 2 L 180 C Air gauge 1 D 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 E Fuel label 1 F Battery electrolyte container 1 G Owner s manual 1 Manual bag 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 D and E in the ab...

Page 5: ...shown indicates the parts dismounted from the model in addition to the items shown in the preceding page A Handlebar assembly B Tool set C Emergency stop switch lanyard D Rear wheel assembly A A C C D D E E F F B B G G ...

Page 6: ...ng position A Bracket B Bolt C Paper D Vinyl mat HANDLEBAR Install the handlebars assembly using the four clamps and four bolts A Clamp Upper B Clamp Lower C 8 45 mm flange bolt D Dot mark E Paint mark Be careful not to scratch the fuel tank NOTE The bracket bolts paper and vinyl mat are no longer needed and may be discarded NOTE The paint mark on the clamp is rear side of lower clamp Align the do...

Page 7: ...e rear of the vehicle by using a hoist as shown in the photograph 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 FRONT The line drawings on page 23 and 24 show the proper routing of the control cables and wi...

Page 8: ...the arrows must indicate forward rotation of the wheels Carefully wipe the rear wheel hubs and drums with a cloth to remove all dust Properly position the wheel on the axle stud bolts Temporarily finger tighten the wheel set nuts A Stud bolt B Air valve C 8 mm flange self lock nut Wheel set nut NOTE The wheels are fixed inside out when they are packed The paper is no longer needed and may be dis c...

Page 9: ... HANDLEBAR PAD Install the handlebar pad to the handlebar reinforcing bar A Handlebar pad B Strap L 180 mm C SUZUKI logo FUEL TANK VENT HOSE Install the fuel tank vent hose into the cable guide as shown in the photograph A Fuel tank vent hose B Cable guide Place the vehicle in a clean working area NOTE The SUZUKI logo should face the backward FRONT Be sure not to bend or twist the hose when instal...

Page 10: ...Store the air gauge with tool set in place A Air gauge Tool set OWNER S MANUAL Store the owner s manual in place A Owner s manual EMERGENCY STOP SWITCH LANYARD Pass the emergency stop switch lanyard through the case Clamp the case to the frame A Case B Emergency stop switch lanyard C Clamp D Frame ...

Page 11: ...label Age 6 D Warning label Parking brake For French only E Front fender Right F 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 RÉGLER LE FREIN DE STATIONNEMENT AVANT LE DÉMARRAGE DU MOTEUR FRONT UNLEADED FUE...

Page 12: ... Seat release lever Filling 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 13: ...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 14: ...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 15: ...rubber boot 4 Connect the lead to the negative terminal of the battery A lead B lead C Rubber boot Reinstall the seat Insert the seat hook into the seat hook retainer and pass the seat lock lever through the hole of the rear fender Push the seat down firmly A Seat assembly B Hook C Hook retainer D Seat lock lever E Hole ...

Page 16: ...dure below 1 Loosen the throttle cable adjuster lock nut A 2 Turn the adjuster B in or out until the correct play 3 Tighten the lock nut A while holding the adjuster Place the rubber boot C After the adjustment is completed check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically ...

Page 17: ...sure that at least 5 mm of the adjuster threads are inserted in the lever holder D as shown in the photograph Tighten the lock nuts E If the cable adjusters C do not provide enough adjustment turn the left and right brake cable adjusters F equally to obtain the specified play 3 Turn the upper or lower cable adjuster so that when the brake lever is fully squeezed the cable holder is in the straight...

Page 18: ...oper slack is obtained tighten the bolts A and B 4 Tighten the adjusting nuts C Verify that the master link clip is installed properly The opening of the master link clip faces away from the direction of travel A Direction of travel B Master link clip Make sure that the rear sprocket is properly aligned with the engine sprocket Verify the reference marks on the swing arm by sighting down along the...

Page 19: ... now be made with the brake lever adjuster A Tighten the lock nut B 2 After adjusting the play check that the rear wheels roll freely with the brake disengaged and the rear wheels off the ground 3 Set the parking brake by squeezing the brake lever and set the stopper C 4 Check that the rear wheels are locked by trying to move the vehicle back and forth 5 Readjust the rear brake lever adjusting nut...

Page 20: ... 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 the level is above the F line drain oil to F line 7 Reinstall the drain plug and engine oil filler plug Tighten them securely A Engine oil filler plug B...

Page 21: ...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 22: ...ompleting all of the servicing procedures adjust the engine idle speed by turning the throttle stop screw Engine idle speed 1 700 1 900 r min A Throttle stop screw Test ride the vehicle checking all mechanical func tions Tighten all nuts bolts and miscellaneous mounting parts to the proper torque specs Confirm that all cables and wiring harnesses are con nected and routed correctly Recommended Not...

Page 23: ...ND REAR BRAKE F Rear wheel nut 28 2 8 G Rear axle nut 75 7 5 H Rear shock absorber bolt and nut Upper and Lower 29 2 9 I Rear brake cam lever nut 7 7 0 77 OTHERS J Front footrest bolt 26 2 6 K Rear swingarm pivot nut 100 10 0 Bolt Diameter mm Conventional or 4 marked bolt 7 marked bolt N m kgf m N m kgf m 4 1 5 0 15 2 3 0 23 5 3 0 3 4 5 0 45 6 5 5 0 55 10 1 0 8 13 1 3 23 2 3 10 29 2 9 50 5 0 12 45...

Page 24: ...ke cable R Front brake cable L Front brake cable L Throttle cable Throttle cable Throttle cable Throttle cable Rear brake cable Rear brake cable Rear brake cable Rear brake cable Rear brake cable D D C C B B A A SECT D D SECT A A SECT B B SECT C C Clamp Cable guide Cable guide Cable guide Cable guide Wiring harness Wiring harness Rear brake cable ...

Page 25: ...Starter relay CDI unit Clamp Clamp Clamp Clamp Clamp Clamp Emergency switch lead wire Wiring harness Wiring harness Wiring harness Magneto lead wire Magneto lead wire Starter motor lead wire Starter motor lead wire Ignition switch lead wire Handlebar switch lead wire L Clamp Case ...

Page 26: ...ever Check Adjust 3 0 7 0 mm Rear Parkingbrake lever Check Adjust 4 0 6 0 mm Drive chain Lubricate Check Adjust 20 30 mm Oiling points All necessary points Battery Filling electrolyte Wiring and cable Routing Operation Wiring connectors Clean Tight Suspensions Front Rear Operation Tighten all nuts and bolts Torque those listed in this manual Cotter pins and circlip Fasteners Check Paint and chrome...

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