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LT-Z90

99011-08H50-01B

LT-Z90

Part No. 99011-08H50-01B
July, 2006 EN, FR

Printed in Taiwan

300 TAKATSUKA, HAMAMATSU, JAPAN

9 mm

No.1992 LT-Z90 99011-08H50-01B 2/1

DIC184(TDP006)

DIC157

OWNER’S MANUAL

MANUEL DU PROPRIETAIRE

This owner’s manual contains
important safety information.
Please read it carefully.

Never allow anyone under 12
years old to ride this ATV.

Ce ’Manuel du propriétaire contient
des informations importantes
concernant la sécurité.
Le lire soigneusement.

Ne jamais autoriser les enfants
âgés de moins de 12 ans à
piloter ce V.T.T.

Summary of Contents for LT-Z90

Page 1: ...1 No 1992 LT Z90 99011 08H50 01B 2 1 DIC184 TDP006 DIC157 OWNER S MANUAL MANUEL DU PROPRIETAIRE This owner s manual contains important safety information Please read it carefully Never allow anyone u...

Page 2: ...idered a permanent part of the vehi cle and should remain with the vehicle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instruct...

Page 3: ...Indicates special information to make maintenance easier or instructions clearer WARNINGs and CAUTIONs are arranged like this WARNING Indicates a potential hazard that could result in death or injury...

Page 4: ...ION 2006 NOTICE TO PARENTS Your SUZUKI LT Z90 is built for use by children but this owner s manual is written for the adults who will be supervising the children SUZUKI strongly recommends therefore t...

Page 5: ...earing an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or dru...

Page 6: ...described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling use the...

Page 7: ...Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this man ual for carrying cargo Allow greater distance for braking Never ride the LT Z90 at night Thi...

Page 8: ...DATIONS CONTROLS EQUIPMENT AND ADJUSTMENTS RIDING YOUR ATV INSTRUCTING THE YOUNG RIDER ACCESSORY USE AND VEHICLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING TRANSPORTING CLEANING PROCEDURE AND...

Page 9: ......

Page 10: ...1 1 1 FUEL AND OIL RECOMMENDATIONS FUEL 1 2 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL 1 3...

Page 11: ...Oxygenated fuels are fuels which contain oxygen carrying addi tives such as MTBE or alcohol Gasoline Containing MTBE Unleaded gasoline containing MTBE Methyl Tertiary Butyl Ether may be used in your...

Page 12: ...nd life Always select good quality engine oil Use oil with an API American Petro leum Institute classification of SF SG or SH SJ or with a JASO classifica tion of MA API American Petroleum Institute J...

Page 13: ...es MA and MB The oil container shows the classifica tion as follows 1 Code number of oil sales company 2 Oil classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oil...

Page 14: ...D ADJUSTMENTS LOCATION OF PARTS 2 2 KEY 2 5 IGNITION SWITCH 2 5 LEFT HANDLEBAR 2 6 RIGHT HANDLEBAR 2 7 THROTTLE LIMITER 2 7 CHOKE LEVER 2 9 FUEL VALVE 2 9 RECOIL STARTER 2 10 FUEL TANK CAP 2 11 SEAT L...

Page 15: ...TROLS EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1 Rear brake lever 2 Parking brake knob 3 Engine stop switch 4 Throttle lever 5 Front brake lever 6 Electric starter button 7 Ignition switch 8 Fuel t...

Page 16: ...2 3 9 Choke lever 0 Fuel valve A Recoil starter B Fuse C Battery D Tools E Seat lock lever F Spark plug G Engine oil filter...

Page 17: ...2 4 H Muffler I Drive chain J Air cleaner K Engine oil filler cap L Engine oil drain plug...

Page 18: ...ber in the box provided for your future refer ence IGNITION SWITCH The ignition switch has two positions OFF position The ignition circuit is off and the engine can not be operated The key can be remo...

Page 19: ...lever in the squeezed position Engine Stop Switch 3 OFF position The ignition circuit is off and the engine cannot start or run RUN position The ignition circuit is on and the engine can run Electric...

Page 20: ...the throttle limiter 1 Loosen the lock nut 1 2 Turn the throttle limiter screw 2 clockwise or counterclockwise to adjust maximum engine power Turning the screw clockwise will restrict maximum engine p...

Page 21: ...ccident Do not remove the maximum speed reduction spacer until the rider develops sufficient skills to operate LT Z90 safely at the maxi mum speed with the maximum speed reduction spacer in place WARN...

Page 22: ...g FUEL VALVE This vehicle has a manually operated fuel valve There are three positions ON RES and PRI ON position The normal operating position for the fuel valve lever is the ON position In this posi...

Page 23: ...Pull the rope gently until you feel the starter engage Pull the rope force fully to start the engine Immediately after the engine starts be sure to gently return the starter rope to its normal positi...

Page 24: ...y overflow when it expands Fuel expands due to engine heat or heating by the sun Fuel that overflows can catch fire Stop adding fuel when the fuel level reaches the bottom of the filler neck WARNING I...

Page 25: ...into the seat hook retainer and push down firmly FLAG BRACKET A bracket is provided so you can mount a flag on your LT Z90 WARNING Improperly installing the seat can be hazardous Failure to install th...

Page 26: ...PECTION BEFORE RIDING 3 3 WHAT TO WEAR 3 6 BREAK IN RUNNING IN 3 7 STARTING THE ENGINE 3 8 STARTING OFF 3 9 BRAKING 3 13 TURNING 3 13 SKIDDING OR SLIDING 3 14 OPERATION ON HILLS 3 15 RIDING OVER OBSTA...

Page 27: ...er age 12 can lead to their severe injury or death Children under age 12 may not have the size strength skills or judgment needed to operate this ATV safely Do not allow any child under age 12 to ride...

Page 28: ...and don t bother wild life With your help your riding areas can remain open for you to use in the future After you have found a good place to practice review the controls on your ATV before riding Lea...

Page 29: ...e tires specified in this owner s manual Always maintain proper tire pres sure as described in the INSPEC TION AND MAINTENANCE section WARNING Operating this ATV with improper modifications can be haz...

Page 30: ...Brake shoes not to be worn down to the limit line Parking brake effectiveness Tire Proper pressure Enough tread depth No cracks rips or other damage Fuel Enough fuel for the intended run Fuel hose con...

Page 31: ...r a good pair of gloves strong boots that fit over the ankle long pants and a long sleeve shirt WARNING Operating this ATV without wear ing an approved motorcycle hel met eye protection and protective...

Page 32: ...light load can cause parts to glaze and not seat properly Allow the engine to accelerate freely through the gears without exceeding the max imum recommended throttle opening Allow the Engine Oil to C...

Page 33: ...escribed above 3 When the engine will operate smoothly without use of the choke return the choke lever all the way When the Engine is Warm Use of the choke should not be nec essary Open the throttle s...

Page 34: ...so you can change position to maneuver the ATV It is not for carrying passengers WARNING Operating this ATV on paved sur faces including sidewalks paths parking lots driveways and streets can be haza...

Page 35: ...highways WARNING Operating this ATV at excessive speeds can be hazardous Riding at excessive speeds increases your chances of losing control of the ATV which can result in an accident Always go at a s...

Page 36: ...his could injure you or cause an accident Always keep both hands on the handlebars and both feet on the foot pegs of your ATV during oper ation WARNING Failure to use extra care when operating on exce...

Page 37: ...gh time to react This could cause the ATV to overturn or go out of con trol Go slowly and be extra careful when operating on unfamiliar ter rain Always be alert to changing terrain conditions when ope...

Page 38: ...de wheel This happens even though both wheels are still turn ing at the same speed WARNING Braking while turning the ATV can be hazardous Use of the brake when turning could cause the ATV to slide or...

Page 39: ...r footrest SKIDDING OR SLIDING You may experience skidding or slid ing when you are not braking You may be able to overcome it by using the techniques listed below If your front wheel skids Gain front...

Page 40: ...s improperly can be hazardous Climbing hills improperly can cause loss of control or cause the ATV to overturn Always follow the proper proce dures for climbing hills as described in this section Alwa...

Page 41: ...low these instructions 1 Turn around on the hill before you lose forward speed As you turn on the side of the hill lean your body weight uphill 2 Once you have turned around ride down the hill as desc...

Page 42: ...e the parking brake and ride down the hill as instructed in the DESCENDING A HILL section If the front brake does not slow the vehicle dismount to the side immedi ately Descending a Hill To ride down...

Page 43: ...at some obstacles are too high for your ATV or for your abili ties If you are not sure that you can safely cross over an obstacle back up and ride around the obstacle WARNING Crossing hills or turning...

Page 44: ...ough deep or fast flowing water can be haz ardous The ATV tires may float causing loss of traction and loss of con trol This could lead to an acci dent Never operate this ATV in fast flowing water or...

Page 45: ...the brakes do not work ade quately stop riding the ATV Bring the ATV to a warmer area to allow the brakes to thaw out After the brakes thaw dry them by applying them sev eral times while riding slowly...

Page 46: ...tempera tures can also lead to hypothermia Hypothermia occurs when your body s inner temperature drops Symptoms include numbness in the extremities hands feet arms and legs and shivering Damp clothing...

Page 47: ...en riding your ATV can be hazardous Loose clothing such as a long scarf or shawl can get caught in an ATV s moving parts Never wear loose clothing when riding your ATV WARNING Riding on snow covered t...

Page 48: ...tection will reduce the amount of light reaching your eyes On overcast days you may find it helpful to use yellow tinted eye protection WARNING Failure to use extra care when operating on slippery sur...

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Page 50: ...4 1 4 INSTRUCTING THE YOUNG RIDER IMPORTANT ADVICE TO THE PARENT 4 2 GETTING TO KNOW THE LT Z90 4 3 STARTING OFF AND STOPPING 4 4 TURNING 4 5 PUTTING IT ALL TOGETHER 4 5...

Page 51: ...ns and warnings it contains Be sure to put special emphasis on safety precautions Question your child as you go through the manual to make sure he she understands what you are saying WARNING Indicates...

Page 52: ...e items that should be checked and how they should be checked Give examples of things to look for WARNING Failure to follow all of the warn ings in the Riding Your ATV sec tion of this manual can be h...

Page 53: ...n the opposite direction Practice with the engine off until your child gets the feel of using the brakes and can stop the vehicle and turn off the engine stop switch without looking at the controls an...

Page 54: ...o it correctly and with confidence PUTTING IT ALL TOGETHER When your child has mastered the basic riding maneuvers in the previ ous steps he she should practice put ting them all together Instruct the...

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Page 56: ...5 1 5 ACCESSORY USE AND VEHICLE LOADING ACCESSORY USE AND VEHICLE LOADING 5 2...

Page 57: ...choose accessories and install them correctly The guidelines below should help you decide how to equip your ATV and how to use it cor rectly when you use accessories or carry cargo WARNING Operating...

Page 58: ...bars of the machine should be as light as possible The extra weight can cause the vehicle to be harder to steer 4 Do not add accessories or cargo which interfere with controls or other equipment 5 Se...

Page 59: ......

Page 60: ...LE SPEED ADJUSTMENT 6 7 FUEL HOSE 6 7 ENGINE OIL 6 8 FINAL REDUCTION GEAR BOX OIL 6 12 AIR CLEANER 6 14 AIR CLEANER DRAIN TUBE 6 16 DRIVE CHAIN 6 17 DRIVE CHAIN CLEANING AND OILING 6 18 TIRES 6 20 BRA...

Page 61: ...nuts and muffler mounting bolts T T T Valve clearance I I Spark plug I Replace every 18 months Spark arrester C Fuel line I I Replace every 4 years Engine oil and oil filter R R Inspect each time the...

Page 62: ...echanical experience If you are not sure how to do any of the jobs ask your Suzuki dealer to do the main tenance CAUTION If you use your ATV under severe conditions it will need mainte nance more ofte...

Page 63: ...e check the color of the plug s porcelain center electrode insulator after vehicle operation A light brown color indicates that the plug is correct A white or dark insulator indicates that the engine...

Page 64: ...4 0 028 in for good ignition Use a thickness gauge to check the gap NGK DENSO REMARKS CR6HSA U20FSR U Standard CR7HSA U22FSR U If the standard plug is apt to overheat replace with this plug CAUTION Im...

Page 65: ...orrect play 3 Tighten the lock nut 1 4 Recheck the throttle cable play Readjust it if it is not within the specified limits 3 0 5 0 mm WARNING Operating the vehicle with an inadequate throttle cable p...

Page 66: ...Inspect the fuel hose for damage and fuel leakage If any defects are found the fuel hose must be replaced WARNING Improper adjustment of the idle speed can be hazardous An idle that is too high can c...

Page 67: ...s out together with the oil filler cap as shown The level on the dipstick should be between the L Low and F Full lines The oil level inspection should be per formed under the following conditions Park...

Page 68: ...NG New and used oil can be hazard ous Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with used oil ma...

Page 69: ...sure that the filter spring 6 and the cap O ring 7 are installed correctly NOTE Install a new O ring each time the filter element is replaced CAUTION Failure to insert the new oil filter element corre...

Page 70: ...allow it to idle for a few minutes 10 Turn the engine off and wait for three minutes Recheck the oil level The oil level should be at the F full mark If it is lower than the F mark add oil until it re...

Page 71: ...il use oil with an API American Petroleum Institute classification of SF SG or SH SJ or with a JASO classification of MA Final Reduction Gear Box Oil Level Check Follow the procedure below to inspect...

Page 72: ...3 Reinstall the drain bolt Pour 90 ml 3 0 3 2 US Imp oz of fresh oil through the oil level check hole 4 Reinstall the oil level check bolt WARNING New and used oil can be hazard ous Children and pets...

Page 73: ...ck from the carburetor to the air intake box without the air cleaner element to stop it Severe engine damage can also occur if dirt enters the engine due to running the engine without the air cleaner...

Page 74: ...ment by pressing it between the palms of both hands to remove excess solvent Do not twist or wring the element or it will develop cracks 3 Immerse the element in a sepa rate pan filled with motor oil...

Page 75: ...harmed from contact with oil and solvent Be sure to keep oil and solvent away from children and pets Dis pose of used oil and solvent prop erly CAUTION Failure to position the air cleaner element pro...

Page 76: ...n correct the problem if you know how If neces sary consult your authorized SUZUKI dealer Damage to the drive chain means that the sprockets may also be dam aged Inspect the sprockets for the followin...

Page 77: ...g the Drive Chain The drive chain should be adjusted so there is 15 25 mm 0 6 1 0 in of slack as shown above To adjust the drive chain follow the procedure below 1 Remove the screws 1 and chain cover...

Page 78: ...2 0 kgf m 87 0 lb ft 4 94 N m 9 4 kgf m 68 0 lb ft 5 Tighten the adjusting nuts 5 6 Check the brake lever travel as shown on page 6 24 Adjust the brake if necessary WARNING Failure to inspect the driv...

Page 79: ...can be hazardous If you use improper tires or improper or uneven tire pressure you may lose control of the ATV Always use the size and type tires specified Always maintain proper tire pressure as desc...

Page 80: ...or tire bead is damaged air may leak Be extremely careful not to damage these sections when replacing tires It is very important to use the proper tools when repairing or replacing tires to prevent da...

Page 81: ...to rotate in a specific direction as indicated by the arrows on the sidewall of each tire Install tires so they rotate in the proper direction WARNING Failure to properly inspect and maintain your AT...

Page 82: ...in the lever holder as shown in the illus tration If the cable adjusters do not provide enough adjustment turn the left and right brake hub adjuster 2 equally to obtain the specified clearance 3 Turn...

Page 83: ...ly with the brake disengaged and the rear wheels off the ground 3 Set the parking brake by squeez ing the brake lever and pressing the lock knob 1 4 Check that the rear wheels are locked by trying to...

Page 84: ...f the index mark is within the range 3 If the extension line is outside this range have the brake shoes replaced by your Suzuki dealer WARNING Failure to maintain the brake shoes and replace them when...

Page 85: ...eel reverse these steps Use the tightening torque chart to determine the tightness of the wheel nuts Tightening Torque Front and Rear 55 N m 5 5 kgf m 40 0 lb ft WARNING Failure to tighten the wheel n...

Page 86: ...Remove the bolt 1 and pull out the spark arrester 2 2 Use a brush to remove carbon deposits from the spark arrester screen Be careful not to damage the spark arrester screen Check that the screen has...

Page 87: ...fuse box CAUTION Failure to install the correct fuse can damage your ATV Installing a fuse of incorrect rating or using aluminum foil or wire instead of a fuse may seriously damage the electrical syst...

Page 88: ...ld do general lubri cation as shown in the MAINTE NANCE CHART He She will lubricate things such as wheel bearings rear axle housings swing arm bearings steering shaft holder cables etc Oil Grease 1 St...

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Page 90: ...7 1 7 TROUBLESHOOTING FUEL SYSTEM CHECK 7 2 IGNITION SYSTEM CHECK 7 3...

Page 91: ...hten the drain screw c Run the engine for a few sec onds Shut off the engine d Loosen the drain screw and check that the carburetor is filled back up with fuel e If fuel is reaching the carburetor the...

Page 92: ...ank 2 Check to see that the spark plug is not fouled Remove the plug and clean it Replace it if neces sary 3 Make sure the fuel valve is not clogged Also check to be sure the air vent hose connected t...

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Page 94: ...8 1 8 TRANSPORTING STARTING THE LT Z90 AFTER TRANSPORT 8 3...

Page 95: ...as drained retighten the drain screw WARNING Spilled battery acid can be hazard ous Battery acid is corrosive and could cause severe burns if you get it on your skin It can also damage ATV parts Remov...

Page 96: ...e to properly secure the ATV when transporting it can be haz ardous Failure to properly secure the vehicle may result in an accident or damage to the vehicle When transporting the LT Z90 lock the park...

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Page 98: ...ANING PROCEDURE AND STORAGE PROCEDURE PREPARATION FOR CLEANING 9 2 WASHING YOUR ATV 9 3 INSPECTION AFTER CLEANING 9 3 STORAGE PROCEDURE 9 4 MAINTENANCE DURING STORAGE 9 5 PROCEDURE FOR RETURNING TO SE...

Page 99: ...aust system can reduce engine cooling conceal damage or increase wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the ATV before any mud dries o...

Page 100: ...plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Remove the rags or wrapping from the exhaust pipe...

Page 101: ...ry from the vehi cle NOTE Be sure to remove the nega tive terminal first then remove the positive terminal Clean the outside of the battery with mild soap and remove any corrosion from the terminals a...

Page 102: ...with fresh oil as outlined in this manual Remove the spark plug Turn the engine a few times by pulling the recoil starter Reinstall the spark plug Reinstall the battery NOTE Be sure to connect the pos...

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Page 104: ...10 10 1 CONSUMER INFORMATION SERIAL NUMBER LOCATION 10 2 LOCATION OF LABELS 10 2...

Page 105: ...of the crankcase assembly Write down the serial numbers here for your future reference LOCATION OF LABELS Read and follow all of the warnings labeled on your ATV Make sure you understand all of the la...

Page 106: ...es the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this ATV A L W A Y S U S E A N A P P R O V E D H E L M E T A N...

Page 107: ...lement Starter system Electric and recoil DRIVE TRAIN Clutch Dry shoe automatic centrifugal type Gearshift pattern Automatic Primary reduction ratio 2 695 1 621 variable change Final reduction ratio G...

Page 108: ...tery 12V 21 6 kC 6Ah 10HR Fuse 10A CAPACITIES Fuel tank 6 0 L 1 6 1 3 US Imp gal Engine oil oil change 950 ml 1 0 0 8 US Imp qt with filter change 1050 ml 1 1 0 9 US Imp qt overhaul 1100 ml 1 2 1 0 US...

Page 109: ...HEEL REMOVAL 6 26 FUEL 1 2 FUEL HOSE 6 7 FUEL SYSTEM CHECK 7 2 FUEL TANK CAP 2 11 FUEL VALVE 2 9 FUSE 6 28 G GENERAL LUBRICATION 6 29 GETTING TO KNOW THE LT Z90 4 3 I IDLE SPEED ADJUSTMENT 6 7 IGNITIO...

Page 110: ...ING OR SLIDING 3 14 SPARK ARRESTER 6 27 SPARK PLUG 6 4 STARTING OFF 3 9 STARTING OFF AND STOPPING 4 4 STARTING THE ENGINE 3 8 STARTING THE LT Z90 AFTER TRANSPORT 8 3 STORAGE PROCEDURE 9 4 T THROTTLE C...

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