Suzuki LT-Z90K7 Setup Manual Download

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Clamp

Throttle cable

Front brake cable

Bracket

Fix the boot of the front brake cable.

Rear brake cable

Pass the rear brake cable through
underside of the frame.

Pass the rear brake cable through
inside of the rear fender.

Pass the rear brake cable through
outside of the rear belt cooling duct.

Clamp

Rear brake cable

Wiring harness

Throttle cable

Front brake cable (L)

Front brake cable (R)

Front brake cable (L)

Front brake cable (R)

Rear brake cable

Mounting plate

Adjuster nut

Cable protector

Summary of Contents for LT-Z90K7

Page 1: ... 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 pot...

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 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 ...

Page 4: ...lange nut 8 10 mm Washer 8 OD 20 0 ID 10 5 E Pin 1 For rear brake cable Adjuster nut 1 F Reflex reflector 2 Right and Left Bracket 2 Flange nut 2 5 mm G 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 H Fuel label 1 I Battery electrolyte container 1 J Owner s manual 1 OD Outside diameter mm ID Inside diameter mm L Length mm T Th...

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

Page 6: ...t 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 A of the front side with specified torque and then tighten the bolt B of the ...

Page 7: ...e 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 c...

Page 8: ...ng 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 ...

Page 9: ...nto 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...

Page 10: ...row 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 card...

Page 11: ...ighten the wheel set nuts to the specified torque Wheel set nut 55 N m 5 5 kgf m A 10 mm flange nut Wheel set nut STEERING HEAD COVER Align the recess of steering head cover on the handle bars Fix the steering head cover by push down firmly A Steering head cover B Handlebars C Recess FRONT GRIP Install the front grip on the frame using four bolts A Front grip B Frame C 8 16 mm flange bolt NOTE Be ...

Page 12: ...r bolts together with the reflector assembly A Front grip B Frame C 8 16 mm flange bolt D Reflex reflector E Bracket F Boss G Mark R and L 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 head cover A Fuel tank vent hose B Fuel tank cap C Hole Be sure not to bend or twist the hose when installing ...

Page 13: ... excédant vos compétences ou les conditions de conduite sur les routes publiques au risque de provoquer une collision avec une autre véhicule avec un passager les passagers affectent l équilibre et la manoeuvrabilité et augmentent le risque de perte de contrôle TOUJOURS utiliser des techniques de conduite acceptées pour éviter le renversement du véhicule sur collines terrains accidentés et dans le...

Page 14: ...our country A Warning label General warning B Warning label Tire information C Warning label Age 12 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 FRONT ...

Page 15: ...d remove the seat A Seat release lever Unhook the clamp to take off the CDI wiring harness Remove the rubber band Remove the battery from the vehicle A Clamp B Rubber band Filling electrolyte Remove the aluminium tape sealing the battery elec trolyte filler holes A Aluminium tape B Electrolyte filler hole ...

Page 16: ...e 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 Use the removed caps as the sealed caps of battery filler holes Do not remove or pierce the sealed areas of the electrolyte container NOTE If no air bubbles are coming up from a filler port...

Page 17: ...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 18: ...battery with rubber band 6 Clamp the wiring harness A lead B lead C Rubber boot D Rubber band E Clamp 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 down the seat firmly A Seat assembly B Hook C Hook retainer D Seat lock lever E Hole Check the rubber cushions are installed in the correct position before inst...

Page 19: ...Loosen the throttle cable adjuster lock nut A 3 Turn the adjuster B in or out until the correct play 4 Tighten the lock nut A while holding the adjuster B Place the rubber boot C 5 Reinstall the steering head cover 3 0 5 0 mm 3 0 5 0 mm 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 20: ...hat at least 5 mm of the adjuster threads are inserted in the lever holder C as shown in the photograph Tighten the lock nuts E If the cable adjusters D 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 up po...

Page 21: ...r nuts C equally 4 When proper slack is obtained tighten the bolts A and B 5 Tighten the adjusting nuts C 6 Reinstall the chain case cover Rear axle housing bolt A 94 N m 9 4 kgf m Rear axle housing bolt B 110 N m 11 0 kgf m Chain adjuster nut C 15 N m 1 5 kgf m Verify that the master link clip is installed properly The opening of the master link clip faces away from the direction of travel A Dire...

Page 22: ...e 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 D if ...

Page 23: ...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 Oil drain plug 18 N m 1 8 kgf m A Engine oil filler plug B Engine oil dipstick Engine oil Oil quality is a major contributor to your engine s per for...

Page 24: ...ation for con firming the standard A Code number of oil sales company B Oil classification Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oils Some engine oils which is API SH or greater has ENERGY CONSERVING indication in API classifica tion doughnut mark These oils can affect engine life and clutch perfor mance NOTE If the vehicle is used in very cold weather below 10 C...

Page 25: ...ne idle speed 1 800 2 000 r min A Throttle stop screw TRANSMISSION OIL Transmission oil is factory filled requiring no mainte nance 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 TIRE PRESSURE FRONT REAR 22 5 kPa 0 225 kgf cm2...

Page 26: ...G Rear axle nut 75 7 5 H Rear shock absorber bolt Upper 29 2 9 I Rear brake cam lever nut 7 7 0 77 OTHERS J Front footrest bolt 55 5 5 K Rear swingarm pivot nut 130 13 0 L Rear axle housing bolt Upper 94 9 4 M Rear axle housing bolt Lower 110 11 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 ...

Page 27: ...arness Wiring harness Wiring harness Battery lead wire Battery lead wire Battery lead wire Battery lead wire Battery lead wire Battery lead wire Regulator Rectifier lead wire Regulator Rectifier lead wire Starter motor lead wire Generator lead wire Generator lead wire Clamp Clamp Clamp Clamp Breather hose Frame Wiring harness Clamp the wiring harness inside of the frame Ignition switch Ignition co...

Page 28: ...h downside of the frame Align the clearance Front brake cable L Front brake cable L Front brake cable R Front brake cable R Rear brake cable Throttle cable Throttle cable Front brake cable R Front brake cable L Front brake cable L Front brake cable R Rear brake cable Pass the throttle cable through inside of the rear brake cable Pass the front brake cable through outside of the rear brake cable ...

Page 29: ...ar brake cable through inside of the rear fender Pass the rear brake cable through outside of the rear belt cooling duct Clamp Rear brake cable Rear brake cable Wiring harness Wiring harness Throttle cable Throttle cable Front brake cable L Front brake cable R Front brake cable L Front brake cable R Rear brake cable Mounting plate Adjuster nut Adjuster nut Cable protector ...

Page 30: ...ar Parkingbrake lever Check Adjust 3 0 5 0 mm Drive chain Lubricate Check Adjust 15 25 mm Oiling points All necessary points Battery Filling electrolyte Wiring and cable Routing Operation Wiring connectors Clean Tight Suspensions Operation 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-Z90K7, Setup Manual

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