Suzuki 2009 LT-R450 Service Manual Download

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Summary of Contents for 2009 LT-R450

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Page 2: ...ce manual for details which are not given in this manual SPECIFICATIONS 3 MAINTENANCE AND TUNE UP PROCEDURES 4 BRAKES 4 OIL JET 6 REMOVAL 6 INSPECTION AND CLEANING 6 INSTALLATION 6 ENGINE LUBRICATION SYSTEM CHART 7 FI SYSTEM DIAGNOSIS 8 FI SYSTEM WIRING DIAGRAM 8 ECM TERMINAL 9 DTC TABLE AND DEFECTIVE CONDITION 10 FI SYSTEM TROUBLESHOOTING 12 COOLING FAN RELAY 20 SENSOR 20 IAP SENSOR INSPECTION 20...

Page 3: ...NG 32 THROTTLE BODY INSTALLATION 33 BRAKE PEDAL INSTALLATION 34 HANDLEBAR INSTALLATION 35 TIGHTENING TORQUE 36 SERVICE DATA 36 WIRING DIAGRAM 45 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO LT R450 Z E 19 E 28 E 33 E U Canada California U S A JSAAL43A 92100001 JSAAL43A 92100001 JSAAL43A 92100001 ...

Page 4: ...96 Links CHASSIS Front suspension Independent double wishbone coil spring oil damped Rear suspension Swingarm type coil spring oil damped Front wheel travel 254 mm 10 0 in Rear wheel travel 277 mm 10 9 in Caster 8 0 Trail 30 mm 1 18 in Toe in 0 mm Camber 3 0 Steering angle 41 Turning radius 3 5 m 11 5 ft Front brake Disc brake twin Rear brake Disc brake Front tire size AT20 7 R10 tubeless Rear tir...

Page 5: ...position The standard adjuster length A is 11 15 mm 0 4 0 6 in Tighten the lock nut 1 securely Front brake lever adjuster lock nut 5 N m 0 5 kgf m 3 5 lbf ft REAR BRAKE PEDAL AND LEVER The procedure for adjusting the rear brake pedal and brake lever is as follows NOTE First adjust the brake pedal and then adjust the brake lever Brake pedal Turn the adjuster 1 in or out until the pedal height A to ...

Page 6: ...LT R450 ZK9 09 MODEL 5 Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed PARKING BRAKE LT R450K8 2 19 ...

Page 7: ...eck the oil jet for clogging If they are clogged clean their oil passage with a proper wire and compressed air INSTALLATION Apply engine oil to the O ring 1 Install the piston cooling oil jet 2 Apply a small quantity of THREAD LOCK to the piston cooling oil jet bolt and then tighten the bolt 99000 32110 THREAD LOCK SUPER 1322 or equivalent Use a new O ring to prevent oil leakage ...

Page 8: ...CRANK PIN CONROD BIG END BEARING RIGHT CRANKCASE CYLINDER CYLINDER HEAD CAMSHAFT JOURNAL IN EX CAM FACE IN EX OIL NOZZLE PISTON PIN PISTON CYLINDER WALL SPACER DRIVESHAFT CLUTCH OIL FILTER OIL STRAINER REAR OIL PUMP NO 2 LEFT CRANKCASE COUNTERSHAFT COUNTER GEARS OIL STRAINER FRONT OIL PUMP FOR RETURN GENERATOR COVER OIL HOSE OIL TANK OIL HOSE OIL PUMP NO 1 OIL JET K8 K9 ...

Page 9: ...or IAPS Engine coolant temperature sensor ECTS Intake air temperature sensor IATS Tip over sensor TOS Fuel injector FI Cooling fan relay Cooling fan 10A 10A 20A Fuel pump Starter switch Starter relay Starter motor Neutral indicator light Fuel indicator light FI light Ignition coil IG COIL to fuel sensor Gear position switch 1 2 3 4 5 N M Battery Engine stop switch Ignition switch Clutch lever posi...

Page 10: ...TP sensor signal TP M 6 IAP sensor signal IAP N Sensors ground E2 7 O IAT sensor signal IAT 8 ECM ground E1 P 9 CKP sensor signal CKP Q 0 Serial data for self diagnosis R A S Mode select switch B Neutral switch NT T Starter motor STA C Power source for sensors VCC U D Fuel pump power source FPP V E Fuel pump FP W Cooling fan relay FAR F Injector 11 X G Fuel indicator Y Ground E01 H Ignition coil Z...

Page 11: ...range C15 P0115 is indicated ECT sensor lead wire coupler connection P0115 H Sensor voltage is higher than specified value ECT sensor circuit open or ground circuit open L Sensor voltage is lower than specified value ECT sensor circuit shorted to ground C17 IAP sensor The sensor should produce following voltage 0 2 V sensor voltage 4 1 V In other than the above range C17 P0105 is indicated IAP sen...

Page 12: ...g coupler con nection power supply from the battery P0351 C31 Gear posi tion signal Gear position signal voltage should be higher than the following for 3 seconds and more Gear position switch voltage 0 9 V If lower than the above value C31 P0705 is indicated GP switch wiring coupler con nection gearshift cam etc P0705 C32 Fuel injector CKP sensor pickup coil signal is pro duced but fuel injector ...

Page 13: ...pheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECM malfunction P0105 H Sensor voltage is higher than specified value I...

Page 14: ...e set Tester knob indication Voltage Is the voltage OK Step 1 When indicating P0105 H 1 Turn the ignition switch OFF 2 Remove the engine mounting left upper bracket 1 by remov ing the bolts 2 and washers 3 LT R450K8 3 6 3 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between Re...

Page 15: ...on switch OFF 2 Remove the engine mounting left upper bracket 1 by remov ing the bolts 2 and washers 3 LT R450K8 3 6 3 Check the IAP sensor coupler for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5 Check the continuity between G B wire B and ground 6 Also check the continuity between G B wire B and B Br wire C If the sound is not ...

Page 16: ...engine at idle speed and measure the IAP sensor output voltage at the wire side coupler between G B and B Br wires IAP sensor output voltage Approx 2 1 V at idle speed G B B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool LT R450K8 4 25 When using the multi circu...

Page 17: ...0 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool LT R450K8 4 25 YES G B Red or B Br wire open or shorted to ground or poor 6 C or N connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a ...

Page 18: ...nt temp 20 30 C 68 86 F ALTITUDE Reference ATMOSPHERIC PRESSURE OUTPUT VOLTAGE ft m mmHg kPa V 0 2 000 0 610 760 707 100 94 3 1 3 6 2 001 5 000 611 1 524 707 634 94 85 2 8 3 4 5 001 8 000 1 525 2 438 634 567 85 76 2 6 3 1 8 001 10 000 2 439 3 048 567 526 76 70 2 4 2 9 ...

Page 19: ... input voltage 4 Disconnect the ECM coupler 5 Insert the needle pointed probe to the ECM coupler 6 Measure the voltage between terminal D and ground FP relay input voltage Battery voltage 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although FP relay is turned ON FP rela...

Page 20: ...onnection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Open or short circuit in the O W wire When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal ben...

Page 21: ...ling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 90 C 194 F after starting the engine 5 Click Stop 3 to check the operation properly SENSOR IAP SENSOR INSPECTION The intake air pressure sensor is installed at the top side of the throttle body Page 12 IAP SENSOR REMOVAL AND INSTALLATION Remove the fuel tank and fuel tank lower cover LT ...

Page 22: ...ve 2 Throttle body 8 Throttle cable cover 3 Fuel delivery pipe 9 IAP sensor ITEM N m kgf m lbf ft 4 O ring A Fuel delivery pipe mounting screw A 3 5 0 35 2 5 5 Fuel injector B Fuel injector mounting screw B 3 5 0 35 2 5 6 Injector seal C TP sensor mounting screw C 3 5 0 35 2 5 ...

Page 23: ...oupler 3 and TP sensor coupler 4 Remove the throttle cable cover 5 Disconnect the throttle cable from drum Loosen the throttle body clamp screws and move the throttle body assembly upward Disconnect the starter cable from the throttle body assembly After disconnecting the throttle cables do not snap the throttle valve from full open to full close It may cause damage to the throttle valve and throt...

Page 24: ...T R450 ZK9 09 MODEL 23 Remove the starter valve 6 and spring 7 from the starter cable NOTE Remove the IAP sensor 8 as shown in the IAP sensor removal and installation Page 20 INSTALLATION LT R450K8 5 18 ...

Page 25: ...e 3 Dust seal D Spring washer 4 Bearing E Cotter pin 5 Collar F Tie rod 6 Upper wishbone arm G Tie rod end ITEM N m kgf m lbf ft 7 Dust seal A Shock absorber mounting nut A 60 6 0 43 5 8 Collar B Wishbone arm pivot nut B 65 6 5 47 0 9 Bearing C Knuckle end nut C 29 2 9 21 0 0 Washer D Tie rod end nut D 29 2 9 21 0 A Spring washer E Tie rod lock nut E 29 2 9 21 0 1 ...

Page 26: ...c cover 0 Bearing 3 Chain guide A Outer spacer 4 Chain guide plate B Thrust bearing 5 Sprocket guard C Thrust washer 6 Chain adjuster rubber seal D Outer dust seal ITEM N m kgf m lbf ft 7 Chain buffer A Rear axle housing set nut A 28 2 8 20 0 8 Inner spacer B Swingarm pivot nut B 95 9 5 68 5 ...

Page 27: ...l the brake pedal in the reverse order of removal Pay attention to the following points Apply grease to the oil seal and brake pedal pivot bolt 99000 25010 SUZUKI SUPER GREASE A or equivalent Tighten the brake pedal pivot bolt 1 to the specified torque Brake pedal pivot bolt 29 N m 2 9 kgf m 21 0 lbf ft Install the return spring 2 properly Page 34 Install cotter pins and clip Adjust the brake peda...

Page 28: ...nd support the vehicle with jack or wooden block Remove the cushion rod lower bolt nut Remove the rear shock absorber mounting bolts nuts NOTE If it is difficult to remove the mounting bolt of the upper side remove the exhaust pipe Remove the rear shock absorber INSTALLATION LT R450K8 7 71 ...

Page 29: ...FORMATION 60 N m 6 0 kgf m 43 5 lbf ft 1 Spacer 60 N m 6 0 kgf m 43 5 lbf ft 2 Washer 78 N m 7 8 kgf m 56 5 lbf ft 3 Dust seal 78 N m 7 8 kgf m 56 5 lbf ft 78 N m 7 8 kgf m 56 5 lbf ft 4 mm 0 6 in 5 75 mm 0 23 in 5 75 mm 0 23 in 1 mm 0 04 in 15 75 mm 0 62 in e d c b a a b c d e ...

Page 30: ...n switch Handlebar switch L Clutch lever position switch Clamp Handlebar switch L Meter panel indicator light Clamp Wiring harness Wiring harness Starter lead wire Generator Gear position switch Clamp Wiring harness Clamp Wiring harness Starter cable Clamp Brake light Taillight ...

Page 31: ... of the hose Clamp Clamp Cooling fan relay Engine mounting upper bracket Install the spark plug cap firmly Ignition coil Clamp Clamp IAP sensor Clamp Clamp Clamp Install the wiring harness to the clamp Clamp Rear brake switch Rear brake switch lead wire Rear brake switch lead wire Wiring harness Clamp Clamp ...

Page 32: ...OSE 4 places 1 K8 K9 1 Install the oil tank cushion to the both sides of the oil tank 6 Breather hose 1 Oil level gauge 7 Breather hose 2 Oil return tank 8 Oil hose R 3 Oil tank 9 Oil hose L 4 Breather hose A Matching mark 5 Oil tank over flow hose ...

Page 33: ...eve shape correctly fitted inside clamp 2 After the under surface of brake pipe joint has contacted the end face of hose bracket of frame tighten the pipe joint mounting bolt 5 After the brake hose union has contacted the under surface of master cylinder tighten the union bolt 3 Clamp the brake hose firmly 6 After the brake hose union has contacted the stopper tighten the union bolt ...

Page 34: ... 1 Face the clamp ends right side 4 Fuel feed hose No 2 2 Pass the fuel vapor return hose through left side of the wiring harness 5 Intake pipe 3 Install the fuel feed hose No 2 with the white paint side to the fuel pump 6 Throttle body 4 Pass the dust guard upward of the wiring harness 7 Air cleaner 1 IAT sensor 8 Dust guard 2 Fuel vapor return hose 9 Fuel pump 3 Fuel feed hose No 1 0 Wiring harn...

Page 35: ... INSTALLATION 5 8 mm 0 22 in 11 3 mm 0 45 in 5 8 mm 0 22 in 11 3 mm 0 45 in 36 5 mm 1 44 in 7 mm 0 3 in 5 mm 0 2 in 125 8 mm 4 95 in 5 mm 0 2 in 1 Cotter pin 4 Brake pedal spring 2 Brake pedal pivot bolt 5 Brake pedal 3 Rear brake switch ...

Page 36: ...on the right grip with mark 4 Align the edge of master cylinder holder with punch mark on handlebars 2 Align the edge of throttle case upper with punch mark on handlebars 5 Align the matching surface of clutch lever holder with mark 3 Align the mark on the left grip with mark ...

Page 37: ...stem clearance IN 0 010 0 037 0 0004 0 0015 EX 0 030 0 057 0 0012 0 0022 Valve stem deflection IN EX 0 25 0 010 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve sprin...

Page 38: ...Compression pressure Automatic de comp actuated 800 kPa 8 0 kgf cm2 114 psi Piston to cylinder clearance 0 045 0 055 0 0018 0 0022 0 120 0 0047 Cylinder bore 95 500 95 515 3 7598 3 7604 Nicks or Scratches Piston diam 95 450 95 465 8 9437 3 7585 Measure at 10 mm 0 4 in from the skirt end 95 380 3 7551 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 7 6 0 30 2nd R Approx 12 3 0 48...

Page 39: ...7487 19 040 0 7496 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 30 0 65 0 012 0 026 1 0 0 04 Conrod big end width 21 75 21 80 0 8563 0 8583 Crank web to web width 62 0 0 1 2 441 0 004 Crankshaft runout 0 08 0 003 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F 10 kPa 0 1 kgf cm2 1 4 psi at 3 000 r min ITEM STANDARD LIMIT Clutch cable play 10 15 0 4 0 6 Drive plate thickness No 1 No 2 ...

Page 40: ... 4 12 57 Drive chain slack 45 55 1 8 2 2 Gearshift lever height 5 10 0 2 0 4 ITEM STANDARD SPECIFICATION NOTE Thermostat valve opening temper ature Approx 76 5 C 169 7 F Thermostat valve lift 4 5 mm 0 18 in and over at 90 C 194 F ECT sensor resistance 20 C 68 F Approx 2 6 kΩ 50 C 122 F Approx 0 772 kΩ 80 C 176 F Approx 0 279 kΩ 110 C 230 F Approx 0 118 kΩ Radiator cap valve opening pres sure 108 1...

Page 41: ... Closed Approx 1 4 kΩ Opened Approx 4 2 kΩ TP sensor output voltage Closed Approx 0 6 V Opened Approx 3 8 V ECT sensor input voltage 4 5 5 5 V ECT sensor output voltage 0 2 4 9 V ECT sensor resistance Approx 2 6 kΩ at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage 0 2 4 9 V IAT sensor resistance Approx 2 6 kΩ at 20 C 68 F TO sensor resistance 15 0 25 0 kΩ TO sensor voltage ...

Page 42: ...rator coil resistance 0 1 1 5 Ω Generator Max output Approx 240 W at 5 000 r min Generator no load voltage When engine is cold 50 V AC and more at 5 000 r min Starter motor brush length Standard 7 0 0 28 Limit 3 5 0 14 Regulated voltage 13 5 15 0 V at 5 000 r min Starter relay resistance 3 6 Ω GP switch voltage 0 9 V and more From 1st to Top Battery Type designation FTX7A BS Capacity 12 V 21 6 kC ...

Page 43: ... 2 0 150 0 165 3 5 0 138 Brake disc runout Front Rear 0 30 0 012 Master cylinder bore Front 12 700 12 743 0 5000 0 5017 Rear 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 12 657 12 684 0 4983 0 4994 Rear 12 657 12 684 0 4983 0 4994 Turning radius 3 5 m 11 5 ft Toe in with 75 kg 165 lbs 0 4 0 0 16 Camber 3 0 Caster 8 0 Wheel rim runout Front 2 0 0 08 Rear 2 0 0 08 Wheel rim size Fro...

Page 44: ... out from stiffest position Front wheel travel 254 10 0 Rear wheel travel 277 10 9 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane R 2 M 2 Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible E 28 33 Gasoline used should be graded 95 octane or hig...

Page 45: ...WIRING DIAGRAM Wiring diagram wire color refer to LT R450 service manual section WIRE COLOR ECM ...

Page 46: ...Prepared by October 2008 Part No 99501 44030 01E Printed in Japan 44 ...

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