Suzuki LT-R450K6 User guide

K6
December ’05 Printed in Japan (TK) 19
99505-01046-01E
FOREWORD
This vehicle has been designed and produced utilizing Suzuki’s most modern tech-
nology. The finest product, however, cannot perform properly unless it is correctly
assembled and serviced. This set-up manual has been produced to aid you in prop-
erly assembling and servicing this vehicle.
Please review this set-up manual carefully before 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 potential hazard that could result in vehicle damage.
This set-up manual is based on a vehicle of standard specification. Some minor dif-
ferences from this manual may be found in other specifications.

1
PREPARATION
WORKSHOP
#
A: Packed vehicle
B: Working space
SELF PROTECTION
#
UNCRATING THE VEHICLE
Remove the carton.
#
A: Crate
The 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.

2
FRONT REAR
Remove the bolts and brackets.
A: Bolt
B: Bracket
C: Vinyl tube
Loosen the front brake master cylinder mounting bolts.
Remove the master cylinder from the bracket.

A: Bolt
B: Front brake master cylinder
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.
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 careful not to scratch the vehicle.

3
LOCATION OF PARTS
Check all the components which have been removed from the base of the crate.
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
AHeadlight cover 1
Tapping screw 4 5 × 16 mm
B Steering head cover 1
CStrap 2 L:120
DHolder 1 For front brake
master cylinder
Flange bolt 2 6 × 25 mm
E Fuel tank vent hose 1
F Warning label set
3For
E-19 CG selection
2For
E-19 CH selection
3For
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
IBattery electrolyte
container 1
J Owner’s manual 1
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
TL
OD ID
NOTE:
The parts shown as Item F, G and H in the above table are supplied for limited markets.
Please hand over the parts shown as Item H in the above table to your customer together with vehicle.
ACB G DEF F

4
The photograph shown indicates 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
EE
FF
DD
CC
AA
BB
G
G
HHJIIJ

5
Before assembling the vehicle, thoroughly under-
stand the “Safety Check Out” described on page
32.
After completion of assembly, carefully 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.

6
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
FRONT BRAKE MASTER CYLINDER
Install the front brake master cylinder onto the handle-
bars.
Align the dot mark on the handlebars with the master
cylinder-to-holder fitting surface.
Tighten the master cylinder mounting bolts to the
specified torque.
"Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: Holder
B: Front brake master 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

Aof the front side with specified
torque and then tighten the bolt

Bof 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, first tighten the
bolt

Cof the upper side with specified torque
and then tighten the bolt

Dof the lower side.
NOTE:
Install the holder in position according to the
mark “UP”.
Make sure that the holder has no clearance at
the upper side as shown.
Check for brake fluid leakage.

7
Connect the front brake light switch lead wires coupler
to the brake light switch.
A: Front brake light switch
B: Lead wire coupler
CLUTCH LEVER HOLDER
Loosen the bolts.
Move the lever holder at the correct position.
Align the dot mark on the handlebars with the clutch
lever 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 wirings.
Refer to them in addition to following the
instructions carefully.

8
STEERING HEAD COVER
Remove the indicator light lens from the socket boot.
A: Indicator light lens
B: Socket boot
Install the socket boot to the steering head cover.
A: Steering head cover
B: Socket boot
C: Yellow with black 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 steering head cover.

9
Align the recess of steering head cover on the handle-
bars.
Push down the steering head cover firmly.
A: Recess
B: Steering head cover
CLAMP
Clamp the wiring harness of handlebar left switch,
clutch lever position switch and choke cable with
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 to bend or twist the hose when
installing.