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.

10
HEADLIGHT COVER
Remove the rubber boot.
Disconnect the headlight coupler.
A: Rubber boot
B: Headlight coupler
Remove the headlight assembly.
A: Headlight assembly
B: Flange stepped bolt
C: Boss
Install the headlight cover to the headlight assembly.
A: Headlight cover
B: Headlight assembly
C: 5 × 16 mm tapping screw
Reinstall the headlight assembly at the correct posi-
tion.
Connect the headlight coupler correctly.
Install the rubber boot.
A: Headlight assembly
B: Flange stepped bolt
C: Headlight coupler

11
RIGHT LEFT
Attach a hoist band onto the vehicle.

A: Hoist band
B: Pad
C: Frame
D: Brake pedal

1Lift the vehicle with a hoist, then balance the vehi-
cle.

2. Raise the front of vehicle.

3. Pull the crate base backward, then balance the
vehicle.
Place the vehicle in a clean working area and then
remove the hoist hook.
RIGHT
OWNER’S MANUAL
Pull the seat lock cable and remove the seat.
A: Seat lock cable
Store the owner’s manual in place.
A: Owner’s manual
Put a suitable pad between the vehicle body
and hoist band to prevent the body from being
damaged.
Pass the hoist band through inside the brake
pedal.

12
Reinstall the seat.
Insert the boss into the guide.
Push the seat down firmly.
A: Seat assembly
B: Guide
C: Boss
WARNING LABEL
(FOR E-19 MARKET)
Select the appropriate language label for your country.
Stick the label selected for your country.
A: Warning label (General warning)
B: Warning label (Tire information)
C: Warning label (Age 16)
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
NOTE:
For E-19 CG selection: German, Spanish, Portuguese
For E-19 CH selection: French, Dutch
For E-19 CI selection: Swedish, Finnish, Danish
UNLEADED
FUEL ONLY

13
SERVICING
BATTERY
Remove the screw to take off battery cover.
Remove the battery from the vehicle.
A: Battery cover
B: Screw
C: Hook
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.

14
With just enough force to break the nozzle seal of elec-
trolyte container, push each nozzle of the electrolyte
container into the battery’s electrolyte filler ports and
hold the container 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.

15
After confirming that the electrolyte has entered the
battery completely, remove the electrolyte containers
from the battery.
Wait for around 20 minutes.
Insert the caps into the filler holes, pressing in firmly so
that the top of the each caps does not protrude above
the upper surface of the battery’s top cover.
A: Caps

Charge the battery with a battery charger.

After charging the battery, install the battery 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 with the cap facing upward
during charging.
When attaching the wiring harness battery
leads to the battery terminals, observe the cor-
rect polarity.
NOTE:
The terminal bolts and nuts are attached to the
battery.

16
1. Set the battery to the box.
2. First connect the

+lead to the

+positive terminal
of the battery.
3. Cover

+terminal with rubber boot.
4. Connect the

-lead to the

-negative terminal of
the battery.
5. Reinstall the battery cover using the screw.
A:

+ lead
B:

- lead
C: Rubber boot
FRONT REAR
BRAKE FLUID
Keep the vehicle upright and place the handlebars
straight.
Check the brake fluid level in both the front and rear
master cylinder reservoirs.
If the fluid level is below the lower level indicated in the
figure, add the correct type of brake fluid.
Refer to the chart below for the proper selection.

A: Lower level line
B: Upper level line
FRONT BRAKE LEVER
Check the brake lever play at the adjuster bolt.
Front brake lever adjuster bolt length: 11–15 mm
If adjustment is necessary, carry out the procedure
below:
1. Loosen the lock nut

A.
2. Turn the adjuster

Bin or out until the correct length.
3. Tighten the lock nut

A.
Specification and Classification
DOT 4
Be careful not to spill any brake fluid on the
paint or plastic components as they will be
damaged.

17
BRAKE AIR BLEEDING
Any air which may have been trapped in the brake fluid
circuit must be bled completely.
If the brake lever or brake pedal feels spongy or weak,
then most likely there is air in the hydraulic circuit.
To bleed the air from the front brake, use the following
procedure.
1. Connect a clear hose to the air bleeder valve and
run the hose into a suitable clear container.
2. Pour approximately 1/2 in of brake fluid into the con-
tainer so that the end of the clear hose is sub-
merged and cannot draw any additional air back into
the circuit during the air bleeding servicing.
3. Close the valve, pump and squeeze the lever, and
open the valve while squeezing brake lever.
4. Repeat this process until the fluid flowing into the
receptacle no longer contains air bubbles.
5. After bleeding the brake circuit, tighten the bleeder
valve to the specified torque.
Replace the rubber protective cap.
6. Be sure to check the brake fluid level in the reser-
voir.
"Brake caliper air bleeder valve:
6.0 N·m (0.60 kgf-m)
A: Bleeder valve
REAR
The procedure to bleed the rear brake is identical to
that of the front.
A: Bleeder valve
NOTE:
Do not drop brake fluid level below lower level
line while bleeding air.
FRONT

18
THROTTLE CABLE
Check the throttle cable play at the throttle lever end.
Throttle cable play: 3.0–5.0 mm
If adjustment is necessary, carry out the procedure
below:
1. Loosen the throttle cable adjuster lock nut

A.
2. Turn the adjuster

Bin or out until the correct play.
3. Tighten the lock nut

Awhile holding the adjuster

B.
Place the rubber boot

C.
#
CHOKE CABLE
Check the free play in the choke cable.
Choke cable play: 0.5–1.0 mm
If the cable needs adjusting, use the following proce-
dure.
1. Loosen the lock nut

Band turn the adjuster

Ato
obtain the correct free play in the choke cable.
2. Move the cable back and forth firmly to ensure that
the correct amount of free play is available and that
the cable housing is properly seated in the adjuster

A.
3. Tighten the lock nut

B, and set the rubber boot

C
to correct position.
CLUTCH CABLE
Check the clutch lever play at the clutch lever end
when the lever is lightly pulled in towards the grip.
Clutch lever play: 10–15 mm
If adjustment is necessary, carry out the procedure
below:
1. Turn in the clutch lever adjuster

D.
2. Loosen the cable adjuster lock nut

A.
3. Turn the cable adjuster

Bto obtain the correct play.
4. Tighten the lock nut

A.
5. 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.
NOTE:
Minor adjustments can now be made with the
clutch lever adjuster

D.

19
BRAKE PEDAL
Check the rear brake pedal height.
Brake pedal height: 0–10 mm
If the rear brake pedal height is not correct, adjust in
the following manner:
1. Loosen the lock nut

A.
2. Rotate the push rod

Bto locate the pedal to the
correct height below the top face of the footrest

C.
Be sure to measure this height carefully.
3. Tighten the lock nut

Ato the specified torque.
"Rear brake push rod lock nut:
18.0 N·m (1.8 kgf-m)
PARKING BRAKE
Parking brake adjustment may be required if the park-
ing brake does not work properly.
Parking brake cable length: 49–53 mm
1. Loosen the lock nut

A. Turn out the adjuster

B.
2. Loosen the lock nut

D. Turn the adjuster

Cto
obtain the correct cable length.
Tighten the lock nut

D.
3. Turn the adjuster

Bclockwise until it stops, then
turn the adjuster counterclockwise 1/8–1/4 turn.
4. Tighten the lock nut

Awhile holding the adjuster

B
in position.
#
After adjusting the parking brake, check that
there is no dragging when turning the rear
wheel with the wheel off the ground.
Also check the rear wheels are locked when the
parking brake is set.