Suzuki LT-R450K6 User manual

GENERAL INFORMATION 1-1
CONTENTS
.........................................................................
WARNING/CAUTION/NOTE 1- 2
GENERAL PRECAUTIONS ......................................................................... 1- 2
SUZUKl LT-R450K6 ('06-MODEL) ............................................................. 1- 4
.....................................................................
SERIAL NUMBER LOCATION 1- 4
.......................
1 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION 1- 5
..........................................................
FUEL (FOR USA AND CANADA)
1- 5
........................................................
FUEL (FOR OTHER COUNTRIES)
1- 5
ENGINE OIL (FOR USA)
........................................................................ 1- 5
ENGINE OIL (FOR OTHER COUNTRIES) ............................................. 1- 5
........................................................................................
BRAKE FLUID 1- 5
ENGINE COOLANT ................................................................................ 1- 6
BREAK-IN PROCEDURES ........................................................................... 1- 6
..............................................................................
INFORMATION LABELS 1- 7
SPECIFICATIONS ......................................................................................... 1- 8
.............................................................
DIMENSIONSAND DRY MASS
1- 8
ENGINE .................................................................................................. 1- 8
DRIVE TRAIN ......................................................................................... 1- 8
CHASSIS ................................................................................................ 1- 9
......................................................................................... ELECTRICAL 1- 9
CAPACITIES .......................................................................................... 1- 9
COUNTRY AND AREA CODES
The following codes stand forthe applicable country(-ies)and area(-s)
CODE
E-19
E-28
E-33
COUNTRY or AREA
E.U.
Canada
California
(U.S.A.)
EFFECTIVE FRAME NO .
JSAAL41A 62100001 -
JSAAL41A 62100001 -
JSAAL41A 62100001 -

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructionscarefully.To emphasize special information,the symbol
and the words WARNING. CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlightedby these signal words.
Indicates a potentialhazardthat could result indeath or injury.
I CAUTION I
lndicates a potential hazard that could resultinvehicledamage.
NOTE:
Indicatessoecialinformationto make maintenanceeasier orinstructionsclearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potentialhazards relating to the sewicing, or lack of servicing,
of the vehicle. In additionto the WARNINGS
and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to performa particular service operation, ask a more experiencedmechanic for advice.
GENERAL PRECAUTIONS
Proper service and repair procedures are Important for thesafety of the service mechanic and
the safety and reliability of the vehicle.
When 2 or more personswork together, pay attention tothe safety of each other.
When it is necessary to run the englne indoors, make sure that exhaust gas isforced out-
doors.
When working with toxic or flammable materials, make sure that the area you work iniswell-
ventilated andthat you follow ail of the material manufacturer's instructions.
Never use gasoline asa cleaning solvent.
'To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
untilthey have cooled.
After servicing thefuel, oil, water, exhaust or brake systems, check all lines andfittings related
tothesystem for leaks.

+ If parts replacement isnecessary, replace the partswith Suzuki Genulne Parts or their equiva-
lent.
When removlng parts that are to be reused, keep them arranged inan orderly manner sothat
they may bereinstalled inthe proper order and orientatlon.
* Besureto use special toolswhen instructed.
Make surethat all parts used in reassembly areclean. Lubricatethem when specifled.
Usethespecified lubricant. bond, or sealant.
* When removingthe battery, dlsconnect the negative cablefirst andthenthe positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover onthe positiveterminal.
When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negativecablefrom the battery.
When tightening the cylinder head or case bolts and nuts, tlghten the larger sizes first.
Always tighten the boltsand nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
Never reuse a circlip. When installinga newcircllp, takecare nottoexpand theendgap larger
than requiredto slip theclrclip over the shaft. After Installinga circlip, always ensurethat itis
completely seated
in itsgrooveand securely fltted.
' Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread issmeared with them.
1 After reassembling, check partsfor tightness and proper operation.
' Toprotecttheenvironment, do notunlawful\ydispose of used motor oil, engine coolant and
other fluids: batteries and tlres.
' To protect Earth's natural resources, properly disposeof usedvehicle and parts.

1-4 GENERAL INFORMATION
SUZUKI LT-R450K6 ('06-MODEL)
a
Differencebetween photograph andactual vehicle may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) (1) is stamped on the right side of the
steering head pipe. The engine serial number
la is located on the rear side of the crankcase. These num-
bers are required especially for registeringthe machine and orderingspare parts.

GENERAL INFORMATION 1-5
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleadedgasoline of at least 90 pump octane (Rl2 + Ml2).
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol
with appropriate cosolvents and corrosion inhibitor is permissible.
FUEL (FOR OTHER COUNTRIES)
Gasoline used should be graded 95 octane (Research Method) or higher. Unleaded gasoline is recom-
mended.
ENGINE OIL (FOR USA)
Oil quality is a major contributorto your engine's performance and life.Always select good quality engine oil.
Suzuki recommends the use of SUZUKl PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of
SFISG or SHISJ in API with MA inJASO.
Suzuki recommends the use of SAE 10W-40engine oil. if SAE 10W-40engine oil is not available,select an
alternativeaccording to the following chart.
ENGINE OIL (FOR OTHER COUNTRIES)
Oil quality is a major contributor to your engine's performance
and life. Always select good quality engine oil. Use of SF/SG or
SHISJ inAPI with MA in JASO.
Suzuki recommends the use of SAE 10W-40 engine oil.
If SAE
10W-40engine oil is not available, select an alternative accord-
ing to the right chart.
BRAKE FLUID
Specificationand classification: DOT 4
Since the brake system of this vehicle isfilled with a glycol-based brakefluid by the manufac-
turer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluidtor refillingthe system, otherwiseserious damage will result.
Donotuseany brake fluid taken from old or usedorunsealedcontainers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

1-6 GENERAL INFORMATION
ENGINE COOLANT
Use an anti-freezelenginecoolant compatible with an aluminum radiator, mixedwith distilledwater only.
WATER FOR MIXING
Use distilledwater only. Water other than distilled water can corrode and clog the aluminum radiator.
ANTI-FREEZUENGINE COOLANT
The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze.Therefore, the engine
coolantshould be usedat all times eventhough the atmospheric temperatureinyour area does not go down
to freezing point.
Suzuki recommends the use of SUZUKl COOLANT anti-freezelengine coolant.
If this is not available, use
an equivalent which is compatiblewith an aluminum radiator.
LIQUID AMOUNT OF WATERlENGlNE COOLANT
Solutioncapacity (total): Approx. 1 400 ml(1.511.2 USllmpqt)
For engine coolant mixtureinformation, refer to cooling system section in page
6-2.
CAUTION
Mixing of anti-freezelengine coolant should be limited to 60%. Mixing beyond it would reduce
itsefficiency. Ifthe anti-freezelengine coolant mixing ratio is below
50% rust inhabiting perfor-
mance isgreatly reduced. Besure to mix it above
50% even though the atmospheric tempera-
ture does notgo downtothefreezing polnt.
BREAK-IN PROCEDURES
Duringmanufacture only the best possible materialsare used and all machinedparts are finished to a very
highstandard but it is still necessary to allow the moving parts to "BREAK-IN"before subjecting the engine
to maximumstresses. The future performanceand reliabilityofthe engine depends on the care and restraint
exercisedduring its early life. The general rules are as follows.
Keep to these break-in engine speed limits:
Break-In englne speeds
Initial
10 hours: Lessthan % throttle
After the engine has been operatedfor 10 hours the engine to full throttle operation, for short periods of
time.

GENERAL INFORMATION 1-7
INFORMATION LABELS
NO
(11
(2' Informationlabel ,EN
(3' Tireair pressurelabel (Warningno-passenger) :E,
(41 Tire air pressurelabel (Warning no-passenger) lr'
(51 Generalwarning and Age,l6 label 'E:
'61 Generalwarning label F'
~~~
-
'I1 Warning no-passengermark (El
-.
LABELor PLATE NAME
Certlf~callonpalo IE'
Swingarm
(81 Wamin
-
0
-
0
-
0
g no-passengermark 8 1Fi
Umersutlace
APPLIED SPECIFICATION
-
-
-
-
-
9'
'I0
(11'
oZ
'13
t14
-
4
'$6
\
@l Rghlside of frame
E-19
-
0
0
0
0
-
Age, 16 label iFI
Manualnolice label 'B
ICESCanada label !E 'F;
Comoliancelabel 'D
-
0
0
-
-
Chain adjuslmenl label {Fi
~ .-
Chain adjuslment label 'El
EC approval mark
Fuelinformation label
:E' !F
Fuel information label E',
eH side offrame
0
0
-
0
-
0
0
0
-
0
n
oiiue~tank cover
E-28
-
-
0
-
-
.,
0
0
-
0
-
E-33
0
-
-
0
-
-
n
-
0

1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ......................................................
Overall width ........................................................
Overall height ............. ...... .............................
Wheelbase ...........................................................
Fronttrack ............................................................
Reartrack .........................................................
Ground clearance .................... ... ...................
Seat height ...................... ... .............................
Dry mass ..............................................................
ENGINE
Type .................... .... .......................................
Number of cylinders .............................................
Bore .....................................................................
Stroke ...................................................................
Displacement .......................................................
Compression ratio .............................................
Fuel system ........................................................
Air cleaner ............................................................
Startersystem ......................................................
Lubricationsystem ...............................................
Idle speed ..................................................
DRIVE TRAIN
Clutch ...................................................................
. .
Transm~ss~on ....... ....... .................................
Gearshiftpattern ..................................................
Primary reduction ratio .........................................
............................................... Gear ratios, Low
2nd..
................... ... ....................
3rd ..................................................
4th ...................................................
Top ..............................................
Finalreduction ratio .............................................
Drivechain ...........................................................
1845 mm (72.6 in)
1245 mm (49.0 in)
1085 mm (42.7 in)
1 285 mm (50.6 in)
1045 mm (41.1 in)
985 mm (38.8in)
240 mm (9.4in)
780 mm (30.7in)
167 kg (368Ibs)
Four stroke, liquid-cooled,DOHC
1
95.5 mm (3.760in)
62.8 mm (2.472in)
450 cm3(27.5 cu. in)
11.7: 1
Fuel injection
Polyurethane foam element
Electric
Dry sump
1800 100 rlmin
Wet multi-platetype
5-forward
1down 4 up, foot operated
2.851 (77127)
2.076 (2711
3)
1.647 (28117)
1.333 (28121)
1.095 (23121)
0.913 (21123)
2.571 (36114)
RK 520SMOZlOS. 96 Links

GENERAL INFORMATION 1-9
CHASSIS
Front suspension .................................................
Rear suspension ................... .. .........................
Frontwheel travel ................................................
.................. Rear wheel travel ................... ....
Caster ..................................................................
Trail .................... ....... ..................................
Toe-in ..................................................................
.................................... .................... Camber ..
Steeringangle ................................... .... ..............
Turning radius ..................... .... .....................
Front brake ..........................................................
Rear brake ................... ... ............................
Front tire size ....................................................
. .
Rear ttre slze .......................................................
ELECTRICAL
Spark plug ...........................................................
Battery .................................................................
Generator ............................................................
Mainfuse ............... ... .......................................
Fan fuse
Ignitionfuse
.........................................................
Headlight .............................................................
Brake lightrraillight ..............................................
Neutralindicator light ......................................
Fuel indicator light ...............................................
Coolant tempereturel
Fuelinjectionwarning light
................ ...........
CAPACITIES
Fueltank, includingreserve ................................
Engineoil, oil change .........................................
with filter change ...............................
......................................... overhaul
Coolant
................................................................
Independent, double wishbone, coilspring, oil damped
Swingarrntype, coil spring, oil damped
254 rnm (10.0
in)
277 mm (10.9 in)
8.0"
30 mm (1.18 in)
0 mm
-3.0"
41"
3.5 m (11.5
fl)
Disc brake,twin
Disc brake
AT20
x 7 RlO.>{f<fy, tubeless
AT18
x 10 R868j>, tubeless
Electronicignition (Transistorized)
8" B.T.D.C. at 1800 rlmin
NGK CR8EB
12 V 21.6 kc(6Ah)/lO HR
Three-phaseA.C. generator
20
A
10 A
10 A
12 V 40140
W
LED
12v3.4 W
12v3.4 W
10.0 L (2.612.2 USIlmpgal)
Oil tank 1200 ml (1.311.1 USIlrnpqt)
Engine 400 ml (0.410.4 USIlmpqt)
Oil tank 1300 ml (1.411.1 USIlmp qt)
Engine 400 ml (0.410.4 USllmp qt)
Oil tank 1400 ml (1.511.2 USllmp qt)
Engine 400 ml (0.410.4 USllmp qt)
1.4 L (1.511.2 USllmpqt)
These specifications are subject to change without notice.