Suzuki LT-Z50 User manual

GROUP INDEX
GENERAL INFORMATION1
PERIODIC MAINTENANCE2
ENGINE3
FUEL SYSTEM4
CHASSIS5
ELECTRICAL SYSTEM6
SERVICING INFORMATION7
FOREWORD
This manual contains an introductory description on
the SUZUKI LT-Z50 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its mainte-
nance. Use this section as well as other sections to
use as a guide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2005
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual vehicle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcy-
cle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.
99500-40011-03E
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03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
SUPPLEMENTS
LT-Z50K9 (09-MODEL) 8
11
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HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front and rear wheel
1Front tire
2Front wheel
3Rear tire
4Rear wheel
A
Wheel set nut (front & rear)

ITEM N·m
kgf-m lb-ft
A28 2.8 20.0
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SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque. Measure in voltage range.
Apply oil. Use engine oil unless other-
wise specified. Measure in current range.
Apply molybdenum oil solution.
(mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1) Measure in resistance range.
Apply SUZUKI SUPER GREASE “A” or
equivalent.
99000-25010 Measure in diode test range.
Apply SUZUKI MOLY PASTE or equiva-
lent.
99000-25140 Measure in continuity test range.
Apply WATER RESISTANCE GREASE
or equivalent.
99000-25161 Use special tool.
Apply SUZUKI BOND “1215” or equiva-
lent.
99000-31110 Indication of service data.
Apply THREAD LOCK “1342” or equiva-
lent.
99000-32050
W
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GENERAL INFORMATION 1-1
1
GENERAL INFORMATION
CONTENTS
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-Z50K6 P-03 U.S.A. LM4AZ413 61100001-P-19 E.U.
P-28 Canada
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS...........................................................................1- 2
SUZUKI LT-Z50K6 (’06-MODEL)..................................................................1- 4
SERIAL NUMBER LOCATION......................................................................1- 4
FUEL AND OIL RECOMMENDATION..........................................................1- 5
FUEL (FOR USA AND CANADA)...........................................................1- 5
FUEL (FOR OTHER COUNTRIES).........................................................1- 5
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL
(FOR USA) ..............................................................................................1- 5
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL
(FOR OTHER COUNTRIES)...................................................................1- 5
BREAK-IN PROCEDURES ...........................................................................1- 6
INFORMATION LABELS...............................................................................1- 7
INFORMATION MARKS................................................................................1- 7
SPECIFICATIONS .........................................................................................1- 8
DIMENSIONS AND DRY MASS .............................................................1- 8
ENGINE...................................................................................................1- 8
DRIVE TRAIN..........................................................................................1- 8
CHASSIS.................................................................................................1- 9
ELECTRICAL..........................................................................................1- 9
CAPACITIES...........................................................................................1- 9
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1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS
and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the vehicle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-
doors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, final reduction gear box oil and
exhaust system until they have cooled.
* After servicing the fuel or exhaust systems, check all lines and fittings related to the system
for leaks.
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GENERAL INFORMATION 1-3

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negative cable from the battery.
* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and 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 installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil: batteries and tires.
* To protect Earth’s natural resources, properly dispose of used vehicle and parts.
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1-4 GENERAL INFORMATION
SUZUKI LT-Z50K6 (’06-MODEL)
• Difference between photograph and actual vehicle may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1is stamped on the left side of the rear
frame pipe. The engine serial number 2is located on the right side of the generator case. These numbers
are required especially for registering the machine and ordering spare parts.
RIGHT SIDE
LEFT SIDE
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GENERAL INFORMATION 1-5
FUEL AND OIL RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the
Research Method.
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 91 octane (Research Method) or higher. Unleaded gasoline is recom-
mended.
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR USA)
Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil.
Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of
API SF/SG or SH/SJ with JASO MA.
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an
alternative according to the following chart.
ENGINE OIL AND FINAL REDUCTION GEAR
BOX 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 API
SF/SG or SH/SJ with JASO MA.
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available, select an alternative accord-
ing to the right chart.
10W-30
10W-40. 10W-50
15W-40. 15W-50
20W-50
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1-6 GENERAL INFORMATION
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine
to maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. Refer to the following throttle position recommendations.
• Keep to these break-in throttle position:
Brake-in engine speeds
Up to 10 hours: Less than 1/2 throttle
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GENERAL INFORMATION 1-7
INFORMATION LABELS
A: Attached
INFORMATION MARKS
DLabel is attached on the left side of frame.
1Certification plate A (For P-03, 19)
2Compliance label A (For P-28)
3Manual notice label A (For P-03)
4Parking brake label (English) A (For P-03, 19, 28)
5Parking brake label (French) A (For P-28)
6Tire air pressure and warning no-passenger label (English) A (For P-03, 19, 28)
7Tire air pressure and warning no-passenger label (French) A (For P-28)
8General warning & AGE 6 label (English) A (For P-03, 19, 28)
9General warning label (French) A (For P-28)
0AGE 6 label (French) A (For P-28)
AEC mark label A (For P-19)
BICES Canada label A (For P-28)
CInformation label A (For P-03)
DApproval label A (For P-19)
ANo passenger mark (English) (For P-03, 19, 28)
BNo passenger mark (French) (For P-28)
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1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length.......................................................................... 1 270 mm(50.0 in)
Overall width........................................................................... 760 mm(29.9 in)
Overall height.......................................................................... 765 mm(30.1 in)
Wheelbase.............................................................................. 830 mm(32.7 in)
Ground clearance ................................................................... 120 mm(4.7 in)
Seat height.............................................................................. 535 mm(21.1 in)
Front track............................................................................... 575 mm(22.6 in)
Rear track ............................................................................... 575 mm(22.6 in)
Dry mass................................................................................. 76 kg (167 lbs)
ENGINE
Type........................................................................................ Four stroke, air-cooled, OHV
Number of cylinders................................................................ 1
Bore ........................................................................................ 36.0 mm (1.417 in)
Stroke...................................................................................... 48.6 mm (1.913 in)
Displacement.......................................................................... 49 cm³ (3.0 cu.in)
Compression ratio................................................................... 8.4:1
Carburetor............................................................................... MIKUNI VM13, single
Air cleaner............................................................................... Polyurethane foam element
Starter system......................................................................... Electric and recoil starter
Idle speed ............................................................................... 2 000 ± 150 r/min
DRIVE TRAIN
Reduction ratio........................................................................ 2.091 – 1.879 (Variable change)
Reduction gear ratio................................................................ 4.272 (47/11)
Final reduction ratio ................................................................ 3.700 (37/10)
Drive chain.............................................................................. D.I.D. 415, 82 links
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GENERAL INFORMATION 1-9
CHASSIS
Front suspension..................................................................... Independent, swing axle, coil spring, oil
damped
Rear suspension..................................................................... Swingarm, coil spring, oil damped
Front wheel travel.................................................................... 52 mm (2.0 in)
Rear wheel travel.................................................................... 51 mm (2.0 in)
Caster...................................................................................... 3 °
Trail......................................................................................... 10 mm (0.39 in)
Toe-in...................................................................................... 1.5 ± 3 mm (0.06 ± 0.12 in)
Camber ................................................................................... 0 °
Steering angle......................................................................... 35 °
Turning radius......................................................................... 2.0 m (6.6 ft)
Front brake.............................................................................. Drum brake
Rear brake .............................................................................. Drum brake
Front tire size .......................................................................... AT16 × 8 – 7✩, tubeless
Rear tire size........................................................................... AT16 × 8 – 7✩, tubeless
ELECTRICAL
Ignition type............................................................................. Electronic ignition (CDI)
Ignition timing.......................................................................... 20 ° B.T.D.C. at 4 600 r/min
Spark plug............................................................................... NGK CR6HSA or DENSO U20FSR-U
Battery..................................................................................... 12 V 14.4 kC (4 Ah)/10 HR
Main fuse................................................................................. 10 A
CAPACITIES
Fuel tank ................................................................................. 2.6 L (0.7/0.6 US/lmp gal)
Engine oil,oil change............................................................... 300 ml (0.6/0.5 US/Imp qt)
overhaul ................................................................. 350 ml (0.7/0.6 US/lmp qt)
Final reduction gear box oil, oil change................................... 25 ml (0.8/0.9 US/lmp oz)
overhaul ..................................... 30 ml (1.0/1.1 US/lmp oz)
These specifications are subject to change without notice.
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2
6
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE .....................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ........................................2- 3
AIR CLEANER .......................................................................................2- 3
EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT ................2- 5
VALVE CLEARANCE ............................................................................2- 5
SPARK PLUG ........................................................................................2- 7
SPARK ARRESTER ...............................................................................2- 8
FUEL LINE .............................................................................................2- 8
ENGINE OIL ...........................................................................................2- 9
FINAL REDUCTION GEAR BOX OIL ....................................................2-10
THROTTLE CABLE PLAY .....................................................................2-10
ENGINE IDLE SPEED ............................................................................2-11
DRIVE BELT ...........................................................................................2-11
DRIVE CHAIN .........................................................................................2-14
BRAKES .................................................................................................2-17
TIRES .....................................................................................................2-18
STEERING ..............................................................................................2-19
SUSPENSIONS ......................................................................................2-19
CHASSIS NUTS AND BOLTS ...............................................................2-20
GENERAL LUBRICATIONS ..................................................................2-22
COMPRESSION PRESSURE CHECK .........................................................2-23
COMPRESSION TEST PROCEDURE ...................................................2-23
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION ..............2-24
INITIAL ENGAGEMENT INSPECTION ..................................................2-24
CLUTCH LOCK-UP INSPECTION .........................................................2-25
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2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the vehicle operating at peak performance and economy.
NOTE:
More frequent servicing may be required on vehicles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
NOTE:
I = Inspect and clean, adjust, replace, or lubricate as necessary.
R = Replace
T = Tighten
C = Clean
L = Lubricate
Interval Initial
1 month Every 3 months Every 6 months
Item
Air cleaner element — C C
Exhaust pipe nuts and muffler mounting bolt T T T
Valve clearance I — I
Spark plug —— I
Replace every 18 months.
Spark arrester — C C
Fuel line —I I
Replace every 4 years.
Engine oil R—R
Inspect each time the vehicle is ridden.
Final reduction gear box oil —— I
Replace every 2 years.
Throttle cable play I I I
Idle speed I I I
Drive belt — I R
Drive chain Clean, lubricate and inspect each time the
vehicle is ridden.
Brakes I I I
Tires Inspect every month.
Steering I I I
Suspensions — — I
Chassis nuts and bolts T T T
General lubrications — L L
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PERIODIC MAINTENANCE 2-3
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item of
the periodic maintenance requirements.
Before performing the servicing procedures mentioned in the
periodic maintenance chart, remove following parts to ease ser-
vicing work;
•Seat.(5-4)
• Front frame cover. (5-4)
• Left frame cover. (5-4)
• Right frame cover. (5-4)
• Frame center cover. (5-5)
• Maintenance lid. (5-6)
• Front grip. (5-6)
AIR CLEANER
If the air cleaner is clogged with dust, intake resistance will be
increase, resulting in a decrease in engine output and an
increase in fuel consumption. Clean the air cleaner element in
the following manner.
• Remove the seat. (5-4)
• Remove the battery holder. (5-5)
• Remove the air cleaner box cap 1.
• When installing the air cleaner box cap 1, face the “UP” mark
to the top.
• Remove the air cleaner element 2.
Clean every 3 months.
UP
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2-4 PERIODIC MAINTENANCE
• Fill a container with a non-flammable cleaning solvent.
• Immerse the air cleaner element in the cleaning solvent and
wash it.
• Squeeze the cleaning solvent out of the washed element by
pressing it between the palms of both hands: do not twist or
wring the element or it will develop tears.
• Immerse the element in motor oil and squeeze the oil out of
the element leaving it slightly wet with oil.

ANon-flammable cleaning solvent
BMotor oil SAE #30
• Reinstall the cleaned air cleaner element in the reverse order
of removal.
• When installing the air cleaner box cap 1, face the “UP” mark
to the top.


Inspect the air cleaner element for tears. A torn ele-
ment must be replaced.
Be sure to position the element snugly and correctly,
so that no incoming air will by-pass it. Remember, the
rapid wear of piston rings and the cylinder bore is
often caused by a defective or poorly fitted element.
If driving under dusty conditions, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to operate the engine without the ele-
ment or to use a torn element. Make sure that the air
cleaner is in good condition at all times. The life of the
engine depends largely on this component!
UP
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PERIODIC MAINTENANCE 2-5
EXHAUST PIPE NUTS AND MUFFLER
MOUNTING BOLT
• Tighten the exhaust pipe nuts 1and muffler mounting bolt 2
to the specified torque.
Exhaust pipe nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Muffler mounting bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
VALVE CLEARANCE
Excessive valve clearance results in valve noise and insufficient
valve clearance results in valve damage and reduced power.
Check the intake and exhaust valve clearances at the interval
indicated above and adjust the valve clearances to specification,
if necessary.
• Remove the right frame cover. (5-4)
• Remove the spark plug. (2-7)
• Remove the cylinder head cover 1.
• Remove the generator rotor cover 2.
NOTE:
* Valve clearance is to be checked when the engine is cold.
* The intake and exhaust valves must be checked and adjusted
when the piston is at Top-Dead-Center (TDC) of the compres-
sion stroke.
Tighten initially at 1 month and every 3 months there-
after.
Inspect initially at 1 month and every 6 months there-
after.
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