Suzuki LT-Z50K6 User guide

K6
June ’05 Printed in Japan (TK) 28
99505-01006-01E
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 special
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) cate-
gories 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.
Remove the straps holding the handlebar assembly.
A: Bolt
B: Bracket
C: Vinyl tube
D: Strap
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.
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
A
Handlebar clamp(Upper) 2
Handlebar clamp(Lower) 2
Flange bolt 4 8 × 45 mm
BHandlebar pad 1
Strap 2 L:180
C Air gauge 1
D Warning label set
3For
E-19 CG selection
2For
E-19 CH selection
3For
E-19 CI selection
Item Part Name Q’ty Remarks
E Fuel label 1
FBattery electrolyte
container 1
GOwner’s manual 1
Manual bag 1
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
TL
OD ID
NOTE:
The parts shown as Item D and E in the above table are supplied for limited markets.
A
BC

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: Tool set
C: Emergency stop switch lanyard
D: Rear wheel assembly
AA
CC
DD
EE
FF
BB
G
G

5
Before assembling the vehicle, thoroughly under-
stand the “Safety Check Out” described on page
25.
After completion of assembly, carefully check the
vehicle referring to the “Safety Check Out”, then
deliver the vehicle to the customer.
ASSEMBLY
REMOVING THE BRACKET
Remove the bracket from the handlebar mounting
position.

A: Bracket
B: Bolt
C: Paper
D: Vinyl mat
HANDLEBAR
Install the handlebars assembly using the four clamps
and four bolts.
A: Clamp (Upper)
B: Clamp (Lower)
C: 8 × 45 mm flange bolt
D: Dot mark
E: Paint mark
Be careful not to scratch the fuel tank.
NOTE:
The bracket, bolts, paper and vinyl mat are no
longer needed and may be discarded.
NOTE:
The paint mark on the clamp is rear side of
lower clamp.
Align the dot mark on the handlebars with the
mating surface of the front side of left clamp.
FRONT
FRONT
UPPER
LOWER

6
Tighten the handlebar clamp bolts to the specified
torque.
"Handlebar clamp bolt: 26 N·m (2.6 kgf-m)

A: 8 × 45 mm flange bolt
B: 8 × 45 mm flange bolt
C: Dot mark
D: Clamp (Upper)
E: Clamp (Lower)
#
A: Front brake cable
B: Throttle cable
C: Left switch wiring harness
D: Rear brake cable
Lift the rear of the vehicle by using a hoist as shown in
the photograph.
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.
FRONT
The line drawings on page 23 and 24 show the
proper routing of the control cables and wiring.
Refer to drawings in addition to following the
instructions carefully.

7
REAR WHEEL
Remove the rear wheels.
A: Rear wheel assembly
B: 8 mm flange self-lock nut
(Wheel set nut)
C: Paper
When installing the rear wheels onto the axles, special
attention must be paid to the arrow of the rotational
direction on the tire sidewall.
When the tires are properly installed, the arrows must
indicate forward rotation of the wheels.
Carefully wipe the rear wheel hubs and drums with a
cloth to remove all dust.
Properly position the wheel on the axle stud bolts.
Temporarily finger-tighten the wheel set nuts.
A: Stud bolt
B: Air valve
C: 8 mm flange self-lock nut
(Wheel set nut)
NOTE:
The wheels are fixed inside out when they are
packed.
The paper is no longer needed and may be dis-
carded.
FRONT
NOTE:
Be sure to install the rear wheels with the air
valves facing outwards.

8
Remove the hoist used to lift the vehicle and then
place the vehicle in place.
Tighten the wheel set nuts to the specified torque.
"Wheel set nut: 28 N·m (2.8 kgf-m)
A: 8 mm flange self-lock nut
(Wheel set nut)
HANDLEBAR PAD
Install the handlebar pad to the handlebar reinforcing
bar.
A: Handlebar pad
B: Strap L:180 mm
C: “SUZUKI” logo
FUEL TANK VENT HOSE
Install the fuel tank vent hose into the cable guide as
shown in the photograph.

A: Fuel tank vent hose
B: Cable guide
Place the vehicle in a clean working area.
NOTE:
The “SUZUKI” logo should face the backward.
FRONT
Be sure not to bend or twist the hose when
installing.

9
AIR GAUGE
Pull the seat release lever toward the rear and remove
the seat.
A: Seat release lever
Store the air gauge with tool set in place.
A: Air gauge (Tool set)
OWNER’S MANUAL
Store the owner’s manual in place.
A: Owner’s manual
EMERGENCY STOP SWITCH LANYARD
Pass the emergency stop switch lanyard through the
case.
Clamp the case to the frame.
A: Case
B: Emergency stop switch lanyard
C: Clamp
D: Frame