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

10
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 6)
D: Warning label (Parking brake) .....For French only
E: Front fender (Right)
F: 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
RÉGLER LE FREIN DE STATIONNEMENT AVANT LE DÉMARRAGE DU MOTEUR
FRONT
UNLEADED
FUEL ONLY

11
SERVICING
BATTERY
The battery is located under the seat.
Pull the seat release lever toward the rear and remove
the seat.
Remove the battery from the vehicle.
A: Seat release lever
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.

12
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.

13
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.

14
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.
A:

+ lead
B:

- lead
C: Rubber boot
Reinstall the seat.
Insert the seat hook into the seat hook retainer and
pass the seat lock lever through the hole of the rear
fender.
Push the seat down firmly.
A: Seat assembly
B: Hook
C: Hook retainer
D: Seat lock lever
E: Hole

15
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.
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.

16
FRONT BRAKE
Check the brake lever play.
The brake lever play

Ameasured at the lever holder
when the lever is squeezed, and the brake cable
holder

Bis in the straight up position as shown in the
photograph.
Front brake lever play: 3–7 mm
If adjustment is necessary, carry out the procedure
below:
1. Place the vehicle on a level surface.
Lift the front end of the vehicle and place a solid
object, such as a wooden block, securely under the
frame.
2. Loosen the lock nuts

Eand turn the upper and
lower cable adjusters

Cequally until the brake lever
play

Ameasured at the lever holder is 3–7 mm
when the lever is squeezed.
Make sure that at least 5 mm of the adjuster threads
are inserted in the lever holder

D, as shown in the
photograph.
Tighten the lock nuts

E.
If the cable adjusters

Cdo not provide enough
adjustment, turn the left and right brake cable
adjusters

Fequally to obtain the specified play.
3. Turn the upper or lower cable adjuster so that when
the brake lever is fully squeezed the cable holder is
in the straight up position.
This adjustment is important for smooth braking,
and to help prevent uneven wear of the brake shoes
on the left and right wheels.
Check the brake lever play again, and repeat step
(2) if necessary.
4. Release the front brake lever and turn the front
wheels by hand to make sure the brakes don’t drag.
If either brake drags, the brake lever play should be
increased slightly.
Repeat steps (2) and (3).
3–7 mm
3–7 mm
5 mm
5 mm

17
DRIVE CHAIN
Check the drive chain slack.
Drive chain slack: 20–30 mm
If it is too tight or too loose, follow these procedures.
1. Loosen bolts

Aand

B.
2. Adjust the slack in the drive chain by turning the
right and left chain adjuster nuts.
3. When proper slack is obtained, tighten the bolts

A
and

B.
4. Tighten the adjusting nuts

C.

Verify that the master link clip is installed properly.
The opening of the master link clip faces away from
the direction of travel.
A: Direction of travel
B: Master link clip
Make sure that the rear sprocket is properly
aligned with the engine sprocket.
Verify the reference marks on the swing-arm by
sighting down along the chain from the rear
end of the vehicle.
20–30 mm

18
REAR/PARKING BRAKE
Check the brake lever play.
The brake lever play measured at the lever holder
when the lever is squeezed.
Rear brake lever play: 4–6 mm
If adjustment is necessary, carry out the procedure
below:
1. To adjust the brake lever play, turn the adjusting nut

D.
Turning the adjusting nut clockwise will decrease
the brake lever play.
Minor adjustments can now be made with the brake
lever adjuster

A.
Tighten the lock nut

B.
2. After adjusting the play, check that the rear wheels
roll freely with the brake disengaged and the rear
wheels off the ground.
3. Set the parking brake by squeezing the brake lever
and set the stopper

C.
4. Check that the rear wheels are locked by trying to
move the vehicle back and forth.
5. Readjust the rear brake lever adjusting nut

Dif the
rear wheels could not roll freely in step 2, or if the
rear wheels did not lock in step 4.
#
Setting the parking brake, check that the wheel
is locked securely.

19
ENGINE OIL

Remove the fastener to take off the engine oil mainte-
nance lid.
A: Engine oil maintenance lid
B: Fastener
C: Boss
Check the engine oil level with the engine oil dipstick.
1. Place the vehicle on level ground.
2. Start the engine and allow it to run for a few minutes
at idling speed.
Stop the engine and wait about three minutes.
3. Remove the oil filler plug.
The engine oil dipstick comes out together with the
oil filler plug.
Wipe the oil from the dipstick with a clean rag.
4. Reinsert the dipstick until the threads touch the filler
neck, but do not screw the plug in.
5. Draw out the dipstick and check the oil level.
The level found on the dipstick should be between
“L” (Low) and “F” (Full) line.
6. If the oil level is below the “L” line, add fresh oil from
the filler hole until the oil level reaches to “F” line.
If the level is above the “F” line, drain oil to “F” line.
7. Reinstall the drain plug and engine oil filler plug.
Tighten them securely.
A: Engine oil filler plug
B: Engine oil dipstick
Reinstall the engine oil maintenance lid.
A: Fastener
This vehicle is shipped from factory with the
engine filled with engine oil.
Be sure to check oil level.
NOTE:
To remove the fastener, push in the center pin
and pull out the fastener.
F
L
NOTE:
To install the fastener, pull the center pin as

B
and fix the fastener by pushing the center pin
as

C.