Suzuki LT-Z90K7 User guide

K7
August ’06 Printed in Japan (TK) 28
99505-01027-01E
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
REAR
Remove the bolts and brackets.
A: Bolt
B: Bracket
C: Vinyl tube
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
Take out the front wheel assembly and various compo-
nent parts packaged around from the crate.
A: Front wheel assembly
B: Component parts
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 Steering head cover 1
B Fuel tank vent hose 1
CFront grip 1
Flange bolt 4 8 × 16 mm
D
Front wheel assembly 2 Right and Left
Flange nut 8 10 mm
Washer 8 OD:20.0 ID:10.5
EPin 1 For rear brake cable
Adjuster nut 1
F
Reflex reflector 2 Right and Left
Bracket 2
Flange nut 2 5 mm
G Warning label set
3For
E-19 CG selection
2For
E-19 CH selection
3For
E-19 CI selection
Item Part Name Q’ty Remarks
H Fuel label 1
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.
CF DAB E FD

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: Throttle cable
C: Front brake cable
D: Rear brake cable
E: Tool set
AA
H
BB
DD
CC
F
I J
G
EE
F
GH
IJ

5
Before assembling the vehicle, thoroughly under-
stand the “Safety Check Out” described on page
29.
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
Align the dot mark on the handlebars with the mating
surface of the front side of right clamp.
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
D: Clamp (Upper)
E: Clamp (Lower)
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

6
#
A: Front brake cable
B: Throttle cable
C: Left switch wiring harness
D: Parking brake switch lead wire
E: Rear brake cable
THROTTLE CABLE
Remove the screw to take off the throttle case cover.
Insert the inner cable end into the recess of throttle
cable lever correctly.
A: Throttle case cover
B: Screw
C: Cable end
D: Throttle cable lever
Pull on the outer cable and insert the outer cable cap
to the recess of throttle case correctly as shown.
A: Throttle cable
B: Outer cable cap
C: Throttle case
D: Recessed area

Reinstall the throttle case cover.
#
A: Gasket
The line drawings on page 26, 27 and 28 show
the proper routing of the control cables and
wiring. Refer to drawings in addition to follow-
ing the instructions carefully.
NOTE:
Before installing the cable, grease the cable
end.
Check the gasket at the correct position.
Check to ensure that the throttle operates
freely and closes automatically.

7
REAR BRAKE CABLE
Turn the brake cable adjuster and lock nut in as far as
possible and align the slots.
Insert the inner cable end into the recess of brake
lever, then pull on the outer cable housing and insert it
into the adjuster.
A: Brake cable
B: Adjuster
C: Lock nut
D: Cable end
Set the pin into the brake cam lever.
Insert the end of the brake cable into the pin hole.
Attach the adjuster nut on the end of the brake cable.
Do not adjust at this time.
Adjustment will be covered in the SERVICING section.
A: Brake cam lever
B: Pin
C: Adjuster nut
NOTE:
Before installing the cable, grease the cable
end.

8
FRONT BRAKE CABLE
Pass the front brake cable through the hole of steering
head cover.
A: Front brake cable
B: Steering head cover
C: Hole
Turn the brake cable adjuster and lock nut in as far as
possible and align the slots.
Insert the inner cable end into the recess of brake
cable equalizer, then pull on the outer cable housing
and insert it into the adjuster.
Do not adjust at this time.
Adjustment will be covered in the SERVICING section.
A: Brake cable
B: Adjuster
C: Lock nut
D: Cable end
E: Brake cable equalizer
The procedure to install the left brake cable is identical
to that of the right.
A: Brake cable
B: Adjuster
C: Lock nut
D: Cable end
E: Brake cable equalizer
NOTE:
Set the right side brake cable to the lower side
adjuster.
Before installing the cable, grease the cable
end.
NOTE:
Set the left side brake cable to the upper side
adjuster.
Before installing the cable, grease the cable
end.

9
Remove the bolts holding the front part of the vehicle.

A: Bolt

1. Lift the front of vehicle by using a hoist.

2. Raise the rear of vehicle.

3. Pull the crate base forward, then balance the vehi-
cle.

FRONT WHEEL
When installing the front wheel onto the axle, special
attention must be paid to the arrow of the rotational
direction on the tire sidewall.
When the tire is properly installed, the arrow must indi-
cate forward rotation of the wheel.
Carefully clean the front wheel hubs and drums with a
cloth to remove all dust.
Before removing bolts, lift the front of the vehi-
cle a little by using a hoist to prevent the dam-
age to the bolt threads.
NOTE:
The bolts are no longer needed and may be dis-
carded.
Be careful the hoist band has clearance at the
cables, guide and wiring harness.
FRONT
FRONT