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QuadRacer LT-R450
Suzuki QuadRacer LT-R450 User Manual
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L
T
-R450
99500-44062-03E
2
Table of Contents
General Information 1
9
Table of Contents
9
Warning/Caution/Note
10
General Precautions
10
Suzuki Lt-R450K6 ('06-Model)
12
Serial Number Location
12
Fuel, Oil and Engine Coolant Recommendation
13
Fuel (for Usa and Canada)
13
Fuel (for Other Countries)
13
Engine Oil (for Usa)
13
Engine Oil (for Other Countries)
13
Brake Fluid
13
Engine Coolant
14
Break-In Procedures
14
Information Labels
15
Specifications
16
Dimensions and Dry Mass
16
Engine
16
Drive Train
16
Chassis
17
Electrical
17
Capacities
17
Periodic Maintenance
18
Periodic Maintenance Schedule
19
Periodic Maintenance Chart
19
Maintenance and Tune-Up Procedures
20
Air Cleaner
20
Exhaust Pipe Nuts and Muffler Bolts
21
Valve Clearance
22
Spark Plug
27
Fuel Line
28
Fuel Filter
28
Throttle Cable Play
28
Engine Idle Speed
29
Throttle Body
29
Engine Oil and Oil Filter
29
Engine Oil Hose
31
Engine Coolant
32
Radiator
33
Radiator Hose
33
Spark Arrester
34
Clutch Cable Play
35
Brakes
35
Brake Fluid
38
Brake Hose
40
Tires
40
Steering
41
Drive Chain
42
Suspensions
45
Front and Rear Wheel Set Nuts
45
Rear Axle Nut and Lock-Nut
46
Chassis Bolts and Nuts
47
General Lubrication
50
Compression Pressure Check
51
Compression Test Procedure
51
Oil Pressure Check
52
Oil Pressure Test Procedure
52
Sds Check
53
Engine
56
Engine Components Removable with Engine in Place
57
Engine Left Side
57
Engine Right Side
57
Engine Center
57
Engine Removal and Remounting
58
Engine Removal
58
Engine Installation
63
Engine Disassembly
66
Engine Components Inspection and Service
79
Cylinder Head
79
Automatic Decomp
88
Camshaft
88
Cam Chain Tension Adjuster and Tensioner
91
Cylinder
91
Piston and Piston Ring
92
Conrod
94
Crankshaft
95
Balancer Shaft and Balancer Driven and Drive Gear
96
Starter Clutch
96
Generator
98
Starter Torque Limiter
98
Oil Pump
99
Clutch
100
Gearshift Fork and Gear
102
Transmission
103
Oil Strainer
106
Crankcase
106
Right Crankcase Cover
111
Gearshift Shaft
112
Engine Reassembly
113
Fi System Diagnosis
135
Precautions in Servicing
137
Electrical Parts
137
Fuse
138
Ecm/Various Sensors
138
Electrical Circuit Inspection Procedure
140
Using the Multi-Circuit Tester
143
Fi System Technical Features
144
Injection Time (Injection Volume)
144
Compensation of Injection Time (Volume)
145
Injection Stop Control
145
Fi System Parts Location
146
Fi System Wiring Diagram
148
Ecm Terminal
149
Self-Diagnosis Function
150
User Mode
150
Dealer Mode
151
Diagnostic Trouble Code Table
152
Tps Adjustment
153
Fail-Safe Function
154
Fi System Troubleshooting
155
Customer Complaint Analysis
155
Visual Inspection
156
Self-Diagnostic Procedures
157
Self-Diagnosis Reset Procedure
157
Use of Sds Diagnostic Procedures
158
Use of Sds Diagnosis Reset Procedure
159
Show Data When Trouble (Displaing Data at the Time of Dtc)
160
Malfunction Code and Defective Condition
161
C12" (P0335) Ckp Sensor Circuit Malfunction
163
C13" (P0105-H/L) Iap Sensor Circuit Malfunction
165
C14" (P0120-H/L) Tp Sensor Circuit Malfunction
171
C15" (P0115-H/L) Ect Sensor Circuit Malfunction
176
C21" (P0110-H/L) Iat Sensor Circuit Malfunction
180
C23" (P1651-H/L) to Sensor Circuit Malfunction
184
C24" (P0351) Ignition System Malfunction
187
C31" (P0705) Gp Switch Circuit Malfunction
188
C32" (P0201) Fuel Injector Circuit Malfunction
190
C41" (P0230) Fp Relay Circuit Malfunction
192
C60" (P0480) Cooling Fan Relay Circuit Malfunction
193
Sensors
194
Ckp Sensor Inspection
194
Ckp Sensor Removal and Installation
194
Iap Sensor Inspection
194
Iap Sensor Removal and Installation
194
Tp Sensor Inspection
194
Tp Sensor Removal and Installation
194
Tps Adjustment
194
Ect Sensor Inspection
194
Ect Sensor Removal and Installation
194
Iat Sensor Inspection
195
Iat Sensor Removal and Installation
195
To Sensor Inspection
195
To Sensor Removal and Installation
195
Fuel System and Throttle Body
196
Fuel Delivery System
197
Fuel System
198
Fuel Tank Removal
198
Fuel Tank Installation
199
Fuel Pressure Inspection
200
Fuel Pump Removal
201
Fuel Pump Installation
201
Fuel Pump Inspection
201
Fuel Discharge Amount Inspection
202
Fuel Pump Relay Inspection
203
Fuel Valve/Fuel Filter
204
Fuel Pressure Regulator
206
Throttle Body
207
Construction
207
Removal
208
Disassembly
209
Cleaning
211
Inspection
211
Reassembly
211
Installation
213
Fuel Injector Removal
213
Fuel Injector Inspection
213
Fuel Injector Installation
213
Throttle Position Sensor (Tps) Setting
213
Cooling and Lubrication System
214
Engine Coolant
215
Cooling Circuit
216
Cooling Circuit Inspection
216
Radiator and Water Hose
217
Radiator Removal
217
Radiator Cap Inspection
219
Radiator Inspection and Cleaning
219
Radiator Installation
219
Water Hose Inspection
220
Radiator Reservoir Tank
220
Cooling Fan
221
Removal
221
Installation
222
Inspection
222
Cooling Fan Relay Inspection
223
Ect Sensor
223
Removal
223
Inspection
223
Installation
224
Thermostat
225
Removal
225
Inspection
225
Installation
226
Water Pump
227
Removal and Disassembly
227
Inspection
229
Reassembly and Installation
230
Oil Tank, Oil Return Tank and Hoses
233
Construction
233
Oil Tank
234
Oil Return Tank
236
Lubrication System
237
Oil Pressure
237
Oil Filter
237
Oil Strainer
237
Oil Pump
237
Engine Lubrication System Chart
238
Chassis
239
Exterior Parts
241
Construction
241
Fastener Removal and Reinstallation
243
Removal
244
Installation
246
Front and Rear Wheels
247
Construction
247
Removal
248
Inspection and Disassembly
249
Reassembly and Installation
250
Tires
253
Tire Replacement
253
Front Brake
256
Construction
256
Brake Pad Replacement
257
Brake Fluid Replacement
258
Brake Caliper Removal and Disassembly
258
Brake Caliper Inspection
260
Brake Caliper Reassembly and Installation
261
Brake Disc Removal and Disassembly
262
Brake Disc Inspection
262
Brake Disc Reassembly and Installation
263
Master Cylinder Removal and Disassembly
263
Master Cylinder Inspection
264
Master Cylinder Reassembly and Installation
265
Front Suspension
267
Construction
267
Removal
268
Inspection and Disassembly
269
Reassembly and Installation
273
Front Shock Absorber Disposal
276
Suspension Setting
276
Handlebars
278
Construction
278
Removal
279
Inspection
279
Installation
280
Steering
282
Construction
282
Removal
283
Inspection and Disassembly
285
Reassembly and Installation
287
Toe Adjustment
290
Rear Brake
292
Construction
292
Brake Pad Replacement
293
Brake Fluid Replacement
294
Brake Caliper Removal and Disassembly
295
Brake Caliper Inspection
297
Brake Caliper Reassembly and Installation
298
Brake Disc Removal and Installation
301
Brake Disc Inspection
301
Master Cylinder Removal and Disassembly
302
Master Cylinder Inspection
303
Master Cylinder Reassembly and Installation
303
Brake Pedal
305
Removal
305
Installation
305
Rear Shock Absorber
306
Construction
306
Removal
306
Inspection and Disassembly
307
Reassembly and Installation
309
Rear Shock Absorber Disposal
310
Suspension Setting
311
Cushion Rod and Cushion Lever
313
Construction
313
Removal
314
Inspection and Disassembly
314
Reassembly and Installation
318
Cushion Rod, Cushion Lever and Rear Shock Absorber Information
320
Swingarm
321
Construction
321
Removal
322
Inspection and Disassembly
324
Reassembly
327
Installation
328
Rear Axle
329
Construction
329
Removal
330
Inspection and Disassembly
332
Reassembly and Installation
334
Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm and Rear Axle Reassembling Information
340
Drive Chain
341
Drive Chain Cutting
341
Drive Chain Connecting
342
Drive Chain Control Roller
345
Construction
345
Removal
345
Inspection
345
Installation
346
Electrical System
347
Cautions in Servicing
348
Connector
348
Coupler
348
Clamp
348
Fuse
348
Semi-Conductor Equipped Part
349
Battery
349
Connecting the Battery
349
Wiring Procedure
349
Using the Multi-Circuit Tester
350
Location of Electrical Components
351
Charging System
353
Troubleshooting
353
Inspection
354
Starter System and Side-Stand/Ignition Interlock System
357
Troubleshooting
357
Starter Motor Removal
358
Starter Motor Disassembly
359
Starter Motor Inspection
359
Starter Motor Reassembly
360
Starter Relay Inspection
361
Ignition System
363
Troubleshooting
363
Inspection
365
Indicator Light
368
Inspection
369
Lamps
372
Headlight, Brake Light/Taillight
372
Relays
373
Starter Relay
373
Fuel Pump Relay
373
Cooling Fan Relay
373
Switches Inspection
374
Battery
375
Specifications
375
Initial Charging
375
Servicing
377
Recharging Operation
377
Servicing Information
378
Troubleshooting
379
Fi System Malfunction Code and Defective Condition
379
Engine
381
Radiator (Cooling System)
387
Chassis
387
Brakes
389
Electrical
390
Battery
391
Wiring Harness, Cable and Hose Routing
392
Wiring Harness Routing
392
Cable Routing
395
Fuel System Hose Routing
396
Cooling System Hose Routing
397
Oil Hose Routing
398
Front Brake Hose Routing
399
Rear Brake Hose Routing
400
Throttle Body Installation
401
Fuel Tank Installation
402
Brake Pedal Installation
403
FRONT SIDE REFLEX REFLECTOR INSTALLATION (for E-28)
404
BRAKE LIGHT/TAILLIGHT INSTALLATION (for Others)
405
BRAKE LIGHT/TAILLIGHT INSTALLATION (for E-28)
406
Drive Chain Roller Installation
407
Special Tools
408
Tightening Torque
411
Engine
411
Fi System and Intake Air System
412
Cooling System
412
Chassis
413
Tightening Torque Chart
414
Service Data
415
Specifications
429
Service Data
430
Front Brake
438
Front Wheel, Front Brake, Front Suspension and Steering
439
Cushion Rod, Cushion Lever and Rear Shock Absorber Information
440
Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm
441
4
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Suzuki QuadRacer LT-R450 Specifications
General
Brand
Suzuki
Model
QuadRacer LT-R450
Category
Offroad Vehicle
Language
English
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