2007-2009 Suzuki King Quad 450 Service & Repair Manual

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 DRIVE TRAIN 4 FI SYSTEM DIAGNOSIS 5 FUEL SYSTEM AND THROTTLE BODY 6 COOLING AND LUBRICATION SYSTEM 7 CHASSIS 8 ELECTRICAL SYSTEM 9 SERVICING INFORMATION 10 EMISSION CONTROL INFORMATION 11 FOREWORD This manual contains an introductory description on the SUZUKI LT-A450X and procedures for its inspection, service and overhaul of its main compo- nents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. 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. ! * 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.

SUPPLEMENTS LT-A450XK9 (’09 MODEL) LT-A450XK8 ( ’ 12 13 WIRING DIAGRAM 14

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: 1 Handlebar 2 Handlebar upper clamp 3 Steering shaft 4 Steering shaft holder 5 Dust seal 6 Bush 7 Dust seal 8 O-ring 9 Tie rod 0 Tie rod end A Handleber upper clamp bolt B Handleber holder nut C Steering shaft holder bolt D Steering shaft lower nut E Tie rod lock-nut F Tie rod end nut " ITEM N·m kgf-m lb-ft A 26 2.6 19.0 B 60 6.0 43.5 C 23 2.3 16.5 D 170 17.0 123.0 E 45 4.5 32.5 F 29 2.9 21.0

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply THREAD LOCK SUPER “1322” or equivalent thread lock. 99000-32110 Indicates service data. Apply THREAD LOCK “1342”. 99000-32050 Apply oil. Use engine oil unless other- wise specified. Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply hypoid gear oil. Apply or use brake fluid. Apply molybdenum oil solution. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Measure in voltage range. Apply SUZUKI SUPER GREASE “A” or equivalent grease. 99000-25010 Measure in resistance range. Apply SUZUKI SILICONE GREASE. 99000-25100 Measure in current range. Apply SUZUKI MOLY PASTE. 99000-25140 Measure in diode test range. Apply WATER RESISTANCE GREASE. 99000-25160 Measure in continuity test range. Apply SUZUKI BOND “1215” or equivalent bond. 99000-31110 Use special tool. Apply SUZUKI BOND “1216B”. 99100-31230 Use engine coolant. 99000-99032-11X Apply THREAD LOCK SUPER “1303”. 99000-32030 H/O W 1216B

ABBREVIATIONS USED IN THIS MANUAL A ABDC : After Bottom Dead Center AC : Alternating Current ACL : Air Cleaner, Air Cleaner Box API : American Petroleum Institute ATDC : After Top Dead Center ATM Pressure : Atmospheric Pressure : Atmospheric Pressure sensor (APS, AP Sensor) A/F : Air Fuel Mixture B BBDC : Before Bottom Dead Center BTDC : Before Top Dead Center B+ : Battery Positive Voltage C CKP Sensor : Crankshaft Position Sensor (CKPS) CKT : Circuit CO : Carbon Monoxide CPU : Central Processing Unit D DC : Direct Current DIFF-LOCK Relay: Differential Lock Relay DMC : Dealer Mode Coupler DOHC : Double Over Head Camshaft DRL : Daytime Running Light DTC : Diagnostic Trouble Code E ECM : Engine Control Module Engine Control Unit (ECU) (FI Control Unit) ECT Sensor : Engine Coolant Temperature Sensor (ECTS), Water Temp. Sensor (WTS) F FI : Fuel Injection, Fuel Injector FP : Fuel Pump FPR : Fuel Pressure Regulator FP Relay : Fuel Pump Relay G GEN : Generator GND : Ground GP Switch : Gear Position Switch H HC : Hydrocarbons I IAP Sensor : Intake Air Pressure Sensor (IAPS) (MAP sensor) IAS : Idle air screw IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition L LCD : Liquid Crystal Display LED : Light Emitting Diode (Malfunction Indicator Lamp) LH : Left Hand

M MAL-Code : Malfunction Code (Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp (LED) Min : Minimum N NOX : Nitrogen Oxides O OHC : Over Head Camshaft P PCV : Positive Crankcase Ventilation (Crankcase Breather) R REC : Rectifier REG : Regulator RH : Right Hand ROM : Read Only Memory S SAE : Society of Automotive Engineers SDS : Suzuki Diagnosis System T TO Sensor : Tip-Over Sensor (TOS) TP Sensor : Throttle Position Sensor (TPS)

SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION A Air Cleaner B Battery Positive Voltage C Crankshaft Position Sensor D Data Link Connector Diagnostic Test Mode Diagnostic Trouble Code E Electronic lgnition Engine Control Module Engine Coolant Level Engine Coolant Temperature Engine Speed F Fan Control Fuel Level Sensor Fuel Pump G Generator Ground I Idle Speed Control Ignition Control Module Intake Air Temperature M Malfunction Indicator Lamp Manifold Absolute Pressure ACL B+ CKP Sensor DLC DTM DTC EI ECM ECL ECT RPM FC ------- FP GEN GND IC ICM IAT MIL MAP Air Cleaner, Air Cleaner Box Battery Voltage, +B Crankshaft Position Sensor (CKPS), Crank Angle Dealer Mode Coupler ------- Diagnostic Code, Malfunction Code ------- Engine Control Module (ECM) FI Control Unit, Engine Control Unit (ECU) Coolant Level Coolant Temperature, Engine Coolant Tem- perature, Water Temperature Engine Speed (RPM) ------- Fuel Level Sensor, Fuel Level Gauge Fuel Pump (FP) Generator Ground (GND, GRD) Electronic Spark Advance (ESA) ------- Intake Air Temperature (IAT), Air Temperature LED Lamp Malfunction Indicator Lamp (MIL) Intake Air Pressure (IAP), Intake Vacuum

SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION O On-Board Diagnostic P Programmable Read Only Memory R Random Access Memory Read Only Memory T Throttle Body Throttle Body Fuel Injection Throttle Position Sensor V Voltage Regulator OBD PROM RAM ROM TB TBI TP Sensor VR Self-Diagnosis Function Diagnostic ------- ------- ROM Throttle Body (TB) Throttle Body Fuel Injection (TBI) TP Sensor (TPS) Voltage Regulator

GENERAL INFORMATION 1-1 1 GENERAL INFORMATION CONTENTS COUNTRY AND AREA CODES The following codes stand for the applicable country (-ies) and area (-s). CODE COUNTRY or AREA EFFECTIVE FRAME NO. E-17 E-24 E-28 E-33 Sweden Australia Canada California (U.S.A.) 5SAAL42A 77100001- WARNING/CAUTION/NOTE .........................................................................1- 2 GENERAL PRECAUTIONS...........................................................................1- 2 SUZUKI LT-A450XK7 (’07-MODEL) .............................................................1- 4 SERIAL NUMBER LOCATION......................................................................1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION........................1- 5 FUEL (FOR USA AND CANADA) ...........................................................1- 5 FUEL (FOR OTHER COUNTRIES) .........................................................1- 5 ENGINE OIL (FOR USA).........................................................................1- 5 ENGINE OIL (FOR OTHER COUNTRIES) .............................................1- 5 FRONT DIFFERENTIAL GEAR OIL .......................................................1- 5 REAR DRIVE (FINAL) GEAR OIL ..........................................................1- 5 BRAKE FLUID.........................................................................................1- 5 ENGINE COOLANT ................................................................................1- 6 BREAK-IN PROCEDURES ...........................................................................1- 7 INFORMATION LABELS...............................................................................1- 8 SPECIFICATIONS .........................................................................................1- 9 DIMENSIONS AND DRY MASS .............................................................1- 9 ENGINE ...................................................................................................1- 9 DRIVE TRAIN ..........................................................................................1- 9 CHASSIS .................................................................................................1-10 ELECTRICAL ..........................................................................................1-10 CAPACITIES ...........................................................................................1-10

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 i s necessary t o run t he en gine i ndoors, make sure t hat exhaust g as i s f orced o ut- 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 g etting burned, d o not t ouch t he engine, engine o il, r adiator and exhaust system until they have cooled. * After servicing t he fu el, oi l, wat er, ex haust o r br ake sy stems, check a ll li nes a nd fittings related to the system for leaks.

2007-2009 Suzuki King Quad 450 Service & Repair Manual

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