Suzuki LT-A50 2000-2005 Workshop Service Manual for Repair

99500-20212-01E LT-A50 Downloaded from www.Manualslib.com manuals search engine

GROUP INDEX 1 FOREWORD This manual contains an introductory description on the SUZUKI LT-A50 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa- miliarize yourself with the vehicle and its maintenance. Use this section as well as other sections 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. ! Inexperienced mechanics or mechanics with- out the proper tools and equipment may not be able to properly perform the services de- scribed in this manual. Improper repair may result in injury to the mechanic and may ren- der the vehicle unsafe for the rider. 2 3 4 5 GENERAL INFORMATION * This manual has been prepared on the basis of the latest specifications at the time of pub- lication. 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 vehicle. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. c COPYRIGHT SUZUKI MOTOR CORPORATION 2001 PERIODIC MAINTENANCE ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS 6 7 ELECTRICAL SYSTEM SERVICING INFORMATION 8 LT-A50K3/K4 (’03, ’04-MODELS) 9 LT-A50K5 (’05-MODEL) Downloaded from www.Manualslib.com manuals search engine

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: Front and rear wheel 1 Oil seal 2 Bearing 3 Spacer 4 Front wheel hub 5 Bearing 6 Oil seal 7 Front wheel 8 Front wheel center cap 9 Rear wheel hub 0 Rear wheel A Rear wheel center cap B Center cap holder A Wheel nut (front and rear) B Front hub nut C Rear hub nut FRONT REAR " ITEM N . m kgf . m lb-ft A 28 2.8 20.5 B 65 6.5 47.5 C 75 7.5 55.0 Downloaded from www.Manualslib.com manuals search engine

SYMBOL (FOR USA) 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. Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply SUZUKI SUPER GREASE “A”. 99000-25030 Apply THREAD LOCK “1342”. 99000-32050 Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply SUZUKI BOND “1207B”. 99104-31140 Apply THREAD LOCK SUPER “1303”. 99000-32030 Measure in voltage range. Measure in current range. Measure in diode test range. Measure in continuity test range. Use special tool. SYMBOL DEFINITION SYMBOL DEFINITION Indication of service data. Apply SUZUKI MOLY PASTE. 99000-25140 Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Downloaded from www.Manualslib.com manuals search engine

SYMBOL (For the other countries) 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. Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply SUZUKI SUPER GREASE “A”. 99000-25010 Apply THREAD LOCK “1342”. 99000-32050 Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply SUZUKI BOND “1207B”. 99000-31140 Apply THREAD LOCK SUPER “1303”. 99000-32030 Measure in voltage range. Measure in current range. Measure in diode test range. Measure in continuity test range. Use special tool. SYMBOL DEFINITION SYMBOL DEFINITION Indication of service data. Apply SUZUKI MOLY PASTE. 99000-25140 Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI BOND “1215” 99000-31110 Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION 1-1 1 GENERAL INFORMATION WARNING/CAUTION/NOTE ............................................................. 1- 2 GENERAL PRECAUTIONS .............................................................. 1- 2 SUZUKI LT-A50K2 (2002-MODEL) ................................................... 1- 4 SERIAL NUMBER LOCATION ......................................................... 1- 4 FUEL AND OIL RECOMMENDATIONS ........................................... 1- 4 FUEL .............................................................................................. 1- 5 ENGINE OIL .................................................................................. 1- 5 TRANSMISSION OIL .................................................................... 1- 5 BREAK-IN PROCEDURES ............................................................... 1- 5 INFORMATION LABELS .................................................................. 1- 6 SPECIFICATIONS ............................................................................. 1- 7 COUNTRY OR AREA CODES ......................................................... 1- 8 CONTENTS Downloaded from www.Manualslib.com manuals search engine

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 is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. * 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 getting burned, do not touch the engine, transmission oil and exhaust system until they have cooled. * After servicing the fuel, oil or exhaust systems, check all of the lines and fittings related to the system for leaks. Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION 1-3 " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When tightening cylinder head nuts and crankcase screws, tighten the larger sizes first. Al- ways tighten the bolts and nuts from the inside working out, in a crisscross pattern and to the specified tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil and tires. * To protect Earth’s natural resources, properly dispose of used vehicle and parts. Downloaded from www.Manualslib.com manuals search engine

1-4 GENERAL INFORMATION SUZUKI LT-A50K2 (2002-MODEL) * Difference between photographs and the actual vehicles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the left side of the frame pipe. The engine serial number 2 is located on the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATIONS FUEL (For USA and CANADA) 1. Use only unleaded gasoline of at least 87 pump octane ( ) method or 91 octane or higher rated by the research method. 2.Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3.Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4.Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10 % ethanol. Gasoline/alcohol fuel may contain up to 5 % methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5.If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline 6.Failure to follow these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above. LEFT RIGHT R + M 2 Downloaded from www.Manualslib.com manuals search engine

GENERAL INFORMATION 1-5 FUEL (For the other countries) Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. ENGINE OIL (For USA) Use SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT or an equivalent good quality synthetic based 2-stroke engine oil rated FC under the JASO classification. ENGINE OIL (For the other countries) Use SUZUKI CCI SUPER OIL. If they are not available, use a good quality 2-stroke engine oil rated FC under the JASO classification. TRANSMISSION OIL Use a good quality SAE 10W-40 multi-grade motor oil. BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. Refer to the following throttle position recommendations. • Keep to these break-in throttle position. Up to 10 hours: Below # throttle Downloaded from www.Manualslib.com manuals search engine

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Suzuki LT-A50 2000-2005 Workshop Service Manual for Repair

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