2006-2009 Suzuki LTR 450 Service & Repair Manual

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 FI SYSTEM DIAGNOSIS 4 FUEL SYSTEM AND THROTTLE BODY 5 COOLING AND LUBRICATION SYSTEM 6 CHASSIS 7 ELECTRICAL SYSTEM 8 SERVICING INFORMATION 9 EMISSION CONTROL INFORMATION 10 FOREWORD This manual contains an introductory description on the SUZUKI LT-R450 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 familiarize 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. * 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. Revised 03/09

SUPPLEMENTS LT-R450K9 (’09-MODEL) LT-R450K8 ( 08-MODEL) 11 12 ' WIRING DIAGRAM 13

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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 c ontents are l isted o n t he f irst p age 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 wheels 1 Front wheel 2 Washer 3 Cotter pin 4 Air valve 5 Front tire 6 Front hub plate 7 Spacer 8 Dust seal 9 Hub bearing 0 Front wheel hub A Spacer B Hub bearing C Dust seal D Collar E Front brake disc F Disc cover G Axle shaft H Rear wheel hub I Rear wheel J Rear tire K Washer A Wheel set nut B Front hub nut C Rear hub nut D Brake disc bolt " ITEM N·m kgf-m lb-ft A 66 6.6 47.5 B 65 6.5 47.0 C 121 12.1 87.5 D 23 2.3 16.5

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 “1342”. 99000-32050 Apply oil. Use engine oil unless otherwise specified. Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply molybdenum oil solution. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply or use brake fluid. Apply SUZUKI SUPER GREASE “A” or equivalent grease. 99000-25010 Measure in voltage range. Apply SUZUKI SILICONE GREASE. 99000-25100 Measure in resistance range. Apply SUZUKI MOLY PASTE. 99000-25140 Measure in current range. Apply SUZUKI BOND “1215” or equivalent bond. 99000-31110 Measure in diode test range. Apply SUZUKI BOND “1216B”. 99000-31230 Measure in continuity test range. Apply THREAD LOCK SUPER “1303”. 99000-32030 Use special tool. Apply THREAD LOCK SUPER “1322” or equivalent thread lock. 99000-32110 Indicates service data. 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 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 CLP Switch : Clutch Lever Position Switch (Clutch Switch) CO : Carbon Monoxide CPU : Central Processing Unit D DC : Direct Current 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) IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition IAS : Idle air screw L LH : Left Hand M MAL-Code : Malfunction Code (Diagnostic Code) Max : Maximum MIL : Malfunction Indicator Lamp Min : Minimum N NOX : Nitrogen Oxides O OHC : Over Head Camshaft P PCV : Positive Crankcase Ventilation (Crankcase Breather) R 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 ACL Air Cleaner, Air Cleaner Box B Battery Positive Voltage B+ Battery Voltage, +B C Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS), Crank Angle D Data Link Connector DLC Dealer Mode Coupler Diagnostic Test Mode DTM –––– Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code E Electronic Ignition El –––– Engine Control Module ECM Engine Control Module (ECM) Fl Control Unit, Engine Control Unit (ECU) Engine Coolant Level ECL Coolant Level Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem- perature, Water Temperature Engine Speed RPM Engine Speed (RPM) F Fan C ontrol FC –––– Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge Fuel Pump FP Fuel Pump (FP) G Generator GE N Generator Ground GND Ground (GND, GRD) I Ignition Control IC Electronic Spark Advance (ESA) Ignition Control Module ICM –––– Intake Air Temperature IAT Intake Air Temperature (IAT), Air Temperature M Malfunction Indicator Lamp MIL Lamp Malfunction Indicator Lamp (MIL) Manifold Absolute Pressure MAP Intake Air Pressure (IAP), Intake Vacuum

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

WIRE COLOR B : Black O : Orange Bl : Blue P : Pink Br : Brown R : Red Dbr : Dark brown W : White Dg : Dark green Y : Yellow Gr : Gray B/Bl : Black with Blue tracer B/Br : Black with Brown tracer B/O : Black with Orange tracer B/R : Black with Red tracer B/W : Black with White tracer B/Y : Black with Yellow tracer Bl/B : Blue with Black tracer Bl/W : Blue with White tracer Br/W : Brown with White tracer G/B : Green with Black tracer G/R : Green with Red tracer G/W : Green with White tracer Gr/W : Gray with White tracer O/G : Orange with Green tracer O/W : Orange with White tracer O/Y : Orange with Yellow tracer R/W : Red with White tracer W/B : White with Black tracer W/Bl : White with Blue tracer W/R : White with Red tracer Y/B : Yellow with Black tracer Y/Bl : Yellow with Blue tracer

GENERAL INFORMATION 1-1 1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ......................................................................... 1- 2 GENERAL PRECAUTIONS .......................................................................... 1- 2 SUZUKI LT-R450K6 (’06-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 BRAKE FLUID ........................................................................................ 1- 5 ENGINE COOLANT................................................................................ 1- 6 BREAK-IN PROCEDURES ........................................................................... 1- 6 INFORMATION LABELS .............................................................................. 1- 7 SPECIFICATIONS......................................................................................... 1- 8 DIMENSIONS AND DRY MASS............................................................. 1- 8 ENGINE .................................................................................................. 1- 8 DRIVE TRAIN ......................................................................................... 1- 8 CHASSIS ................................................................................................ 1- 9 ELECTRICAL ......................................................................................... 1- 9 CAPACITIES .......................................................................................... 1- 9 COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA EFFECTIVE FRAME NO. E-19 E-28 E-33 E.U. Canada California (U.S.A.) JSAAL41A 62100001 – JSAAL41A 62100001 – JSAAL41A 62100001 –

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2006-2009 Suzuki LTR 450 Service & Repair Manual

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