Suzuki QUAD Sport LT Z 50 ATV 2004-2009 Workshop Manual

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 FUEL SYSTEM 4 CHASSIS 5 ELECTRICAL SYSTEM 6 SERVICING INFORMATION 7 FOREWORD This manual contains an introductory description on the SUZUKI LT-Z50 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 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 mecha nics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair m ay result in i njury to the mechanic and ma y re nder t he vehicle unsafe for the rider.

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 Front tire 2 Front wheel 3 Rear tire 4 Rear wheel A Wheel set nut (front & rear)  ITEM N·m kgf-m lb-ft A 28 2.8 20.0

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. Measure in voltage range. Apply oil. Use engine oil unless other- wise specified. Measure in current range. Apply molybdenum oil solution. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Measure in resistance range. Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Measure in diode test range. Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Measure in continuity test range. Apply WATER RESISTANCE GREASE or equivalent. 99000-25161 Use special tool. Apply SUZUKI BOND “1215” or equivalent. 99000-31110 Indication of service data. Apply THREAD LOCK “1342” or equivalent. 99000-32050 W

GENERAL INFORMATION 1-1 1 GENERAL INFORMATION CONTENTS COUNTRY AND AREA CODES The following codes stand for the applicable country (-ies) and area (-s). MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO. LT-Z50 P-03 U.S.A. LM4AZ413 61100001- P-19 E.U. P-28 Canada WARNING/CAUTION/NOTE .........................................................................1- 2 GENERAL PRECAUTIONS...........................................................................1- 2 SUZUKI LT-Z50 .............................................................................................1- 4 SERIAL NUMBER LOCATION......................................................................1- 4 FUEL AND OIL RECOMMENDATION ..........................................................1- 5 FUEL (FOR USA AND CANADA)...........................................................1- 5 FUEL (FOR OTHER COUNTRIES) .........................................................1- 5 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR USA) ..............................................................................................1- 5 ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR OTHER COUNTRIES) ...................................................................1- 5 BREAK-IN PROCEDURES ...........................................................................1- 6 INFORMATION LABELS...............................................................................1- 7 INFORMATION MARKS ................................................................................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

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 out- 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 getting burned, do not touch the engine, engine oil, final reduction gear box oil and exhaust system until they have cooled. * After servicing the fuel or exhaust systems, check all lines and fittings related to the system for leaks.

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 and orientation. * 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 removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures do not require use of battery power, disconnect the negative cable from the battery. * When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside toward outside 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: batteries and tires. * To protect Earth’s natural resources, properly dispose of used vehicle and parts.

1-4 GENERAL INFORMATION SUZUKI LT-Z50 • Difference between photograph and actual vehicle may exist depending 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 rear frame pipe. The engine serial number 2 is located on the right side of the generator case. These numbers are required especially for registering the machine and ordering spare parts. RIGHT SIDE LEFT SIDE

GENERAL INFORMATION 1-5 FUEL AND OIL RECOMMENDATION FUEL (FOR USA AND CANADA) Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible. FUEL (FOR OTHER COUNTRIES) Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom- mended. ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR USA) Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of API SF/SG or SH/SJ with JASO MA. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart. ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR OTHER COUNTRIES) Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of API SF/SG or SH/SJ with JASO MA. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the right chart. 10W-30 10W-40. 10W-50 15W-40. 15W-50 20W-50

1-6 GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but 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: Brake-in engine speeds Up to 10 hours: Less than 1/2 throttle

GENERAL INFORMATION 1-7 INFORMATION LABELS A: Attached INFORMATION MARKS D Label is attached on the left side of frame. 1 Certification plate A (For P-03, 19) 2 Compliance label A (For P-28) 3 Manual notice label A (For P-03) 4 Parking brake label (English) A (For P-03, 19, 28) 5 Parking brake label (French) A (For P-28) 6 Tire air pressure and warning no-passenger label (English) A (For P-03, 19, 28) 7 Tire air pressure and warning no-passenger label (French) A (For P-28) 8 General warning & AGE 6 label (English) A (For P-03, 19, 28) 9 General warning label (French) A (For P-28) 0 AGE 6 label (French) A (For P-28) A EC mark label A (For P-19) B ICES Canada label A (For P-28) C Information label A (For P-03) D Approval label A (For P-19) A No passenger mark (English) (For P-03, 19, 28) B No passenger mark (French) (For P-28)

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Suzuki QUAD Sport LT Z 50 ATV 2004-2009 Workshop Manual

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