Suzuki LT-A450X Manuale utente

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 mainte-

nance. 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

WIRING DIAGRAM14

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:



1Handlebar



2Handlebar upper clamp



3Steering shaft



4Steering shaft holder



5Dust seal



6Bush



7Dust seal



8O-ring



9Tie rod



0Tie rod end



AHandleber upper clamp

bolt



BHandleber holder nut



CSteering shaft holder

bolt



DSteering shaft lower nut



ETie rod lock-nut



FTie rod end nut

ITEM N·m

kgf-m

lb-ft



A26 2.6 19.0



B60 6.0 43.5



C23 2.3 16.5



D170 17.0 123.0



E45 4.5 32.5



F29 2.9 21.0

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. 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 equiva-

lent 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

1216B

ABBREVIATIONS USED IN THIS

MANUAL

AABDC : 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

BBBDC : Before Bottom Dead Center

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

CCKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CO : Carbon Monoxide

CPU : Central Processing Unit

DDC : 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

EECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

FFI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

FP Relay : Fuel Pump Relay

GEN : Generator

GND : Ground

GP Switch : Gear Position Switch

HC : Hydrocarbons

IIAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP sensor)

IAS : Idle air screw

IAT Sensor : Intake Air Temperature Sensor

(IATS)

IG : Ignition

LLCD : Liquid Crystal Display

LED : Light Emitting Diode

(Malfunction Indicator Lamp)

LH : Left Hand

MAL-Code : Malfunction Code

(Diagnostic Code)

Max : Maximum

MIL : Malfunction Indicator Lamp

(LED)

Min : Minimum

NNOX : Nitrogen Oxides

OHC : Over Head Camshaft

PPCV : Positive Crankcase

Ventilation (Crankcase Breather)

RREC : Rectifier

REG : Regulator

RH : Right Hand

ROM : Read Only Memory

SSAE : Society of Automotive Engineers

SDS : Suzuki Diagnosis System

TTO 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

Air Cleaner

Battery Positive Voltage

Crankshaft Position Sensor

Data Link Connector

Diagnostic Test Mode

Diagnostic Trouble Code

Electronic lgnition

Engine Control Module

Engine Coolant Level

Engine Coolant Temperature

Engine Speed

Fan Control

Fuel Level Sensor

Fuel Pump

Generator

Ground

Idle Speed Control

Ignition Control Module

Intake Air Temperature

Malfunction Indicator Lamp

Manifold Absolute Pressure

ACL

B+

CKP Sensor

DLC

DTM

DTC

ECM

ECL

ECT

RPM

-------

GEN

GND

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

On-Board Diagnostic

Programmable Read Only Memory

Random Access Memory

Read Only Memory

Throttle Body

Throttle Body Fuel Injection

Throttle Position Sensor

Voltage Regulator

OBD

PROM

RAM

ROM

TBI

TP Sensor

Self-Diagnosis Function

Diagnostic

-------

ROM

Throttle Body (TB)

Throttle Body Fuel Injection (TBI)

TP Sensor (TPS)

Voltage Regulator

GENERAL INFORMATION 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 is necessary t o run t he en gine indoors, ma ke sure that exhaust g as i s forced 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 av oid g etting burned, do 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.

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