Suzuki LT-A50 Manuale utente

99500-20212-01E

LT-A50

GROUP INDEX

FOREWORD

This manual contains an introductory description on

the SUZUKI LT-A50 and procedures for its inspec-

tion/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 mainte-

nance. 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.

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 pro-

cedures. 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.

cCOPYRIGHT SUZUKI MOTOR CORPORATION 2001

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

LT-A50K3/K4 (’03, ’04-MODELS)

LT-A50K5 (’05-MODEL)

HOWTO USETHIS MANUAL

TO LOCATE WHATYOU 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 WORKTO 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

1Oil seal

2Bearing

3Spacer

4Front wheel hub

5Bearing

6Oil seal

7Front wheel

8Front wheel center cap

9Rear wheel hub

0Rear wheel

ARear wheel center cap

BCenter cap holder

AWheel nut (front and rear)

BFront hub nut

CRear hub nut

FRONT

REAR

ITEM N.m kgf.m lb-ft

A28 2.8 20.5

B65 6.5 47.5

C75 7.5 55.0

SYMBOL (FOR USA)

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.

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

ApplyTHREAD 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)

SYMBOL (For the other countries)

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.

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

ApplyTHREAD LOCK SUPER

“1360”.

99000-32130

Apply SUZUKI BOND “1207B”.

99000-31140

ApplyTHREAD 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

GENERAL INFORMATION 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

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.

GENERAL INFORMATION 1-3

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lent.

* 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.

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) 1is stamped on the left side of the frame

pipe.The engine serial number 2is 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

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

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