Suzuki LT-Z90K7 Setup Manual

Brand: Suzuki

Model: LT-Z90K7

Category: Motorcycle Accessories

Type: Setup Manual

August ’06 Printed in Japan (TK) 28

99505-01027-01E

FOREWORD

This vehicle has been designed and produced utilizing Suzuki’s most modern tech-

nology. The finest product, however, cannot perform properly unless it is correctly

assembled and serviced. This set-up manual has been produced to aid you in prop-

erly assembling and servicing this vehicle.

Please review this set-up manual carefully before performing any work. Take spe-

cial care to properly perform the required assembly and servicing marked by either

a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-

egories could lead to serious problems. #and  areas

are denoted to emphasize certain areas and carry the following meanings:

Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in vehicle damage.

This set-up manual is based on a vehicle of standard specification. Some minor dif-

ferences from this manual may be found in other specifications.

PREPARATION

WORKSHOP

A: Packed vehicle

B: Working space

SELF PROTECTION

UNCRATING THE VEHICLE

Remove the carton.

A: Crate

The workshop where the machine is assembled

should be clean, spacious, and have a level

floor.

The technician should wear protective clothing

such as leather gloves, a long sleeve shirt, eye

protection and safety shoes as shown in the

illustration when handling metal crates.

Metal crates may have sharp edges and may

cause injury.

REAR

Remove the bolts and brackets.

A: Bolt

B: Bracket

C: Vinyl tube

Remove the bolts from the crate.

A: Bolt

Lift the steel frame to separate it from the base of the

crate.



A: Steel frame

B: Crate base

Take out the front wheel assembly and various compo-

nent parts packaged around from the crate.

A: Front wheel assembly

B: Component parts

NOTE:

The brackets, bolts and vinyl tube are no longer

needed and these may be discarded.

Handling crates requires two operators.

Be careful not to scratch the vehicle.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

A Steering head cover 1

B Fuel tank vent hose 1

Front grip 1

Flange bolt 4 8 × 16 mm

Front wheel assembly 2 Right and Left

Flange nut 8 10 mm

Washer 8 OD:20.0 ID:10.5

Pin 1

For rear brake cable

Adjuster nut 1

Reflex reflector 2 Right and Left

Bracket 2

Flange nut 2 5 mm

G Warning label set

For

E-19 CG selection

For

E-19 CH selection

For

E-19 CI selection

Item Part Name Q’ty Remarks

H Fuel label 1

Battery electrolyte

container

J Owner’s manual 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item F, G and H in the above table are supplied for limited markets.

CF D

B E

The photograph shown indicates the parts dismounted

from the model in addition to the items shown in the

preceding page.

A: Handlebar assembly

B: Throttle cable

C: Front brake cable

D: Rear brake cable

E: Tool set

I J

Before assembling the vehicle, thoroughly under-

stand the “Safety Check Out” described on page

29.

After completion of assembly, carefully check the

vehicle referring to the “Safety Check Out”, then

deliver the vehicle to the customer.

ASSEMBLY

HANDLEBARS

Loosen the handlebar clamp bolts.

A: Handlebar clamp bolt

Align the dot mark on the handlebars with the mating

surface of the front side of right clamp.

Tighten the handlebar clamp bolts to the specified

torque.

" Handlebar clamp bolt: 26 N·m (2.6 kgf-m)



A: Flange bolt

B: Flange bolt

C: Dot mark

D: Clamp (Upper)

E: Clamp (Lower)

NOTE:

To install the handlebars correctly, first tighten

the bolt

A of the front side with specified

torque and then tighten the bolt

B of the rear

side.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

FRONT

A: Front brake cable

B: Throttle cable

C: Left switch wiring harness

D: Parking brake switch lead wire

E: Rear brake cable

THROTTLE CABLE

Remove the screw to take off the throttle case cover.

Insert the inner cable end into the recess of throttle

cable lever correctly.

A: Throttle case cover

B: Screw

C: Cable end

D: Throttle cable lever

Pull on the outer cable and insert the outer cable cap

to the recess of throttle case correctly as shown.

A: Throttle cable

B: Outer cable cap

C: Throttle case

D: Recessed area



Reinstall the throttle case cover.

A: Gasket

The line drawings on page 26, 27 and 28 show

the proper routing of the control cables and

wiring. Refer to drawings in addition to follow-

ing the instructions carefully.

NOTE:

Before installing the cable, grease the cable

end.

Check the gasket at the correct position.

Check to ensure that the throttle operates

freely and closes automatically.

REAR BRAKE CABLE

Turn the brake cable adjuster and lock nut in as far as

possible and align the slots.

Insert the inner cable end into the recess of brake

lever, then pull on the outer cable housing and insert it

into the adjuster.

A: Brake cable

B: Adjuster

C: Lock nut

D: Cable end

Set the pin into the brake cam lever.

Insert the end of the brake cable into the pin hole.

Attach the adjuster nut on the end of the brake cable.

Do not adjust at this time.

Adjustment will be covered in the SERVICING section.

A: Brake cam lever

B: Pin

C: Adjuster nut

NOTE:

Before installing the cable, grease the cable

end.

FRONT BRAKE CABLE

Pass the front brake cable through the hole of steering

head cover.

A: Front brake cable

B: Steering head cover

C: Hole

Turn the brake cable adjuster and lock nut in as far as

possible and align the slots.

Insert the inner cable end into the recess of brake

cable equalizer, then pull on the outer cable housing

and insert it into the adjuster.

Do not adjust at this time.

Adjustment will be covered in the SERVICING section.

A: Brake cable

B: Adjuster

C: Lock nut

D: Cable end

E: Brake cable equalizer

The procedure to install the left brake cable is identical

to that of the right.

A: Brake cable

B: Adjuster

C: Lock nut

D: Cable end

E: Brake cable equalizer

NOTE:

Set the right side brake cable to the lower side

adjuster.

Before installing the cable, grease the cable

end.

NOTE:

Set the left side brake cable to the upper side

adjuster.

Before installing the cable, grease the cable

end.

Remove the bolts holding the front part of the vehicle.



A: Bolt

1. Lift the front of vehicle by using a hoist.

2. Raise the rear of vehicle.

3. Pull the crate base forward, then balance the vehi-

cle.



FRONT WHEEL

When installing the front wheel onto the axle, special

attention must be paid to the arrow of the rotational

direction on the tire sidewall.

When the tire is properly installed, the arrow must indi-

cate forward rotation of the wheel.

Carefully clean the front wheel hubs and drums with a

cloth to remove all dust.

Before removing bolts, lift the front of the vehi-

cle a little by using a hoist to prevent the dam-

age to the bolt threads.

NOTE:

The bolts are no longer needed and may be dis-

carded.

Be careful the hoist band has clearance at the

cables, guide and wiring harness.

FRONT

Properly position the wheel on the axle stud bolts.

Temporarily finger-tighten the wheel set nuts.

A: Stud bolt

B: Air valve

C: Washer OD:20.0 mm ID:10.5 mm

D: 10 mm flange nut (Wheel set nut)

Remove the hoist used to lift the vehicle and then

place the vehicle in place.

Tighten the wheel set nuts to the specified torque.

" Wheel set nut: 55 N·m (5.5 kgf-m)

A: 10 mm flange nut (Wheel set nut)

STEERING HEAD COVER

Align the recess of steering head cover on the handle-

bars.

Fix the steering head cover by push down firmly.

A: Steering head cover

B: Handlebars

C: Recess

FRONT GRIP

Install the front grip on the frame using four bolts.

A: Front grip

B: Frame

C: 8 × 16 mm flange bolt

NOTE:

Be sure to install the front wheels with the air

valves facing outwards.

FRONT GRIP AND REFLEX REFLECTOR FRONT

SIDE (FOR LIMITED MARKET)

Install the reflex reflector to the bracket.

A: Reflex reflector

B: Bracket

C: 5 mm flange nut

Install the front grip with four bolts together with the

reflector assembly.

A: Front grip

B: Frame

C: 8 × 16 mm flange bolt

D: Reflex reflector

E: Bracket

F: Boss

G: Mark (R and L)

FUEL TANK VENT HOSE

Install the fuel tank vent hose to the fuel tank cap.

Insert the free end of fuel tank vent hose to the hole of

steering head cover.



A: Fuel tank vent hose

B: Fuel tank cap

C: Hole

Be sure not to bend or twist the hose when

installing.

OWNER’S MANUAL

Pull the seat release lever toward the rear and remove

the seat.

A: Seat release lever

Store the owner’s manual in place.

A: Owner’s manual

WARNING LABEL

(FOR E-19 MARKET)

Select the appropriate language label for your country.

NOTE:

For E-19 CG selection: German, Spanish, Portuguese

For E-19 CH selection: French, Dutch

For E-19 CI selection: Swedish, Finnish, Danish

MOINS DE

ANS

MOINS DE

ANS

AVERTISSEMENT

L'utilisation de ce VTT par des

enfants de moins de 12 ans

augmente le risque de subir des

accidents graves ou mortels.

Les enfants de moins de 16 ans

doivent

tre surveill

s par des

adultes.

NE JAMAIS permettre aux enfants

de moins de 12 ans de conduire

ce VTT.

L'utilisation incorrecte du VTT peut résulter en

BLESSURES GRAVES ou MEME LA MORT

TOUJOURS PORTER

UN CASQUE ET DES

VETEMENTS DE

SECURITE

APPROUVES

NE JAMAIS

UTILISER SUR

DES ROUTES

PUBLIQUES

NE JAMAIS

ACCEPTER DE

PASSAGER

NE JAMAIS

CONDUIRE SOUS

L'INFLUENCE DE

STUPEFIANTS OU

D'ALCOOL

NE JAMAIS conduire :

•

sans avoir re

u une formation ou des directives

adéquates au préalable

• à

des vitesses excédant vos compétences ou les

conditions de conduite

•

sur les routes publiques - au risque de provoquer une

collision avec une autre véhicule

•

avec un passager - les passagers affectent l'équilibre et

la manoeuvrabilité et augmentent le risque de perte de

contr

TOUJOURS :

•

utiliser des techniques de conduite acceptées pour

éviter le renversement du véhicule sur collines, terrains

accidentés et dans les virages

•

éviter les chaussées pavées - au risque d'affecter

gravement la manoeuvrabilité et le contr

le.

REPERER ET LIRE LE MANUEL DU PROPRIETAIRE

SE CONFORMER A TOUS LES AVERTISSEMENTS ET DIRECTIVES

AVERTISSEMENT

JAMAIS

accepter de passager

AVERTISSEMENT

Les passagers risquent

de causer une perte de

contrôle, résultant en

BLESSURES GRAVES

ou MÉME LA MORT

AVERTISSEMENT

Une mauvaise pression des pneus ou une

surcharge peut entraîner une perte de

contrôle.

Une perte de contrôle peut entraîner des

accidents graves ou mortels.

Garder TOUJOURS une pression des

pneus appropriée selon le tableau indiqué ci-

dessous.

NE JAMAIS dépasser la capacité de

charge du véhicule qui est de

90 kg (198 lbs).

AVANT :

ARRIÈRE :

22,5 kPa, 0,225 kgf/cm

, 3,3 psi

20 kPa, 0,20 kgf/cm

, 2,9 psi

DIMENSION AVANT AT19 × 7-8

DU PNEU ARRIÈRE AT19 × 7-8

PRESSION DU PNEU A FROID

CHARGE

Jusqu’à 90 kg (198 lbs)

Stick the label selected for your country.

A: Warning label (General warning)

B: Warning label (Tire information)

C: Warning label (Age 12)

D: Front fender (Right)

E: Rear fender (Right)

FUEL LABEL (FOR LIMITED MARKET)

Stick the label on the fuel tank.

A: Fuel tank

B: Fuel label

FRONT

SERVICING

BATTERY

The battery is located under the seat.

Pull the seat release lever toward the rear and remove

the seat.

A: Seat release lever

Unhook the clamp to take off the CDI wiring harness.

Remove the rubber band.

Remove the battery from the vehicle.

A: Clamp

B: Rubber band

Filling electrolyte

Remove the aluminium tape sealing the battery elec-

trolyte filler holes.

A: Aluminium tape

B: Electrolyte filler hole

Remove the caps from the electrolyte container.

A: Caps

B: Sealed area

With just enough force to break the nozzle seal of elec-

trolyte container, push each nozzle of the electrolyte

container into the battery’s electrolyte filler ports and

hold the container firmly so that it does not fall.

Take precaution not to allow any of the fluid to spill.

A: Electrolyte containers

Make sure air bubbles are coming up in each electro-

lyte container, and leave in this position for about 20

minutes.

A: Air bubbles

NOTE:

Use the removed caps as the sealed caps of

battery filler holes.

Do not remove or pierce the sealed areas of the

electrolyte container.

NOTE:

If no air bubbles are coming up from a filler

port, tap the bottom of the container two or

three times.

Never remove the container from the battery.

After confirming that the electrolyte has entered the

battery completely, remove the electrolyte containers

from the battery.

Wait for around 20 minutes.

Insert the caps into the filler holes, pressing in firmly so

that the top of the each caps does not protrude above

the upper surface of the battery’s top cover.

A: Caps



Charge the battery with a battery charger.



After charging the battery, install the battery in the

vehicle as follows.



Never use anything except the specified battery

electrolyte.

Once the sealing cap has been installed in the

battery, do not remove the sealing cap.

For charging the battery, make sure to use the

charger specially designed for MF battery.

Otherwise, the battery may be overcharged

resulting in shortened service life.

Do not remove the cap during charging.

Position the battery with the cap facing upward

during charging.

When attaching the wiring harness battery

leads to the battery terminals, observe the cor-

rect polarity.

NOTE:

The terminal bolts and nuts are attached to the

battery.



A: Rubber cushion

1. Set the battery to the box.

2. First connect the

+ lead to the + positive terminal

of the battery.

3. Cover

+ terminal with rubber boot.

4. Connect the

- lead to the - negative terminal of

the battery.

5. Fix the battery with rubber band.

6. Clamp the wiring harness.

A: + lead

- lead

C: Rubber boot

D: Rubber band

E: Clamp

Reinstall the seat.

Insert the seat hook into the seat hook retainer and

pass the seat lock lever through the hole of the rear

fender.

Push down the seat firmly.

A: Seat assembly

B: Hook

C: Hook retainer

D: Seat lock lever

E: Hole

Check the rubber cushions are installed in the

correct position before installing the battery.

THROTTLE CABLE

Check the throttle cable play at the throttle lever end.

Throttle cable play: 3.0–5.0 mm

If adjustment is necessary, carry out the procedure

below:

1. Remove the steering head cover.

2. Loosen the throttle cable adjuster lock nut

3. Turn the adjuster

B in or out until the correct play.

4. Tighten the lock nut

A while holding the adjuster B.

Place the rubber boot

5. Reinstall the steering head cover.

3.0–5.0 mm

After the adjustment is completed, check that

handlebar movement does not raise the engine

idle speed and that the throttle grip returns

smoothly and automatically.

FRONT BRAKE

Check the brake lever play.

The brake lever play

A measured at the lever holder

when the lever is squeezed, and the brake cable

holder

B is in the straight up position as shown in the

photograph.

Front brake lever play: 3–7 mm

If adjustment is necessary, carry out the procedure

below:

1. Place the vehicle on a level surface.

Lift the front end of the vehicle and place a solid

object, such as a wooden block, securely under the

frame.

2. Loosen the lock nuts

E and turn the upper and

lower cable adjusters

D equally until the brake lever

play

A measured at the lever holder is 3–7 mm

when the lever is squeezed.

Make sure that at least 5 mm of the adjuster threads

are inserted in the lever holder

C, as shown in the

photograph.

Tighten the lock nuts

If the cable adjusters

D do not provide enough

adjustment, turn the left and right brake cable

adjusters

F equally to obtain the specified play.

3. Turn the upper or lower cable adjuster so that when

the brake lever is fully squeezed the cable holder is

in the straight up position.

This adjustment is important for smooth braking,

and to help prevent uneven wear of the brake shoes

on the left and right wheels.

Check the brake lever play again, and repeat step

(2) if necessary.

4. Release the front brake lever and turn the front

wheels by hand to make sure the brakes don’t drag.

If either brake drags, the brake lever play should be

increased slightly.

Repeat steps (2) and (3).

3–7 mm

5 mm

Least

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Suzuki LT-Z90K7 Setup Manual

Brand: Suzuki

Model: LT-Z90K7

Category: Motorcycle Accessories

Type: Setup Manual

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Suzuki LT-Z90K7 Setup Manual

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