Suzuki LT-Z90K7 Setup Manual

Category
Motorcycle Accessories
Type
Setup Manual
K7
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.
1
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.
2
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.
3
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
C
Front grip 1
Flange bolt 4 8 × 16 mm
D
Front wheel assembly 2 Right and Left
Flange nut 8 10 mm
Washer 8 OD:20.0 ID:10.5
E
Pin 1
For rear brake cable
Adjuster nut 1
F
Reflex reflector 2 Right and Left
Bracket 2
Flange nut 2 5 mm
G Warning label set
3
For
E-19 CG selection
2
For
E-19 CH selection
3
For
E-19 CI selection
Item Part Name Q’ty Remarks
H Fuel label 1
I
Battery electrolyte
container
1
J Owner’s manual 1
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
T
L
OD ID
NOTE:
The parts shown as Item F, G and H in the above table are supplied for limited markets.
CF D
A
B E
FD
4
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
AA
H
BB
DD
CC
F
I J
G
EE
F
G
H
IJ
5
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
6
#
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.
7
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.
8
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.
9
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
FRONT
10
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.
11
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.
12
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
12
ANS
MOINS DE
12
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
ê
tre surveill
é
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
ç
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
ô
le
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
ô
le.
REPERER ET LIRE LE MANUEL DU PROPRIETAIRE
SE CONFORMER A TOUS LES AVERTISSEMENTS ET DIRECTIVES
AVERTISSEMENT
NE
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
2
, 3,3 psi
20 kPa, 0,20 kgf/cm
2
, 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)
13
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
14
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
15
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.
16
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.
17
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
B:
- 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.
18
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
A.
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
C.
5. Reinstall the steering head cover.
#
3.0–5.0 mm
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.
19
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
E.
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
3–7 mm
5 mm
5 mm
Least
Least
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Suzuki LT-Z90K7 Setup Manual

Category
Motorcycle Accessories
Type
Setup Manual

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