Lt-r450/zk9

Transcript

LT-R450/ZK9 (’09-MODEL) 1 LT-R450/ZK9 (’09-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the LT-R450/ZK8 (’08-MODEL). NOTE: • Any differences between the LT-R450/ZK8 (’08-MODEL) and LT-R450/ZK9 (’09-MODEL) in specifications and service data are indicated with an asterisk mark (*). • Please refer to the LT-R450K8 (’08-MODEL) service manual for details which are not given in this manual. CONTENTS SPECIFICATIONS .............................................................................................. MAINTENANCE AND TUNE-UP PROCEDURES ............................................. BRAKES.................................................................................................... OIL JET............................................................................................................... REMOVAL ................................................................................................. INSPECTION AND CLEANING ................................................................ INSTALLATION......................................................................................... ENGINE LUBRICATION SYSTEM CHART ....................................................... FI SYSTEM DIAGNOSIS .................................................................................... FI SYSTEM WIRING DIAGRAM ............................................................... ECM TERMINAL ....................................................................................... DTC TABLE AND DEFECTIVE CONDITION ........................................... FI SYSTEM TROUBLESHOOTING .......................................................... COOLING FAN RELAY............................................................................. SENSOR ............................................................................................................. IAP SENSOR INSPECTION...................................................................... IAP SENSOR REMOVAL AND INSTALLATION...................................... THROTTLE BODY.............................................................................................. CONSTRUCTION ...................................................................................... REMOVAL ................................................................................................. FRONT SUSPENSION CONSTRUCTION ......................................................... SWINGARM CONSTRUCTION .......................................................................... BRAKE PEDAL .................................................................................................. REMOVAL ................................................................................................. INSTALLATION......................................................................................... REAR SHOCK ABSORBER .............................................................................. REMOVAL ................................................................................................. © COPYRIGHT SUZUKI MOTOR CORPORATION 2008 3 4 4 6 6 6 6 7 8 8 9 10 12 20 20 20 20 21 21 22 24 25 26 26 26 27 27 2 LT-R450/ZK9 (’09-MODEL) LT-R450/ZK9 (’09-MODEL) CONTENTS CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER INFORMATION .................................................................................................. WIRING HARNESS ROUTING .......................................................................... OIL HOSE ROUTING......................................................................................... FRONT BRAKE HOSE ROUTING..................................................................... THROTTLE BODY INSTALLATION.................................................................. BRAKE PEDAL INSTALLATION ...................................................................... HANDLEBAR INSTALLATION ......................................................................... TIGHTENING TORQUE ..................................................................................... SERVICE DATA................................................................................................. WIRING DIAGRAM ............................................................................................ 28 29 31 32 33 34 35 36 36 45 COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). MODEL LT-R450/Z CODE E-19 E-28 E-33 COUNTRY or AREA E.U. Canada California (U.S.A.) EFFECTIVE FRAME NO. JSAAL43A 92100001 – JSAAL43A 92100001 – JSAAL43A 92100001 – LT-R450/ZK9 (’09-MODEL) SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................................................................................... Overall width....................................................................................... Overall height ..................................................................................... Wheelbase ......................................................................................... Front track .......................................................................................... Rear track ........................................................................................... Ground clearance ............................................................................... Seat height ......................................................................................... * Curb mass........................................................................................ 1 845 mm (72.6 in) 1 245 mm (49.0 in) 1 085 mm (42.7 in) 1 285 mm (50.6 in) 1 045 mm (41.1 in) 985 mm (38.8 in) 240 mm (9.4 in) 780 mm (30.7 in) 188 kg (414 lbs) ENGINE Type ................................................................................................... Number of cylinders ........................................................................... Bore .................................................................................................... Stroke ................................................................................................. Displacement...................................................................................... Compression ratio .............................................................................. Fuel system ........................................................................................ Air cleaner .......................................................................................... Starter system .................................................................................... Lubrication system ............................................................................. Idle speed ........................................................................................... Four stroke, liquid-cooled, DOHC 1 95.5 mm (3.760 in) 62.8 mm (2.472 in) 450 cm³ (27.5 cu. in) 11.7 : 1 Fuel injection Polyurethane foam element Electric Dry sump 1 800 ± 100 r/min DRIVE TRAIN Clutch ................................................................................................. Transmission ...................................................................................... Gearshift pattern................................................................................. Primary reduction ratio ....................................................................... Gear ratios, Low ................................................................................ 2nd ................................................................................. 3rd.................................................................................. 4th .................................................................................. Top................................................................................. Final reduction ratio ............................................................................ Drive chain ......................................................................................... Wet multi-plate type 5-forward 1 down, 4 up (Foot operated) 2.851 (77/27) 2.076 (27/13) 1.647 (28/17) 1.333 (28/21) 1.095 (23/21) 0.913 (21/23) 2.642 (37/14) RK 520SMOZ10S, 96 Links CHASSIS Front suspension ................................................................................ Rear suspension ................................................................................ Front wheel travel ............................................................................... Rear wheel travel ............................................................................... Caster ................................................................................................. Trail .................................................................................................... Toe-in ................................................................................................. Camber............................................................................................... Steering angle .................................................................................... Turning radius .................................................................................... Front brake ......................................................................................... Rear brake.......................................................................................... Front tire size...................................................................................... Rear tire size ...................................................................................... Independent, double wishbone, coil spring, oil damped Swingarm type, coil spring, oil damped 254 mm (10.0 in) 277 mm (10.9 in) 8.0° 30 mm (1.18 in) 0 mm –3.0° 41° 3.5 m (11.5 ft) Disc brake, twin Disc brake AT20 × 7 R10, tubeless AT18 × 10 R8, tubeless ELECTRICAL lgnition type ........................................................................................ lgnition timing ..................................................................................... * Spark plug .......................................................................................... Battery ................................................................................................ Generator ........................................................................................... Main fuse ............................................................................................ Fuse ................................................................................................... Headlight ............................................................................................ Brake light/Taillight ............................................................................. Neutral indicator light.......................................................................... Reverse indicator light ........................................................................ Coolant tempereture indicator light .................................................... Electronic ignition (CDI) 3° B.T.D.C. at 1 800 r/min NGK CR8EB 12 V 21.6 kC (6 Ah)/10 HR Three-phase A.C. generator 20 A 10/10 A 12 V 40/40 W LED 12 V 3.4 W 12 V 3.4 W 12 V 3.4 W CAPACITIES Fuel tank............................................................................................. * 9.0 L (2.4/2.0 US/lmp gal) Engine oil, oil change......................................................................... Oil tank 1 200 ml (1.3/1.1 US/Imp qt) Engine 400 ml (0.4/0.4 US/Imp qt) With filter change ............................................................. Oil tank 1 300 ml (1.4/1.1 US/lmp qt) Engine 400 ml (0.4/0.4 US/lmp qt) Overhaul .......................................................................... Oil tank 1 400 ml (1.5/1.2 US/lmp qt) Engine 400 ml (0.4/0.4 US/lmp qt) Coolant ............................................................................................... 1.4 L (1.5/1.2 US/lmp qt) 3 4 LT-R450/ZK9 (’09-MODEL) MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each Periodic Maintenance item which differ from those of the LT-R450/ZK8 (’08-MODEL). For details other than the following items, refer to the LT-R450 Service Manual. BRAKES Inspect initially at 1 month and every 3 months thereafter. BRAKE PADS LT-R450K8 2-18 FRONT BRAKE LEVER ADJUSTMENT Adjust the brake lever position as follows: • Loosen the lock-nut 1. • Turn in or out adjuster 2 to obtain the proper brake lever position. • The standard adjuster length A is 11 – 15 mm (0.4 – 0.6 in). • Tighten the lock-nut 1 securely.  Front brake lever adjuster lock-nut: 5 N·m (0.5 kgf-m, 3.5 lbf-ft) REAR BRAKE PEDAL AND LEVER The procedure for adjusting the rear brake pedal and brake lever is as follows: NOTE: First adjust the brake pedal, and then adjust the brake lever. Brake pedal • Turn the adjuster 1 in or out until the pedal height A to the specification, after loosening the lock-nut 2. • Make sure to tighten the lock-nut 2 securely.  Brake pedal height A: 0 – 10 mm (0 – 0.4 in)  Rear brake master cylinder rod lock-nut: 18 N·m (1.8 kgf-m, 13.0 lbf-ft) LT-R450/ZK9 (’09-MODEL) • Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. PARKING BRAKE LT-R450K8 2-19 5 6 LT-R450/ZK9 (’09-MODEL) OIL JET REMOVAL • Separate the left and right crankcase. (LT-R450K8 3-22) • Remove the piston cooling oil jet 1 from the right crankcase. INSPECTION AND CLEANING • Check the oil jet for clogging. • If they are clogged, clean their oil passage with a proper wire and compressed air. INSTALLATION • Apply engine oil to the O-ring 1.  Use a new O-ring to prevent oil leakage. • Install the piston cooling oil jet 2. • Apply a small quantity of THREAD LOCK to the piston cooling oil jet bolt, and then tighten the bolt.  99000-32110: THREAD LOCK SUPER “1322” or equivalent LT-R450/ZK9 (’09-MODEL) ENGINE LUBRICATION SYSTEM CHART CAM FACE (IN & EX) CONROD BIG END BEARING CAMSHAFT JOURNAL (IN & EX) CRANK PIN CYLINDER HEAD RIGHT CRANKSHAFT PISTON PIN PISTON CYLINDER WALL CYLINDER CRANKSHAFT RIGHT END OIL NOZZLE RIGHT CRANKCASE CAM CHAIN ORIFICE LEFT CRANKSHAFT STARTER CLUTCH K8 OIL FILTER BY-PASS OIL JET OIL PUMP (NO. 1) K9 OIL HOSE COUNTER GEARS OIL TANK SPACER DRIVESHAFT COUNTERSHAFT DRIVE GEARS LEFT CRANKCASE GENERATOR COVER OIL PUMP (NO. 2) OIL PUMP (FOR RETURN) OIL STRAINER (REAR) OIL STRAINER (FRONT) CLUTCH OIL PAN OIL HOSE 7 Tip-over sensor (TOS) Intake air temperature sensor (IATS) Engine coolant temperature sensor (ECTS) Intake air pressure sensor (IAPS) Throttle position sensor (TPS) Crankshaft position sensor (CKPS) Br/W Dg B/Bl B/Br G/B R Y G/W Bl Fuel pump relay W/Bl P B/W B/W B/W 3 5 N Fuel indicator light FI light 2 1 to fuel sensor Ignition coil (IG COIL) Gear position 4 switch Bl/B B Y/B G/R Fuel injector (FI) Fuel pump O/W O/G O/W Gr/W Y/B Neutral indicator light Engine stop switch Cooling fan relay M 20A 10A Clutch lever position switch Ignition switch Starter motor Starter relay Starter switch 10A Cooling fan Battery 8 LT-R450/ZK9 (’09-MODEL) FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM LT-R450/ZK9 (’09-MODEL) ECM TERMINAL TERMINAL NO. 1 2 3 4 5 6 7 8 9 0 A B C D E F G H CIRCUIT Power source TO sensor signal (TOS) CKP sensor signal (CKP+) GP switch signal (GP) TP sensor signal (TP) IAP sensor signal (IAP) — ECM ground (E1) CKP sensor signal (CKP–) Serial data for self-diagnosis — Neutral switch (NT) Power source for sensors (VCC) Fuel pump power source (FPP) Fuel pump (FP) Injector (#11) Fuel indicator Ignition coil TERMINAL NO. I J K L M N O P Q R S T U V W X Y Z CIRCUIT — — FI/ECT indicator ECT sensor signal (ECT) — Sensors ground (E2) IAT sensor signal (IAT) — — — Mode select switch Starter motor (STA) — — Cooling fan relay (FAR) — Ground (E01) Ground (E02) 9 10 LT-R450/ZK9 (’09-MODEL) DTC TABLE AND DEFECTIVE CONDITION DETECTED DETECTED FAILURE CONDITION ITEM CKP sensor The signal does not reach ECM for 1 sec. or more, after receiving the IAP sensor input signal. DTC No. C12 P0335 TP sensor C14 H P0120 L ECT sensor C15 H P0115 L IAP sensor C17 H P0105 L IAT sensor C21 H P0110 L The sensor should produce following voltage. 0.4 V sensor voltage < 4.5 V In other than the above range, C14 (P0120) is indicated. Sensor voltage is higher than specified value. Sensor voltage is lower than specified value. The sensor voltage should be the following. 0.2 V sensor voltage < 4.9 V In other than the above range, C15 (P0115) is indicated. Sensor voltage is higher than specified value. Sensor voltage is lower than specified value. The sensor should produce following voltage. 0.2 V sensor voltage < 4.1 V In other than the above range, C17 (P0105) is indicated. Sensor voltage is higher than specified value. Sensor voltage is lower than specified value. The sensor voltage should be the following. 0.2 V sensor voltage < 4.9 V In other than the above range, C21 (P0110) is indicated. Sensor voltage is higher than specified value. Sensor voltage is lower than specified value. CHECK FOR CKP sensor wiring and mechanical parts CKP sensor, lead wire/coupler connection TP sensor, lead wire/coupler connection TP sensor circuit shorted to VCC or ground circuit open TP sensor circuit open or shorted to ground or VCC circuit open ECT sensor, lead wire/coupler connection ECT sensor circuit open or ground circuit open ECT sensor circuit shorted to ground IAP sensor, lead wire/coupler connection IAP sensor circuit shorted to VCC or ground circuit open IAP sensor circuit open or shorted to ground or VCC circuit open IAT sensor, lead wire/coupler connection IAT sensor circuit open or ground circuit open IAT sensor circuit shorted to ground LT-R450/ZK9 (’09-MODEL) DTC No. C23 H P1651 L C24 DETECTED DETECTED FAILURE CONDITION ITEM TO sensor The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON. 0.2 V sensor voltage < 4.7 V In other than the above value, C23 (P1651) is indicated. Sensor voltage is higher than specified value. Sensor voltage is lower than specified value. Ignition signal P0351 C31 Gear position signal P0705 Fuel injector C32 P0201 C41 Fuel pump relay P0230 C60 P0480 Cooling fan relay 11 CHECK FOR TO sensor, lead wire/coupler connection TO sensor circuit shorted to VCC or ground circuit open TO sensor circuit open or shorted to ground or VCC circuit open CKP sensor (pick-up coil) signal is pro- Ignition coil, wiring/coupler connection, power supply from the duced, but signal from ignition coil is battery interrupted 5 times or more continuously. In this case, the code C24 (P0351) is indicated. Gear position signal voltage should be higher than the following for 3 seconds and more. Gear position switch voltage 0.9 V If lower than the above value, C31 (P0705) is indicated. CKP sensor (pickup coil) signal is produced, but fuel injector signal is interrupted 8 times or more continuously. In this case, the code C32 (P0201) is indicated. GP switch, wiring/coupler connection, gearshift cam, etc. Fuel injector, wiring/coupler connection, power supply to the injector No voltage is applied to the fuel pump, Fuel pump relay, lead wire/coualthough fuel pump relay is turned ON. pler connection, power source to the fuel pump relay and fuel NOTE: The FP relay is incorporated in the injector ECM. Cooling fan relay signal is not input to ECM. Cooling fan relay, lead wire/coupler connection 12 LT-R450/ZK9 (’09-MODEL) FI SYSTEM TROUBLESHOOTING “C17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION C17 P0105 DETECTED CONDITION IAP sensor voltage is not within the following range. 0.2 V Sensor voltage < 4.1 V NOTE: * Note that atmospheric pressure varies depending on weather conditions as well as altitude. * Take that into consideration when inspecting voltage. Sensor voltage is higher than specified H value. Sensor voltage is lower than specified L value. • • • • • POSSIBLE CAUSE Clogged vacuum passage between throttle body and IAP sensor. Air being drawn from vacuum passage between throttle body and IAP sensor. IAP sensor circuit open or shorted to ground. IAP sensor malfunction. ECM malfunction. • IAP sensor circuit shorted to VCC or ground circuit open. • IAP sensor circuit open or shorted to ground or VCC circuit open. ECM IAP sensor B/Br E2 G/B IAP R VCC INSPECTION Step 1 (When indicating C17:) 1) Turn the ignition switch OFF. 2) Remove the engine mounting left upper bracket 1 by removing the bolts 2 and washers 3. (LT-R450K8 3-6) 1 LT-R450/ZK9 (’09-MODEL) 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then measure the IAP sensor input voltage. 1 4) 5) 6) 7) 1 Disconnect the IAP sensor coupler. Turn the ignition switch ON. Measure the voltage at the Red wire and ground. If OK, then measure the voltage at the Red wire and B/Br wire. V  IAP sensor input voltage: 4.5 – 5.5 V (+ Red – - Ground) (+ Red – - B/Br)  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set  Tester knob indication: Voltage () Is the voltage OK? YES NO Go to Step 2. • Loose or poor contacts on the ECM coupler (terminal C or N). • Open or short circuit in the Red wire or B/Br wire. Step 1 (When indicating P0105-H:) 1) Turn the ignition switch OFF. 2) Remove the engine mounting left upper bracket 1 by removing the bolts 2 and washers 3. (LT-R450K8 3-6) 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then check the IAP sensor lead wire continuity. 1 4) Disconnect the IAP sensor coupler. 5) Check the continuity between Red wire A and G/B wire B. If the sound is not heard from the tester, the circuit condition is OK. 1 13 14 6) 7) 8) 9) LT-R450/ZK9 (’09-MODEL) Remove the front fender. (LT-R450K8 7-6) Disconnect the ECM coupler. Check the continuity between G/B wire B and terminal 6. If OK, then check the continuity between B/Br wire C and terminal N. 1  IAPS lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set ECM coupler (Harness side)  Tester knob indication: Continuity test ()  When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Is the continuity OK? YES NO Go to Step 2. G/B wire shorted to VCC, or B/Br wire open. 10)After repairing the trouble, clear the DTC using SDS tool. (LT-R450K8 4-25) Step 1 (When indicating P0105-L:) 1) Turn the ignition switch OFF. 2) Remove the engine mounting left upper bracket 1 by removing the bolts 2 and washers 3. (LT-R450K8 3-6) 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then check the IAP sensor lead wire continuity. 1 4) Disconnect the IAP sensor coupler. 5) Check the continuity between G/B wire B and ground. 6) Also, check the continuity between G/B wire B and B/Br wire C. If the sound is not heard from the tester, the circuit condition is OK. 1 LT-R450/ZK9 (’09-MODEL) 7) Remove the front fender. (LT-R450K8 7-6) 8) Disconnect the ECM coupler. 9) Check the continuity between Red wire A and terminal C. 10)Also, check the continuity between G/B wire B and terminal 6. 1  IAPS lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set ECM coupler (Harness side)  Tester knob indication: Continuity test ()  When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Is the continuity OK? YES NO Go to Step 1 (Page 12) and go to Step 2. Red wire or G/B wire open, or G/B wire shorted to ground 11)After repairing the trouble, clear the DTC using SDS tool. (LT-R450K8 4-25) Step 2 1) Connect the IAP sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed and measure the IAP sensor output voltage at the wire side coupler (between G/B and B/ Br wires).  IAP sensor output voltage: Approx. 2.1 V at idle speed (+ G/B – - B/Br)  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set  Tester knob indication: Voltage () Is the voltage OK? YES NO Go to Step 3. • Open or short circuit in the G/B wire • If wire is OK, replace the IAP sensor with a new one. 4) After repairing the trouble, clear the DTC using SDS tool. (LT-R450K8 4-25) 2 V 15 16 LT-R450/ZK9 (’09-MODEL) Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. (Page 20) 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. Arrange 3 new 1.5 V batteries in series 1 (check that total voltage is 4.5 – 5.0 V) and connect - terminal to the ground terminal 2 and + terminal to the VCC terminal 3. 4) Check the voltage between Vout 4 and ground. Also, check if voltage reduces when vacuum is applied up to 53 kPa (400 mmHg) by using vacuum pump gauge. (Page 17) 3 V  09917-47011: Vacuum pump gauge 09900-25008: Multi-circuit tester set  Tester knob indication: Voltage () Is the voltage OK? YES NO • G/B, Red or B/Br wire open or shorted to ground, or poor 6, C or N connection • If wire and connection are OK, intermittent trouble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. If check result is not satisfactory, replace the IAP sensor with a new one.  When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. 5) After repairing the trouble, clear the DTC using SDS tool. (LT-R450K8 4-25) 3 ECM coupler (Harness side) LT-R450/ZK9 (’09-MODEL) Output voltage (VCC voltage 4.5 – 5.0 V, ambient temp. 20 – 30 °C, 68 – 86 °F) ALTITUDE (Reference) (ft) (m) 0 0 ATMOSPHERIC PRESSURE (mmHg) kPa 760 100 OUTPUT VOLTAGE (V) 3.1 – 3.6 2 000 2 001 610 611 707 707 94 94 5 000 5 001 1 524 1 525 634 634 85 85 2.8 – 3.4 2.6 – 3.1 8 000 8 001 2 438 2 439 567 567 76 76 2.4 – 2.9 10 000 3 048 526 70 17 18 LT-R450/ZK9 (’09-MODEL) “C41” (P0230) FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE No voltage is applied to fuel pump although FP relay • FP relay circuit open or short. is turned ON. • FP relay (ECM) malfunction.
                  INSPECTION Step 1 (When indicating C41:) 1) Turn the ignition switch OFF. 2) Remove the front fender. (LT-R450K8 7-6) 3) Check the ECM coupler for loose or poor contacts. If OK, then check the FP relay input voltage. 1 4) Disconnect the ECM coupler. 5) Insert the needle pointed probe to the ECM coupler. 6) Measure the voltage between terminal D and ground. 1  FP relay input voltage: Battery voltage  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set  Tester knob indication: Voltage () V LT-R450/ZK9 (’09-MODEL) Is the voltage OK? YES NO • FP relay (ECM) malfunction. • O/W or O/G wire open or shorted, or poor terminal D or E connection. • If wire and connection are OK, intermittent trouble or faulty ECM. • Recheck each terminal and wire harness for open circuit and poor connection. • Replace the ECM with a known good one, and inspect it again. Open or short circuit in the O/W wire.  When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. 7) After repairing the trouble, clear the DTC using SDS tool. (LT-R450K8 4-25) 1 ECM coupler (Harness side) 19 20 LT-R450/ZK9 (’09-MODEL) COOLING FAN RELAY ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Start the engine and run it idling condition. 3) Click “Cooling fan relay control” 1. 4) Click “Operate” 2. At this time, if an operation sound is heard from the cooling fan relay and cooling fan motor is operated, the function is normal. NOTE: Cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 90 °C (194 °F) after starting the engine. 5) Click “Stop” 3 to check the operation properly. SENSOR IAP SENSOR INSPECTION The intake air pressure sensor is installed at the top side of the throttle body. (Page 12) IAP SENSOR REMOVAL AND INSTALLATION • Remove the fuel tank and fuel tank lower cover. (LT-R450K8 5-4) • Disconnect the IAP sensor coupler 1. • Remove the plate 2, IAP sensor 3 and O-ring 4. • Install the IAP sensor in the reverse order of removal.  Replace the O-ring 4 with a new one. LT-R450/ZK9 (’09-MODEL) 21 THROTTLE BODY CONSTRUCTION 1 2 3 4 5 6 TP sensor Throttle body Fuel delivery pipe O-ring Fuel injector Injector seal 7 8 9 A B C Starter valve Throttle cable cover IAP sensor Fuel delivery pipe mounting screw Fuel injector mounting screw TP sensor mounting screw  ITEM A B C N·m 3.5 3.5 3.5 kgf-m lbf-ft 0.35 2.5 0.35 2.5 0.35 2.5 22 LT-R450/ZK9 (’09-MODEL) REMOVAL • Remove the front fender. (LT-R450K8 7-6) • Remove the fuel tank and fuel tank lower cover. (LT-R450K8 5-4) • Remove the rubber cap 1. • Disconnect the fuel injector coupler 2, IAP sensor coupler 3 and TP sensor coupler 4. • Remove the throttle cable cover 5. • Disconnect the throttle cable from drum.  After disconnecting the throttle cables, do not snap the throttle valve from full open to full close. It may cause damage to the throttle valve and throttle body. • Loosen the throttle body clamp screws and move the throttle body assembly upward. • Disconnect the starter cable from the throttle body assembly. LT-R450/ZK9 (’09-MODEL) • Remove the starter valve 6 and spring 7 from the starter cable. NOTE: Remove the IAP sensor 8 as shown in the IAP sensor removal and installation. (Page 20) INSTALLATION (LT-R450K8 5-18) 23 24 LT-R450/ZK9 (’09-MODEL) FRONT SUSPENSION CONSTRUCTION 1 1 2 3 4 5 6 7 8 9 0 A Front shock absorber Collar Dust seal Bearing Collar Upper wishbone arm Dust seal Collar Bearing Washer Spring washer B C D E F G A B C D E Lower wishbone arm Steering knuckle Spring washer Cotter pin Tie rod Tie rod end Shock absorber mounting nut Wishbone arm pivot nut Knuckle end nut Tie rod end nut Tie rod lock-nut 1 Spring washer A eliminated as K9 model  ITEM A B C D E N·m 60 65 29 29 29 kgf-m 6.0 6.5 2.9 2.9 2.9 lbf-ft 43.5 47.0 21.0 21.0 21.0 LT-R450/ZK9 (’09-MODEL) SWINGARM CONSTRUCTION 1 2 3 4 5 6 7 8 Swingarm Rear brake disc cover Chain guide Chain guide plate Sprocket guard Chain adjuster rubber seal Chain buffer Inner spacer 9 0 A B C D A B Inner dust seal Bearing Outer spacer Thrust bearing Thrust washer Outer dust seal Rear axle housing set nut Swingarm pivot nut  ITEM A B N·m 28 95 kgf-m 2.8 9.5 lbf-ft 20.0 68.5 25 26 LT-R450/ZK9 (’09-MODEL) BRAKE PEDAL REMOVAL • Remove the brake pedal cover 1 and clip 2. • Remove the cotter pin 3 and washer 4. • Remove the master cylinder rod pin 5. • Remove the brake pedal pivot bolt 6. • Remove the return spring 7 and brake pedal 8. INSTALLATION Install the brake pedal in the reverse order of removal. Pay attention to the following points: • Apply grease to the oil seal and brake pedal pivot bolt.  99000-25010: SUZUKI SUPER GREASE “A” or equivalent • Tighten the brake pedal pivot bolt 1 to the specified torque.  Brake pedal pivot bolt: 29 N·m (2.9 kgf-m, 21.0 lbf-ft) • Install the return spring 2 properly. (Page 34) • Install cotter pins and clip.  Replace the removed cotter pin with a new one. • Adjust the brake pedal height. (Page 4) LT-R450/ZK9 (’09-MODEL) REAR SHOCK ABSORBER REMOVAL • Raise the rear wheel off the ground and support the vehicle with jack or wooden block. • Remove the cushion rod lower bolt/nut. • Remove the rear shock absorber mounting bolts/nuts. NOTE: If it is difficult to remove the mounting bolt of the upper side, remove the exhaust pipe. • Remove the rear shock absorber. INSTALLATION (LT-R450K8 7-71) 27 28 LT-R450/ZK9 (’09-MODEL) CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER INFORMATION (a) (b) 4 mm (0.6 in) (c) 5.75 mm (0.23 in) 1 mm (0.04 in) 15.75 mm (0.62 in) (d) (e) 5.75 mm (0.23 in) (a) 60 N·m (6.0 kgf-m, 43.5 lbf-ft) 1 Spacer (b) 60 N·m (6.0 kgf-m, 43.5 lbf-ft) 2 Washer (c) 78 N·m (7.8 kgf-m, 56.5 lbf-ft) 3 Dust seal (d) 78 N·m (7.8 kgf-m, 56.5 lbf-ft) (e) 78 N·m (7.8 kgf-m, 56.5 lbf-ft) LT-R450/ZK9 (’09-MODEL) WIRING HARNESS ROUTING Handlebar switch (L) Clutch lever position switch Clamp Clamp Handlebar switch (L) Meter panel indicator light Headlight Clamp Wiring harness Starter cable Clamp Clamp Brake light/Taillight Clamp Wiring harness Wiring harness Generator Gear position switch Ignition switch Clamp Wiring harness Starter lead wire 29 30 LT-R450/ZK9 (’09-MODEL) Wiring harness Set the ignition coil coupler to the downside of the hose. Clamp Hose Fuel level switch Clamp Clamp Cooling fan relay Clamp Clamp Clamp IAP sensor Engine mounting upper bracket Install the spark plug cap firmly. Clamp Install the wiring harness to the clamp. Ignition coil Clamp Wiring harness Clamp Rear brake switch lead wire Rear brake switch Clamp Rear brake switch lead wire LT-R450/ZK9 (’09-MODEL) OIL HOSE ROUTING *1 K8 OIL HOSE (4 places) K9 *1 1 2 3 4 5 Install the oil tank cushion to the both sides of the oil tank. Oil level gauge Oil return tank Oil tank Breather hose Oil tank over-flow hose 6 Breather hose 7 8 9 A Breather hose Oil hose (R) Oil hose (L) Matching mark 31 32 LT-R450/ZK9 (’09-MODEL) FRONT BRAKE HOSE ROUTING *1 *5 30 ˚ *3 *2 *4 FRONT RIGHT BRAKE HOSE 21 ˚ LEFT BRAKE HOSE 14˚ 21˚ 21 ˚ *6 Fit the brake hose with brake hose sleeve shape correctly fitted inside clamp. After the under surface of brake pipe joint has After the brake hose union has contacted the *2 contacted the end face of hose bracket of frame, *5 under surface of master cylinder, tighten the tighten the pipe joint mounting bolt. union bolt. After the brake hose union has contacted the *3 Clamp the brake hose firmly. *6 stopper, tighten the union bolt. *1 The black paint is forward. *4 LT-R450/ZK9 (’09-MODEL) THROTTLE BODY INSTALLATION 1.8 N·m (0.18 kgf-m, 1.3 lbf-ft) *1 UPPER UPPER L R LOWER INTAKE PIPE R L LOWER OUTLET TUBE *4 12 N·m (1.2 kgf-m, 8.5 lbf-ft) *2 4.5 N·m (0.45 kgf-m, 3.3 lbf-ft) *3 *1 Face the clamp ends right side. *2 Pass the fuel vapor return hose through left side of the wiring harness. Install the fuel feed hose No.2 with the white paint side to the fuel *3 pump. *4 Pass the dust guard upward of the wiring harness. 1 IAT sensor 2 Fuel vapor return hose 3 Fuel feed hose No.1 4 Fuel feed hose No.2 5 Intake pipe 6 Throttle body 7 8 9 0 Air cleaner Dust guard Fuel pump Wiring harness 33 34 LT-R450/ZK9 (’09-MODEL) BRAKE PEDAL INSTALLATION 36.5 mm (1.44 in) 5.8 mm (0.22 in) 11.3 mm (0.45 in) 5 mm (0.2 in) 1 Cotter pin 2 Brake pedal pivot bolt 3 Rear brake switch 7 mm (0.3 in) 5 mm (0.2 in) 125.8 mm (4.95 in) 4 Brake pedal spring 5 Brake pedal LT-R450/ZK9 (’09-MODEL) 35 HANDLEBAR INSTALLATION *2 *1 *3 *4 *1 Align the “ ” mark on the right grip with mark. Align the edge of throttle case upper with punch mark on handlebars. *3 Align the “ ” mark on the left grip with mark. *2 *5 Align the edge of master cylinder holder with punch mark on handlebars. Align the matching surface of clutch lever holder *5 with mark. *4 36 LT-R450/ZK9 (’09-MODEL) TIGHTENING TORQUE ENGINE ITEM Engine mounting bolt (Lower) N·m 75 kgf-m 7.5 lbf-ft 54.0 N·m 29 kgf-m 2.9 lbf-ft 21.0 CHASSIS ITEM Steering knuckle end nut (Upper & Lower) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM Valve diam. IN. EX. Tappet clearance (when cold) IN. EX. Valve guide to valve stem clearance IN. EX. STANDARD 36 (1.42) 29 (1.14) 0.10 – 0.20 (0.0039 – 0.0078) 0.20 – 0.30 (0.0078 – 0.0118) 0.010 – 0.037 (0.0004 – 0.0015) 0.030 – 0.057 (0.0012 – 0.0022) LIMIT — — — — — — Valve stem deflection IN. & EX. — 0.25 (0.010) Valve guide I.D. IN. & EX. — Valve stem O.D. IN. EX. 5.500 – 5.512 (0.2165 – 0.2170) 5.475 – 5.490 (0.2156 – 0.2161) 5.455 – 5.470 (0.2148 – 0.2154) Valve stem runout IN. & EX. — Valve head thickness IN. & EX. — 0.05 (0.002) 0.5 (0.02) Valve seat width IN. & EX. 0.9 – 1.1 (0.035 – 0.043) — Valve head radial runout IN. & EX. — Valve spring free length IN. — EX. — 0.03 (0.001) 34.0 (1.34) 33.3 (1.31) Valve spring tension IN. EX. 119 – 137 N (11.9 – 13.7 kgf, 26.2 – 30.2 lbs) at length 30.9 mm (1.22 in) 78.5 N (7.85 kgf, 17.3 lbs) at length 30.9 mm (1.22 in) — — — — LT-R450/ZK9 (’09-MODEL) CAMSHAFT + CYLINDER HEAD ITEM Cam height IN. EX. Camshaft journal oil clearance IN. & EX. Camshaft journal holder I.D. IN. & EX. Camshaft journal O.D. IN. & EX. Cam chain pin Cylinder head distortion Unit: mm (in) STANDARD 32.890 – 32.930 (1.2949 – 1.2965) 33.451 – 33.491 (1.3170 – 1.3185) 0.032 – 0.066 (0.0013 – 0.0026) 22.012 – 22.025 (0.8666 – 0.8671) 21.959 – 21.980 (0.8645 – 0.8653) 15th pin — CYLINDER + PISTON + PISTON RING ITEM Compression pressure (Automatic de-comp. actuated) Piston to cylinder clearance Cylinder bore Piston diam. Piston ring free end gap Piston ring end gap Piston ring to groove clearance — 1st 2nd R 2nd Approx. 7.6 (0.30) Approx. 12.3 (0.48) 0.08 – 0.20 (0.003 – 0.008) 0.08 – 0.20 (0.003 – 0.008) 1st — 2nd — 1st Piston ring groove width 1st 2nd Oil LIMIT 32.590 (1.2831) 33.151 (1.3052) 0.150 (0.0059) — — — 0.05 (0.002) Unit: mm (in) STANDARD 800 kPa (8.0 kgf/cm2, 114 psi) 0.045 – 0.055 (0.0018 – 0.0022) 95.500 – 95.515 (3.7598 – 3.7604) 95.450 – 95.465 (8.9437 – 3.7585) Measure at 10 mm (0.4 in) from the skirt end. Cylinder distortion 37 0.78 – 0.80 (0.0307 – 0.0315) 1.30 – 1.32 (0.0512 – 0.0520) 1.01 – 1.03 (0.0398 – 0.0406) 2.01 – 2.03 (0.0791 – 0.0799) LIMIT — 0.120 (0.0047) Nicks or Scratches 95.380 (3.7551) 0.05 (0.002) — — 0.50 (0.020) 0.50 (0.020) 0.180 (0.007) 0.150 (0.006) — — — — 38 LT-R450/ZK9 (’09-MODEL) ITEM Piston ring thickness 1st 2nd Piston pin bore Piston pin O.D. STANDARD 0.71 – 0.76 (0.0280 – 0.0299) 1.08 – 1.10 (0.0425 – 0.0433) 0.97 – 0.99 (0.0382 – 0.0390) 19.002 – 19.008 (0.7481 – 0.7483) 18.994 – 19.000 (0.7478 – 0.7480) CONROD + CRANKSHAFT ITEM Conrod small end I.D. Conrod deflection Conrod big end side clearance Conrod big end width Crank web to web width Crankshaft runout LIMIT — — — 19.030 (0.7492) 18.980 (0.7472) Unit: mm (in) STANDARD 19.010 – 19.018 (0.7484 – 0.7487) — 0.30 – 0.65 (0.012 – 0.026) 21.75 – 21.80 (0.8563 – 0.8583) 62.0 ± 0.1 (2.441 ± 0.004) LIMIT 19.040 (0.7496) 3.0 (0.12) 1.0 (0.04) — — — 0.08 (0.003) STANDARD 10 kPa (0.1 kgf/cm2, 1.4 psi) at 3 000 r/min LIMIT OIL PUMP ITEM Oil pressure (at 60°C, 140°F) CLUTCH ITEM Clutch cable play Drive plate thickness (No. 1 & No. 2) Drive plate claw width (No. 1 & No. 2) Driven plate distortion Clutch spring free length — Unit: mm (in) STANDARD 10 – 15 (0.4 – 0.6) 3.07 – 3.23 (0.120 – 0.127) 13.85 – 13.95 (0.545 – 0.549) — 53.06 (2.09) LIMIT — 2.77 (0.109) 13.35 (0.528) 0.10 (0.004) 50.4 (1.98) LT-R450/ZK9 (’09-MODEL) DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) Except ratio ITEM Primary reduction ratio Final reduction ratio Gear ratios Low 2nd 3rd 4th Top Shift fork to groove clearance Shift fork groove width Shift fork thickness Drive chain Drive chain slack Gearshift lever height No.1, No.2 & No.3 No.1, No.2 & No.3 Type Links 20-pitch length STANDARD 2.851 (77/27) 2.571 (36/14) 2.076 (27/13) 1.647 (28/17) 1.333 (28/21) 1.095 (23/21) 0.913 (21/23) 0.1 – 0.3 (0.004 – 0.012) 4.8 – 4.9 (0.189 – 0.193) 4.8 – 4.9 (0.189 – 0.193) RK 520SMOZ10S 96 — 45 – 55 (1.8 – 2.2) 5 – 10 (0.2 – 0.4) LIMIT — — — — — — — 0.5 (0.020) — — — — 319.4 (12.57) — — THERMOSTAT + RADIATOR + FAN + COOLANT ITEM Thermostat valve opening temperature Thermostat valve lift ECT sensor resistance Radiator cap valve opening pressure Cooling fan operating temperature Engine coolant type Engine coolant including reserve 39 STANDARD/SPECIFICATION NOTE Approx. 76.5 °C (169.7 °F) — 4.5 mm (0.18 in) and over at 90 °C (194 °F) 20 °C Approx. 2.6 kΩ (68 °F) 50 °C Approx. 0.772 kΩ (122 °F) 80 °C Approx. 0.279 kΩ (176 °F) 110 °C Approx. 0.118 kΩ (230 °F) 108 – 137 kPa (1.08 – 1.37 kgf/cm², 15.4 – 19.5 psi) OFF → ON Approx. 98 °C (208 °F) ON → OFF Approx. 93 °C (199 °F) Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Approx. 1 400 ml (1.5 – 1.2 US/lmp qt) — — — — — — — — — — 40 LT-R450/ZK9 (’09-MODEL) INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM Injector resistance Fuel pump discharge amount Fuel pressure regulator operating set pressure SPECIFICATION 9 – 17 Ω at 20 °C (68 °F) Approx. 83 ml (2.8/ 2.9 US/lmp oz) and more/10 sec. NOTE Approx. 294 kPa (2.94 kgf/cm², 41.81 psi) FI SENSORS ITEM CKP sensor resistance CKP sensor peak voltage IAP sensor input voltage IAP sensor output voltage TP sensor input voltage TP sensor resistance TP sensor output voltage ECT sensor input voltage ECT sensor output voltage ECT sensor resistance IAT sensor input voltage IAT sensor output voltage IAT sensor resistance TO sensor resistance TO sensor voltage SPECIFICATION 155 – 232 Ω 0.5 V and more 4.5 – 5.5 V * Approx. 2.1 V at idle speed 4.5 – 5.5 V Approx. 4.5 kΩ Closed Approx. 1.4 kΩ Opened Approx. 4.2 kΩ Closed Approx. 0.6 V Opened Approx. 3.8 V 4.5 – 5.5 V 0.2 – 4.9 V Approx. 2.6 kΩ at 20 °C (68 °F) 4.5 – 5.5 V 0.2 – 4.9 V Approx. 2.6 kΩ at 20 °C (68 °F) 15.0 – 25.0 kΩ Normal 0.4 – 1.4V Leaning GP switch voltage Injector voltage Ignition coil primary peak voltage * FP relay input voltage 3.7 – 4.4 V 0.9 V and more Battery voltage 150 V and more Battery voltage THROTTLE BODY ITEM Bore size I.D. No. Idle r/min Idle air screw Throttle cable play SPECIFICATION 43 mm * 45G1 1 800 ± 100 r/min * 2-1/4 turns back 3 – 5 mm (0.12 – 0.20 in) NOTE When cranking When leaning 65° From 1st to Top When cranking LT-R450/ZK9 (’09-MODEL) ELECTRICAL Unit: mm (in) ITEM Spark plug SPECIFICATION NGK: CR8EB 0.7 – 0.8 (0.028 – 0.031) Over 8 (0.3) at 1 atm. 155 – 232 Ω 0.5 V and more Type Gap Spark performance CKP sensor resistance CKP sensor peak voltage Ignition coil resistance Ignition coil primary peak voltage Generator coil resistance Generator Max. output Generator no-load voltage (When engine is cold) Starter motor brush length Regulated voltage Starter relay resistance GP switch voltage Battery Type designation Capacity Fuse size Ignition Fan Main Primary 0.1 – 1.0 Ω Secondary 8 – 15 kΩ 150 V and more 0.1 – 1.5 Ω Approx. 240 W at 5 000 r/min NOTE When cranking Terminal – Terminal Plug cap – Terminal When cranking 50 V (AC) and more at 5 000 r/min Standard Limit 7.0 (0.28) 3.5 (0.14) 13.5 – 15.0 V at 5 000 r/min 3–6Ω 0.9 V and more (From 1st to Top) FTX7A-BS 12 V 21.6 kC (6 Ah)/10 HR 10 A 10 A 20 A WATTAGE Unit: W ITEM Headlight 41 HI LO Brake light/Taillight Fuel indicator light Neutral indicator light Engine coolant temp. FI warning indicator light SPECIFICATION 40 40 LED 3.4 3.4 3.4 42 LT-R450/ZK9 (’09-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM Rear brake pedal height Brake caliper cylinder bore Front Rear Brake caliper piston diam. Front Rear Brake fluid type Brake disc thickness Front Rear Brake disc runout (Front & Rear) Master cylinder bore — Front Rear Master cylinder piston diam. Front Rear Turning radius Toe-in (with 75 kg, 165 lbs) Camber Caster Wheel rim runout Wheel rim size Tire size Tire type Tire tread depth Wheel axle runout STANDARD/SPECIFICATION 0 – 10 (0 – 0.4) 25.40 – 25.45 (1.0000 – 1.0020) 33.96 – 34.01 (1.3370 – 1.3390) 25.318 – 25.368 (0.9968 – 0.9987) 33.878 – 33.928 (1.3338 – 1.3357) DOT 4 2.8 – 3.2 (0.110 – 0.126) 3.8 – 4.2 (0.150 – 0.165) 12.700 – 12.743 (0.5000 – 0.5017) 12.700 – 12.743 (0.5000 – 0.5017) 12.657 – 12.684 (0.4983 – 0.4994) 12.657 – 12.684 (0.4983 – 0.4994) 3.5 m (11.5 ft) 0±4 (0 ± 0.16) – 3.0° 8.0° Front — Rear — Front Rear Front Rear Front Rear 10 × 5.5 AT 8 × 8.0 AT AT20 × 7R10  AT18 × 10R8  * DUNLOP: KT382 DUNLOP: KT385 Front — Rear — Rear — LIMIT — — — — — — 2.5 (0.098) 3.5 (0.138) 0.30 (0.012) — — — — 2.0 (0.08) 2.0 (0.08) — — — — — — 4.0 (0.16) 4.0 (0.16) 6.0 (0.24) LT-R450/ZK9 (’09-MODEL) TIRE PRESSURE COLD INFLATION TIRE PRESSURE FRONT REAR kPa kgf/cm2 psi 45 45 0.45 0.45 6.5 6.5 VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs) SUSPENSION ITEM Front shock absorber spring preset length Front shock absorber damping force adjuster STANDARD/SPECIFICATION 274 (9.7) Rebound * 1-3/4 turns out from stiffest position Compression * 3-1/2 turns out from stiffest position Rear shock absorber spring pre-set 229.75 length (9.0) * 11 clicks out from stiffest position Rear shock absorber damping Rebound force adjuster Compression 9 clicks out from stiffest position (Low speed) Compression * 1-1/6 turns out from stiffest position (High speed) Front wheel travel 254 (10.0) Rear wheel travel 277 (10.9) LIMIT — — — — — — — — FUEL + OIL ITEM Fuel type Fuel tank including reserve Engine oil type Engine oil capacity SPECIFICATION Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 95 octane or higher. An unleaded gasoline is recommended. * 9.0 L (2.4/2.0 US/lmp gal) SAE 10 W-40, API SF/SG or SH/SJ with JASO MA 1 200 ml (1.3/1.1 US/lmp qt) Change 400 ml (0.4/0.4 US/lmp qt) 1 300 ml (1.4/1.1 US/lmp qt) Filter change 400 ml (0.4/0.4 US/lmp qt) 1 400 ml (1.5/1.2 US/lmp qt) Overhaul 400 ml (0.4/0.4 US/lmp qt) NOTE E-28, 33 Others Oil tank side Engine side Oil tank side Engine side Oil tank side Engine side 43 WIRING DIAGRAM Wiring diagram wire color, refer to LT-R450 service manual section “WIRE COLOR”. ECM Prepared by October, 2008 Part No. 99501-44030-01E Printed in Japan 44