2006-2009 Suzuki LT-R450 QuadRacer Repair Service Manual

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Covers: 2006, 2007, 2008, 2009 Suzuki LT-R450 QuadRacer R450
Pages: 492
Format: PDF
Compatibility: Windows/Mac/Tablet

This service manual contains all the necessary instructions needed for any repair your 2006-2009 Suzuki LT-R450 QuadRacer may require. This is the same manual technicians use to diagnose and repair your 2006-2009 LT-R450 QuadRacer. Whether its routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, this manual provides the most reliable information to perform the job.

The following is a list of topics contained in the Service Repair Manual

01 – GENERAL INFORMATION
WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SUZUKI LT-R450K6 (’06-MODEL)
SERIAL NUMBER LOCATION
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
FUEL (FOR OTHER COUNTRIES)
ENGINE OIL (FOR USA)
ENGINE OIL (FOR OTHER COUNTRIES)
BRAKE FLUID
ENGINE COOLANT
WATER FOR MIXING
ANTI-FREEZE/ENGINE COOLANT
LIQUID AMOUNT OF WATER/ENGINE COOLANT
BREAK-IN PROCEDURES
INFORMATION LABELS
SPECIFICATIONS
DIMENSIONS AND DRY MASS
ENGINE
DRIVE TRAIN
CHASSIS
ELECTRICAL
CAPACITIES
02 – PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
MAINTENANCE AND TUNE-UP PROCEDURES
AIR CLEANER
EXHAUST PIPE NUTS AND MUFFLER BOLTS
VALVE CLEARANCE
SPARK PLUG
FUEL LINE
FUEL FILTER
THROTTLE CABLE PLAY
ENGINE IDLE SPEED
THROTTLE BODY
ENGINE OIL AND OIL FILTER
ENGINE OIL HOSE
ENGINE COOLANT
RADIATOR HOSE
SPARK ARRESTER
CLUTCH CABLE PLAY
BRAKES
BRAKE FLUID
BRAKE HOSE
TIRES
STEERING
DRIVE CHAIN
SUSPENSIONS
FRONT AND REAR WHEEL SET NUTS
REAR AXLE NUT AND LOCK-NUT
CHASSIS BOLTS AND NUTS
GENERAL LUBRICATION
COMPRESSION PRESSURE CHECK
COMPRESSION TEST PROCEDURE
OIL PRESSURE CHECK
OIL PRESSURE TEST PROCEDURE
SDS CHECK
03 – ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
ENGINE LEFT SIDE
ENGINE RIGHT SIDE
ENGINE CENTER
ENGINE REMOVAL AND REMOUNTING
ENGINE REMOVAL
ENGINE INSTALLATION
ENGINE DISASSEMBLY
ENGINE COMPONENTS INSPECTION AND SERVICE
CYLINDER HEAD
AUTOMATIC DECOMP
CAMSHAFT
CAM CHAIN TENSION ADJUSTER ANDTENSIONER
CYLINDER
PISTON AND PISTON RING
CONROD
CRANKSHAFT
BALANCER SHAFT AND BALANCER DRIVEN AND DRIVE GEAR
STARTER CLUTCH
GENERATOR
STARTER TORQUE LIMITER
OIL PUMP
CLUTCH
GEARSHIFT FORK AND GEAR
OIL STRAINER
CRANKCASE
RIGHT CRANKCASE COVER
GEARSHIFT SHAFT
ENGINE REASSEMBLY
04 – FI SYSTEM DIAGNOSIS
PRECAUTIONS IN SERVICING
ELECTRICAL PARTS
FUSE
ECM/VARIOUS SENSORS
ELECTRICAL CIRCUIT INSPECTION PROCEDURE
USING THE MULTI-CIRCUIT TESTER
FI SYSTEM TECHNICAL FEATURES
INJECTION TIME (INJECTION VOLUME)
COMPENSATION OF INJECTION TIME (VOLUME)
INJECTION STOP CONTROL
FI SYSTEM PARTS LOCATION
FI SYSTEM WIRING DIAGRAM
ECM TERMINAL
SELF-DIAGNOSIS FUNCTION
USER MODE
DEALER MODE
DIAGNOSTIC TROUBLE CODE TABLE
TPS ADJUSTMENT
FAIL-SAFE FUNCTION
FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
VISUAL INSPECTION
SELF-DIAGNOSTIC PROCEDURES
SELF-DIAGNOSIS RESET PROCEDURE
USE OF SDS DIAGNOSTIC PROCEDURES
USE OF SDS DIAGNOSIS RESETPROCEDURE
SHOW DATA WHEN TROUBLE (DISPLAING DATA AT THE TIME OF DTC)
MALFUNCTION CODE AND DEFECTIVE CONDITION
“C12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION
“C14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION
“C15” (P0115-H/L) ECT SENSOR CIRCUIT MALFUNCTION
“C17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION
“C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION
“C23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION
“C31” (P0705) GP SWITCH CIRCUIT MALFUNCTION
“C32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION
“C41” (P0230) FP RELAY CIRCUIT MALFUNCTION
“C60” (P0480) COOLING FAN RELAY CIRCUIT MALFUNCTION
SENSORS
CKP SENSOR INSPECTION
CKP SENSOR REMOVAL AND INSTALLATION
IAP SENSOR INSPECTION
IAP SENSOR REMOVAL AND INSTALLATION
TP SENSOR INSPECTION
TP SENSOR REMOVAL AND INSTALLATION
TPS ADJUSTMENT
ECT SENSOR INSPECTION
ECT SENSOR REMOVAL AND INSTALLATION
IAT SENSOR INSPECTION
IAT SENSOR REMOVAL AND INSTALLATION
TO SENSOR INSPECTION
TO SENSOR REMOVAL AND INSTALLATION
05 – FUEL SYSTEM AND THROTTLE BODY
FUEL DELIVERY SYSTEM
FUEL SYSTEM
FUEL TANK REMOVAL
FUEL TANK INSTALLATION
FUEL PRESSURE INSPECTION
FUEL PUMP REMOVAL
FUEL PUMP INSTALLATION
FUEL PUMP INSPECTION
FUEL DISCHARGE AMOUNT INSPECTION
FUEL PUMP RELAY INSPECTION
FUEL VALVE/FUEL FILTER
FUEL PRESSURE REGULATOR
THROTTLE BODY
CONSTRUCTION
REMOVAL
DISASSEMBLY
CLEANING
NSPECTION
REASSEMBLY
INSTALLATION
FUEL INJECTOR REMOVAL
FUEL INJECTOR INSPECTION
FUEL INJECTOR INSTALLATION
THROTTLE POSITION SENSOR (TPS) SETTING
06 – COOLING AND LUBRICATION SYSTEM
ENGINE COOLANT
COOLING CIRCUIT
COOLING CIRCUIT INSPECTION
RADIATOR AND WATER HOSE
RADIATOR REMOVAL
RADIATOR CAP INSPECTION
RADIATOR INSPECTION AND CLEANING
RADIATOR INSTALLATION
WATER HOSE INSPECTION
RADIATOR RESERVOIR TANK
COOLING FAN
REMOVAL
INSTALLATION
INSPECTION
COOLING FAN RELAY INSPECTION
ECT SENSOR
REMOVAL
INSPECTION
INSTALLATION
THERMOSTAT
REMOVAL
INSPECTION
INSTALLATION
WATER PUMP
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND INSTALLATION
OIL TANK, OIL RETURN TANK AND HOSES
CONSTRUCTION
OIL TANK
OIL RETURN TANK
LUBRICATION SYSTEM
OIL PRESSURE
OIL FILTER
OIL STRAINER
OIL PUMP
ENGINE LUBRICATION SYSTEM CHART
07 – CHASSIS
EXTERIOR PARTS
CONSTRUCTION
FASTENER REMOVAL ANDREINSTALLATION
REMOVAL
INSTALLATION
FRONT AND REAR WHEELS
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
TIRES
TIRE REPLACEMENT
FRONT BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT
BRAKE CALIPER REMOVAL AND DISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND INSTALLATION
BRAKE DISC REMOVAL AND DISASSEMBLY
BRAKE DISC INSPECTION
BRAKE DISC REASSEMBLY AND INSTALLATION
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND INSTALLATION
FRONT SUSPENSION
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
FRONT SHOCK ABSORBER DISPOSAL
SUSPENSION SETTING
HANDLEBARS
CONSTRUCTION
REMOVAL
INSPECTION
INSTALLATION
STEERING
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
TOE ADJUSTMENT
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION
REAR BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT
BRAKE CALIPER REMOVAL ANDDISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND INSTALLATION
BRAKE DISC REMOVAL AND INSTALLATION
BRAKE DISC INSPECTION
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND INSTALLATION
BRAKE PEDAL
REMOVAL
INSTALLATION
REAR SHOCK ABSORBER
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
REAR SHOCK ABSORBER DISPOSAL
SUSPENSION SETTING
CUSHION ROD AND CUSHION LEVER
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER INFORMATION
SWINGARM
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY
INSTALLATION
REAR AXLE
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND INSTALLATION
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE REASSEMBLING
INFORMATION
DRIVE CHAIN
DRIVE CHAIN CUTTING
DRIVE CHAIN CONNECTING
DRIVE CHAIN CONTROL ROLLER
CONSTRUCTION
REMOVAL
INSPECTION
INSTALLATION
08 – ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTOR
COUPLER
CLAMP
FUSE
SEMI-CONDUCTOR EQUIPPED PART
BATTERY
CONNECTING THE BATTERY
WIRING PROCEDURE
USING THE MULTI-CIRCUIT TESTER
LOCATION OF ELECTRICAL COMPONENTS
CHARGING SYSTEM
TROUBLESHOOTING
INSPECTION
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
TROUBLESHOOTING
STARTER MOTOR REMOVAL
STARTER MOTOR DISASSEMBLY
STARTER MOTOR INSPECTION
STARTER MOTOR REASSEMBLY
STARTER RELAY INSPECTION
IGNITION SYSTEM
TROUBLESHOOTING
INSPECTION
INDICATOR LIGHT
INSPECTION
LAMPS
HEADLIGHT, BRAKE LIGHT/TAILLIGHT
RELAYS
STARTER RELAY
FUEL PUMP RELAY
COOLING FAN RELAY
SWITCHES INSPECTION
BATTERY
SPECIFICATIONS
INITIAL CHARGING
SERVICING
RECHARGING OPERATION
09 – SERVICING INFORMATION
TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
ENGINE
RADIATOR (COOLING SYSTEM)
CHASSIS
BRAKES
ELECTRICAL
BATTERY
WIRING HARNESS, CABLE AND HOSE ROUTING
WIRING HARNESS ROUTING
CABLE ROUTING
FUEL SYSTEM HOSE ROUTING
COOLING SYSTEM HOSE ROUTING
OIL HOSE ROUTING
FRONT BRAKE HOSE ROUTING
REAR BRAKE HOSE ROUTING
THROTTLE BODY INSTALLATION
FUEL TANK INSTALLATION
BRAKE PEDAL INSTALLATION
FRONT SIDE REFLEX REFLECTOR INSTALLATION (For E-28)
BRAKE LIGHT/TAILLIGHT INSTALLATION (For others)
BRAKE LIGHT/TAILLIGHT INSTALLATION (For E-28)
DRIVE CHAIN ROLLER INSTALLATION
SPECIAL TOOLS
TIGHTENING TORQUE
ENGINE
FI SYSTEM AND INTAKE AIR SYSTEM
COOLING SYSTEM
CHASSIS
TIGHTENING TORQUE CHART
SERVICE DATA
10 – EMISSION CONTROL INFORMATION
EMISSION CONTROL SYSTEMS
FUEL INJECTION SYSTEM
CRANKCASE EMISSION CONTROL SYSTEM
11 – CHANGES FOR 2008 MODELS
SPECIFICATIONS
SERVICE DATA
FRONT BRAKE
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION
CUSHION ROD, CUSHION LEVER AND REAR SHOCK ABSORBER INFORMATION
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE REASSEMBLING
INFORMATION
12 – CHANGES FOR 2009 MODELS
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
INSTALLATION
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
13 – WIRING DIAGRAMS
2006-2008 MODELS
2009 MODELS

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