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Page 1 * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicles. View and Download Suzuki LT-Z service manual online. LT-Z offroad vehicle pdf manual download.
 
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DOWNLOAD Suzuki ATV Repair Manuals: DOWNLOAD Suzuki LT-Z Repair Manual ATV.SUZUKI LT-Z LTZ Repair Service Manual ATV PDF Download – DSManuals

Quick Links. See also: Service Manual. Table of Contents. Previous Page. Next Page. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. Page 7: Engine Oil Use an antifreeze designed for aluminum radiator. Independent, double wishbone, coil spring, oil damped Rear suspension Swingarm type, coil spring, oil damped Front wheel travel The text of this manual is divided into sections.

Holding the manual as shown at the right will allow you to find the first page of the section easily. Page 14 Apply molybdenum oil solution. Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first. NOTE: More frequent servicing may be performed on vehicles that are use under severe conditions.

If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an increase in fuel consumption. A torn ele- ment must be replaced. The surest way to accelerate engine wear is to operate the engine with- out the element or with torn element. Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power.

Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification, if necessary. Page 21 After rotating the crankshaft, check the tappet clearance again to make sure that it is within specification. Replace every 18 months. If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.

Repeat the above procedure several times and make sure the radiator is filled with engine coolant to the upper line of the engine coolant reservoir. Replace every 4 years. If any damages are found, replace the brake hoses with new ones. When fill- ing air into the tires, never exceed 70 kPa 0. Visually check the drive chain for the possible defects listed below. Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.

If the distance exceeds the service limit, the chain must be replaced. Such oil can damage the O-rings. Check that all chassis nuts and bolts are tightened to their specified torque.

Refer to page and for the locations of the following nuts and bolts. Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service.

This will give a good indication of the condition of the moving parts. Refer to the page listed in each section for removal and installation instructions. Engine removal is sequentially explained in the following steps. Be sure to use new nuts, and then tighten them to the specified torque. NOTE: If the cylinder head does not come off easily, lightly tap it using a plastic mallet.

Organize the parts in their respective groups i. Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance read- ings at several places. If any clearance reading exceeds the ser- vice limit, replace the cylinder head with a new one.

Position the dial gauge as shown. If the deflection exceeds the service limit, determine whether the valve or the guide should be replaced with a new one. Rotate the cutter one or two turns. A weak- ened spring results in reduced engine power output and accounts for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.

Fit the cotter halves to the stem end and release the lifter to allow the cotter 1 to wedge between the retainer and the valve stem. Make sure that the rounded lip 2 of the cotter fits snugly into the groove 3 in the stem end. If push rod does not slide smoothly, replace the cam chain ten- sion adjuster with a new one.

Check the contacting surface of the cam chain tensioner and cam chain guide. If the piston diameter is less than the service limit, replace the piston with a new one. If any measurement exceeds the service limit, replace the piston ring with a new one.

Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one. Balancer shaft ” Balancer driven gear Spring 4 pcs. Pin 2 pcs. NOTE: When installing the starter clutch onto the rotor, make sure that the flange side A in the bearing faces to the rotor. If an attempt is made to overhaul the oil pump assembly, the screw may be damaged.

Only the oil pump unit is available as a replacement. If a clutch drive plate is not within the service limit, replace the clutch plates as a set. Measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge. If the clearance exceeds specification, replace the fork, its respective gear, or both. Pay special attention to the following points: NOTE: Before installing the gears, apply engine oil to the inner surface of each gear and bushing.

After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed. Countershaft Driveshaft Pay special attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling the engine. If a large resistance is felt to rotation, try to free the shafts by tap- ping them with a plastic mallet.

The large shoulder A must face to the outside. Neutral switch bolt: 6. NOTE: Install the piston with the punch mark 1 on the piston head fac- ing toward the exhaust side. NOTE: Make sure that the guide 1 is inserted properly or binding of the cam chain and guide may result. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.

If any damages are found, replace the defective parts with the new ones. Keep heat, sparks and flames away from gasoline. Do not use compressed air on the carburetor body before removing the diaphragm; Replace the removed O-ring with a new one to prevent leakage of fuel. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber. Page Remounting Replace the removed O-ring with a new one.

The tube- and-fin type radiator is made of aluminum, which is characterized by lightness in weight and good heat dissi- pation. Check the cooling system for leaks with a radiator tester 1. Remove the radiator cap and connect the radiator tester to the filler.

Any leakage from the connecting section should be corrected by proper tightening. Test the cooling fan motor for load current with an ammeter con- nected as shown in the illustration. The voltmeter is for making sure that the battery applies 12 volts to the motor.

Connect the thermo-switch 1 to a circuit tester and place it in the oil con- tained in a pan, which is placed on a stove. Test the thermostat at the bench for control action, in the follow- ing manner. NOTE: If there is no abnormal condition, the oil seal removal is not nec- essary. The removed oil seal must be replaced with a new one.

Use the new O-rings to prevent engine coolant leak- age. Pay attention to the following points. Do not use high pressure air to prevent brake caliper piston damage. If any damages are found, replace the brake cal- iper with a new one. Remove the brake hose union bolt and disconnect the brake hose.

 
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