2006-2009 Suzuki LT-Z50 QuadSport ATV Factory Service Manual
This manual contains service, maintenance, and troubleshooting information for the SUZUKI LT-Z50 QuadSport.
The manual is designed to aid service personnel in service-oriented applications and may be used as a textbook for service training.
Manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
A table of contents is placed at the beginning of each section.
Part number: 99500-40011-03E
Service Repair Manual Covers:
- General information
- Periodic maintenance
- Engine
- Fuel system
- Chassis
- Electrical system
- Servicing information
Manual comes complete with the following supplement manual:
- 08 LT-Z50K9 ('09-MODEL)
All manual pages are printable.
Manual is indexed and searchable.
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This Manual PDF file is:
- + Printable: Yes
- + Viewable on: MS Windows, Mac, Android, iOS, Linux
- + Requires: Adobe Acrobat/Preview
Once manual is downloaded any number of pages could be printed or it could be printed in whole.
Manual could be opened in Adobe Acrobat on any mobile device (like iPad, iPhone or Android device etc.) any computer capable of viewing a PDF files including IBM compatible computers running Windows, Linux (or any other flavor of UNIX). Apple Computers have native support for PDF files.
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Full list of manual chapters:
FOREWORD
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR
COMPONENT PARTS AND WORK TO BE DONE
SYMBOL
01 GENERAL INFORMATION
WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SUZUKI LT-Z50K6 ('06-MODEL)
SERIAL NUMBER LOCATION
FUEL AND OIL RECOMMENDATION
FUEL (FOR USA AND CANADA)
FUEL (FOR OTHER COUNTRIES)
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR USA)
ENGINE OIL AND FINAL REDUCTION GEAR BOX OIL (FOR OTHER COUNTRIES)
BREAK-IN PROCEDURES
INFORMATION LABELS
INFORMATION MARKS
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 MOUNTING BOLT
VALVE CLEARANCE
SPARK PLUG
SPARK ARRESTER
FUEL LINE
ENGINE OIL
FINAL REDUCTION GEAR BOX OIL
THROTTLE CABLE PLAY
ENGINE IDLE SPEED
DRIVE BELT
DRIVE CHAIN
BRAKES
TIRES
STEERING
SUSPENSIONS
CHASSIS NUTS AND BOLTS
GENERAL LUBRICATIONS
COMPRESSION PRESSURE CHECK
COMPRESSION TEST PROCEDURE
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION
INITIAL ENGAGEMENT INSPECTION
CLUTCH LOCK-UP INSPECTION
03 ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
ENGINE CENTER
ENGINE LEFT SIDE
ENGINE RIGHT SIDE
ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
ENGINE INSTALLATION
POWER REDUCTION SPACER
ENGINE DISASSEMBLY
ENGINE COMPONENTS INSPECTION AND SERVICING
CYLINDER HEAD
ROCKER ARM PUSH ROD
CAMSHAFT ASSEMBLY
UPPER CRANKCASE/CYLINDER
PISTON AND PISTON RING
CONROD AND CRANKSHAFT
CAM ROCKER ARM
FINAL REDUCTION GEAR BOX AND CVT CASE
CVT CASE COVER
GENERATOR CASE
STARTER PINION
MOVABLE AND FIXED DRIVE AND DRIVEN FACE
RECOIL STARTER
ENGINE REASSEMBLY
04 FUEL SYSTEM
FUEL TANK AND FUEL VALVE
REMOVAL
FUEL FILTER INSPECTION AND CLEANING
REMOUNTING
CARBURETOR
SPECIFICATIONS
I.D. NO. LOCATION
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION AND ADJUSTMENT
REASSEMBLY AND REMOUNTING
05 CHASSIS
EXTERIOR PARTS
CONSTRUCTION
FASTENER REMOVAL AND INSTALLATION
REMOVAL
REMOUNTING
FRONT AND REAR WHEELS
CONSTRUCTION
REMOVAL
REMOUNTING
TIRES
TIRE REPLACEMENT
FRONT BRAKE
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
STEERING AND FRONT SUSPENSION
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
TOE-IN ADJUSTMENT
REAR BRAKE AND REAR AXLE HOUSING
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
REAR SUSPENSION
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
06 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
TROUBLESHOOTING
STARTER MOTOR REMOVAL
STARTER MOTOR DISASSEMBLY
STARTER MOTOR INSPECTION
STARTER MOTOR REASSEMBLY
STARTER MOTOR INSTALLATION
STARTER RELAY INSPECTION
IGNITION SYSTEM
TROUBLESHOOTING
INSPECTION
SWITCHES
BATTERY
SPECIFICATIONS
INITIAL CHARGING
SERVICING
RECHARGING OPERATION
07 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
CARBURETOR
CHASSIS
BRAKES
ELECTRICAL
BATTERY
WIRING DIAGRAM
WIRING HARNESS, CABLE AND HOSE ROUTING
WIRING HARNESS ROUTING
CABLE ROUTING
FUEL HOSE PIPING
CARBURETOR AND CVT CASE HOSE ROUTING
HANDLEBARS AND HANDLEBAR PAD INSTALLATION
HEAT SHIELD INSTALLATION
SPECIAL TOOLS
TIGHTENING TORQUE
ENGINE
FUEL
CHASSIS
TIGHTENING TORQUE CHART
SERVICE DATA
08 LT-Z50K9 ('09-MODEL)
SPECIFICATIONS