2006 suzuki ltr 450 repair manual free download

The data in this Suzuki LT-R manual was compiled to provide the mechanic a handy reference thats easy to read, and a Suzuki LT-R manual that contains comprehensive explanations of all removal, assembly, repair, overhaul and inspection operations. Troubleshooting sections in this Suzuki LT-R manual are provided in each appropriate chapter.

There's nothing this Suzuki LT-R factory service manual doesn't cover. From maintenance procedures to complete engine overhaul, this Suzuki LT-R manual covers it all. The following list is a TINY sample of repair operations you'll learn how to do:. Buy Suzuki LT-R owners service manual download pdf, after purchase you can download instantly and save the Suzuki LT-R manual to your computer forever!

Free up your time by fixing it right the first time. If this is not available, use an equivalent which is compatible with an aluminum radiator. Independent, double wishbone, coil spring, oil damped Rear suspension Swingarm type, coil spring, oil damped Front wheel travel Maintenance intervals are expressed in terms of months. 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 24 After rotating the crankshaft, check the valve clearance again to make sure that it is within specification. Replace every 18 months. Replace every 4 years. Inspect the fuel hose for damage and fuel leakage.

If any defects are found, replace the fuel hoses with new ones. Inspect the fuel filter for damage and rust. NOTE: Make this adjustment when the engine is hot. Then drain out the engine oil by removing the engine oil drain plug 2, 3, 4 and engine oil filler cap 5, 6. Apply engine oil to the O-rings. 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 2 years. Replace the reservoir cap to prevent dirt from entering. Inspect the brake hoses for leakage, cracks, wear and damage. If any defects are found, replace the brake hoses with new ones. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.

Such oil can damage the O-rings. Suzuki recommends to use this standard drive chain as a replacement. If any defects are found, replace the suspension arm or bearing with a new one.

Check that all chassis nuts and bolts are tightened to their specified torque. Refer to page , for the locations of the following nuts and bolts on the vehicle. 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.

Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the vehicle.

Refer to the page listed in each section for removal and installation instructions. Engine removal is sequentially explained in the following steps. NOTE: The swingarm will come off when the swingarm pivot shaft is completely removed. Be sure to use new nuts, and then tighten them to the specified torque. Use new gaskets to prevent exhaust gas leakage. Do not drop the dowel pins, cam chain and C-rings into the crankcase.

NOTE: If there is no wear or damage at oil seal lip, the oil seal 3 removal is not necessary. NOTE: Be careful not to drop the pins and springs when removing the gearshift cam driven gear. The primary drive gear nut has left-hand threads. Do not hit the generator rotor with a hammer, otherwise the rotor may be damaged. Do not pull out the gearshift fork shaft 4 at this point because the gearshift fork comes off in the crankcase.

Organize the parts in their respective groups i. Identify the position of each removed part. Do not reuse the removed oil seal. Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated.

If it is worn or damaged, replace the valve with a new one. Measure the valve stem deflection in two directions, perpendicu- lar to each other, by positioning the dial gauge as shown. Weak- ened spring results in reduced engine power output, and often accounts for the chattering noise coming from the valve mecha- nism.

Check the valve spring for proper strength by measuring its free length and also by the force required to compress it. Move the outer race by finger and inspect for smooth move- ment. If there is anything unusual, replace the camshaft assem- bly.

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 guides. Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, replace the cyl- inder. Cylinder bore Standard: If the measurement is out of specifications replace the piston. Piston pin bore I. This method can also be used to check the extent of wear on the parts of the conrod big end.

If any defects are found, replace the defec- tive part. If any damages are found, replace them with new ones. Rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, replace the oil pump assembly.

Measure the thickness of drive plates using the vernier calipers. If the drive plate thickness is found to have reached the limit, replace it with a new one. If any defects are found, replace the push rod with a new one. Move the inner race by finger and inspect for smooth movement. If any defects are found, replace the release bearing with a new one. The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action.

Page The removed oil seals must be replaced with new ones. Bearing A:. If any defects are found, replace the clutch release camshaft or bearings with new ones. The removed bearings and oil seal must be replaced with new ones. Inspect the return spring for damage or fatigue. Replace the defective parts with a new one if necessary. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reassembling.

Always use the special tool, otherwise the accuracy of the crankshaft alignment will be affected. The punch mark B on the outer rotor must face to the crankcase side. The slit must face to the crankcase side. Use a new gasket to prevent oil leakage.

Engine lacks power. Poor performance at low speed. Poor performance at high or top speed. Poor Handling and more.

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