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 there- after.
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LT-R450/ZK9 (’09-MODEL) 5 • 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...
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.
LT-R450/ZK9 (’09-MODEL) 7 ENGINE LUBRICATION SYSTEM CHART CONROD BIG CAM FACE (IN & EX) END BEARING CAMSHAFT JOURNAL CAM CHAIN CRANK PIN (IN & EX) ORIFICE CYLINDER HEAD RIGHT CRANKSHAFT PISTON PIN LEFT CRANKSHAFT PISTON CYLINDER CRANKSHAFT CYLINDER WALL RIGHT END STARTER CLUTCH OIL NOZZLE RIGHT CRANKCASE...
LT-R450/ZK9 (’09-MODEL) 9 ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT Power source — TO sensor signal (TOS) — CKP sensor signal (CKP+) FI/ECT indicator GP switch signal (GP) ECT sensor signal (ECT) TP sensor signal (TP) — IAP sensor signal (IAP) Sensors ground (E2) —...
10 LT-R450/ZK9 (’09-MODEL) DTC TABLE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM CKP sensor The signal does not reach ECM for 1 CKP sensor wiring and mechan- sec. or more, after receiving the IAP ical parts sensor input signal.
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LT-R450/ZK9 (’09-MODEL) 11 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <...
12 LT-R450/ZK9 (’09-MODEL) FI SYSTEM TROUBLESHOOTING “C17” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.2 V Sensor voltage < 4.1 V •...
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LT-R450/ZK9 (’09-MODEL) 13 3) Check the IAP sensor coupler for loose or poor contacts. If OK, then measure the IAP sensor input voltage. 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire and ground. 7) If OK, then measure the voltage at the Red wire and B/Br wire.
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14 LT-R450/ZK9 (’09-MODEL) 6) Remove the front fender. (LT-R450K8 7-6) 7) Disconnect the ECM coupler. 8) Check the continuity between G/B wire B and terminal 6. 9) If OK, then check the continuity between B/Br wire C and ter- minal N. ...
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LT-R450/ZK9 (’09-MODEL) 15 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 IAPS lead wire continuity: Continuity () ...
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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 –...
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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. ngine stop switch Ignition switch...
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LT-R450/ZK9 (’09-MODEL) 19 Is the voltage OK? ECM coupler (Harness side) • FP relay (ECM) malfunction. • O/W or O/G wire open or shorted, or poor ter- minal D or E connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM.
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”...
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.
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LT-R450/ZK9 (’09-MODEL) 23 • 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)
24 LT-R450/ZK9 (’09-MODEL) FRONT SUSPENSION CONSTRUCTION 1 Front shock absorber B Lower wishbone arm Spring washer A eliminated 2 Collar C Steering knuckle as K9 model 3 Dust seal D Spring washer 4 Bearing E Cotter pin 5 Collar F Tie rod 6 Upper wishbone arm G Tie rod end...
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.
LT-R450/ZK9 (’09-MODEL) 27 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.
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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 Clamp Clamp fan relay Clamp IAP sensor Install the spark plug Clamp cap firmly. Engine mounting upper bracket Install the wiring harness to the clamp.
32 LT-R450/ZK9 (’09-MODEL) FRONT BRAKE HOSE ROUTING FRONT RIGHT BRAKE HOSE LEFT BRAKE HOSE Fit the brake hose with brake hose sleeve shape *1 The black paint is forward. correctly fitted inside clamp. After the under surface of brake pipe joint has After the brake hose union has contacted the contacted the end face of hose bracket of frame, under surface of master cylinder, tighten the...
LT-R450/ZK9 (’09-MODEL) 35 HANDLEBAR INSTALLATION Align the edge of master cylinder holder with *1 Align the “ ” mark on the right grip with mark. punch mark on handlebars. Align the edge of throttle case upper with punch Align the matching surface of clutch lever holder mark on handlebars.