Suzuki LT-A500 02-07.pdf

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FOREWORD
This manual contains an introductory description on
the SUZUKI LT-A500F and procedures for its
inspection, service, and overhaul of its main compo-
nents.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its mainte-
nance. Use this section as well as other sections as
a guide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.
GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
m
2
ENGINE
3
P a r t S h a r k . c o
4
DRIVE TRAIN
*This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual vehicle.
*Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
*This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI vehicles.
If you do not have the proper knowledge and
tools, ask your authorized SUZUKI motorcy-
cle dealer to help you.
8 7 7 - 9 9 9 - 5 6 8 6
FUEL SYSTEM
5
COOLING AND LUBRICATION
SYSTEM
6
CHASSIS
7
ELECTRICAL SYSTEM
8
#
SERVICING INFORMATION
9
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle
unsafe for the rider.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001
99500-44045-01E
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P a r t S h a r k . c o
m
8 7 7 - 9 9 9 - 5 6 8 6
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SUPPLEMENTS
LT-A500FK3 (’03-MODEL)
10
LT-A500FK4 (’04-MODEL)
m
11
LT-A500FK5 (’05-MODEL)
12
P a r t S h a r k . c o
8 7 7 - 9 9 9 - 5 6 8 6
13
LT-A500FK7 (’07-MODEL)
14
LT-A500FK6 (’06-MODEL)
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HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
P a r t S h a r k . c o
m
8 7 7 - 9 9 9 - 5 6 8 6
@
1 Rear shock absorber
2 Swingarm
3 Spacer
4 Dust seal
5 Bearing
ITEM
N·m
kgf-m
lb-ft
A 34
3.4
24.5
B 60
6.0
43.5
C 100
10.0
72.5
A Rear shock absorber monting
upper nut
B Rear shock absorber monting
lower nut
C Swingarm pivot locknut
D Swingarm pivot bolt (LH)
E Swingarm pivot bolt (RH)
D 100
10.0
72.5
E 9.5
1.0
7.0
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit there is an exploded view which provides work instructions and other
service information (e.g.; tightening torque, lubricating points, and locking agent points).
Example: Rear suspension
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SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL
DEFINITION
SYMBOL
DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1305”.
99000-32100
Indicates service data.
Apply THREAD LOCK SUPER “1322”.
99000-32110 (Except USA)
m
Apply oil. Use engine oil unless
otherwise specified.
Apply THREAD LOCK “1342”.
99000-32050
P a r t S h a r k . c o
Apply THREAD LOCK SUPER “1360”.
99000-32130
8 7 7 - 9 9 9 - 5 6 8 6
Apply molybdenum oil solution.
(mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Apply or use brake fluid.
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (USA)
99000-25010 (Others)
Measure in voltage range.
Apply SUZUKI SILICONE GREASE.
99000-25100
Measure in resistance range.
Apply SUZUKI MOLY PASTE.
99000-25140
Measure in current range.
Apply WATER RESISTANCE GREASE.
99000-25160
Measure in diode test range.
W
Apply SUZUKI BOND “1207B”
99104-31140 (USA)
Measure in continuity test range.
Apply SUZUKI BOND “1215”.
99000-31110 (Except USA)
Use special tool.
1216B
Apply SUZUKI BOND “1216B”.
99100-31230
Use engine coolant.
99000-99032-11X (Except USA)
Apply THREAD LOCK SUPER “1303”.
99000-32030
Apply hypoid gear oil.
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