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 H 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) Apply oil. Use engine oil unless otherwise specified. Apply THREAD LOCK "1342". 99000-32050 if Apply molybdenum oil solution, (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1) Apply or use brake fluid. Apply SUZUKI SUPER GREASE "A". 99000-25030 (For USA) 99000-25010 (For the other countries) 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. ^12Q7B] Apply SUZUKI BOND "1207B". 99104-31140 (For USA) 99000-31140 (For the other countries) II Measure in continuity test range. ^1215] Apply SUZUKI BOND "1215". 99000-31110 (Except USA) Use special tool. ^1216] Apply SUZUKI BOND "1216". 99104-31160 (For USA) 99000-31160 (For the other countries) Use engine coolant. 99000-99032-11X (Except USA) Apply THREAD LOCK SUPER "1303". 99000-32030
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE 1- 2 GENERAL PRECAUTIONS 7- 2 SUZUKI LT-A500FY (2000-MODEL) 1- 4 SERIAL NUMBER LOCATION 1- 4 FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS 1- 4 FUEL 1- 4 ENGINE OIL 1- 5 DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL 1- 5 BRAKE FLUID 1- 5 ENGINE COOLANT 1-5 BREAK-IN PROCEDURES 1- 6 INFORMATION LABELS 1- 7 SPECIFICATIONS 1- 8 COUNTRY AND AREA CODES 1-10
1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. ACAUTIOINT Indicates a potential hazard that could result in vehicle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS A WARNING * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle. * When two or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors. * When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, radiator, and exhaust system until they have cooled. * After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all of the lines, and fittings related to the system for leaks.
GENERAL INFORMATION 1-5 FUEL (For CANADA) Use only unleaded gasoline of at least 87 pump octane ( R * ^ ) or 91 octane or higher rated by the Research Method. FUEL (For the other countries) Use unleaded gasoline that is graded 91 octane or higher by the Research Method. ENGINE OIL (For USA) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W/40. If engine oil with a rating of SAE 10W/40 is not available, select an alter- native according to the chart. ENGINE OIL (For the other countries) Use a premium quality 4-stroke motor oil to ensure longer ser- vice life of your vehicle. Use only oils that meet API service classifications SF or SG and that have a viscosity rating of SAE 10W/40. If engine oil with a rating of SAE 10W/40 is not available, select an alternative according to the chart. DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL Use hypoid gear oil that meets the API service classification GL-5 and is rated SAE #90. Use a hypoid gear oil with a rating of SAE #80 if the vehicle is operated where the ambient temperature is below 0°C (32°F). BRAKE FLUID Specification and classification: DOT 4 A WARNING This vehicle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious damage will result to the brake system. Never use any brake fluid taken from old, used, or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for a long period of time. ENGINE COOLANT Since antifreeze also has corrosion- and rust-inhibiting properties, always use engine coolant containing antifreeze, even if the atmospheric temperature does not go below the freezing point. Use an antifreeze designed for aluminum radiators. SUZUKI recommends the use of SUZUKI COOLANT antifreeze. If this is not available, use an equivalent antifreeze for aluminum radiators. Mix only distilled water with the antifreeze. Other types of water can corrode and clog the aluminum radia- tor. Mix distilled water and antifreeze at a ratio of 50:50 - 40:60. For more information, refer to page 6-5 in the Cooling System section. MULTIGRADE Mt.wgi.mr.iva^ °C TEMP • -30 -20-10 0 10 20 30 40 °F -22 -4 14 32 50 68 86 104
1-6 GENERAL INFORMATION A CAUTION The percentage of antifreeze in the coolant should be between 50 to 60%. If the percentage of antifreeze is above or below this range the coolant's frost protection and rust-inhibiting capa- bilities will be reduced. Always keep the antifreeze content above 50% even if the atmospheric temperature does not go below the freezing point. BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. Refer to the following break-in engine speed recommendations. • Keep to these brake-in engine speed limits. Break-in engine speeds Initial 500 km (300 miles): Less than 1 2 throttle • Upon reaching an odometer reading of 500 km (300 miles) you can subject the vehicle to full throttle operation, for short periods of time.
The Suzuki Quadmaster 500 2000 2001 Workshop Service Repair Manual is a comprehensive resource for all repair and service needs related to the Suzuki Quadmaster 500 from the years 2000 and 2001.
It is designed for both DIY enthusiasts and experienced mechanics, offering a cost-effective solution to ensure the vehicle remains in optimal working condition.
This manual covers all styles of the Suzuki Quadmaster 500, providing step-by-step instructions, detailed photos, and illustrations for each service and repair procedure.
It addresses general information, fuel system, cooling system, engine top end, clutch, engine lubrication system, engine removal/installation, crankshaft/transmission, wheels/tires, final drive, brakes, suspension, steering, frame, electrical system, and appendix-related issues.
The user-friendly format allows for printing only the necessary pages or the entire manual, providing convenience and flexibility.
Each chapter includes numbered instructions, notes, cautions, and warnings to ensure access to critical information.
It simplifies troubleshooting and electrical service procedures with detailed wiring diagrams and is compatible with all PC-based Windows operating systems and Mac.
No need to wait for shipping or pay for overpriced paper textbooks or CD-ROMs, as it can be saved directly to your hard drive or burned onto a CD-ROM.
Get your professional-quality, in-depth Service & Repair manual for your Suzuki Quadmaster 500 2000 2001 now and ensure your vehicle receives the care it deserves.
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2000-2001 Suzuki Quadmaster 500 Service & Repair Manual