2000-2001 Suzuki Quadmaster 500 Service & Repair Manual

SUZUKI LT-A500F SERVICE MANUAL

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 maintenance. 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. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content 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, includ- ing special tools, for servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. A WARNING 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. GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SHAFT DRIVE AND DIFFERENTIAL GEARS FUEL AND LUBRICATION SYSTEM COOLING SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION LT-A500FK1 ('01-MODEL) SUZUKI MOTOR CORPORATION Motorcycle Service Department © COPYRIGHT SUZUKI MOTOR CORPORATION 1999

HOW TO USE THIS MANUAL T O L O C A T E WHAT Y O U A R E L O O K I N G 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. C O M P O N E N T P A R T S A N D W O R K T O B E D O N E 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: Front brake © Master cylinder reservoir cap © Diaphragm © Master cylinder clamp © Boot © Piston/cup set © Cup ® Spring © Master cylinder © Brake hose No.1 ® Brake hose No.2 ® Brake hose No.3 © Brake pipe joint © Brake pipe, RH @ Brake pipe, LH @ Piston © Piston seal ® Dust seal © Brake caliper ® Brake caliper holder © Brake pad © Pad Spring ® Master cylinder clamp bolt ® Brake hose union bolt © Brake pipe nut © Air bleeder valve © Brake caliper mounting bolt © Brake pad mounting pin H ITEM Nm kgf-m Ib-ft ® 10 1.0 7.0 ® 23 2.3 16.5 © 16 1.6 11.5 ® 7.5 0.75 5.0 © 26 2.6 19.0 © 18 1.8 13.0

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. 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 1-3 A CAUTION * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricants, bonds, or sealants. * When removing the battery, disconnect the 0 battery lead wire first, then the 0 battery lead wire. * When reconnecting the battery, connect the 0 battery lead wire first, then the 0 battery lead wire. Finally, cover the © battery terminal with the terminal cover. * When performing service to electrical parts, disconnect the 0 battery lead wire, unless the service procedure requires the battery power. * When tightening cylinder head and crankcase nuts and bolts, tighten the larger sizes first. Always tighten the nuts and bolts from the inside working out, diagonally and to the specified torque. * Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking wash- ers, cotter pins, circlips, and other specified parts, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil, engine coolant, all other fluids, batteries, and tires. * To protect the earth's natural resources, properly dispose of used vehicles and parts.

1-4 GENERAL INFORMATION SUZUKI LT-A500FY (2000-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and the actual vehicles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) © is stamped on the right side of the rear frame pipe. The engine serial number © is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL, OIL, AND ENGINE COOLANT RECOMMENDATION FUEL (For USA) • Use only unleaded gasoline of at least 87 pump octane ( R * M ) method or 91 octane or higher rated by the Research Method. • SUZUKI recommends that customers use alcohol-free unleaded gasoline whenever possible. • Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. • Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% eth- anol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhib- itors are present in it. • If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. • Failure to follow these guidelines could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

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 alternative according to the chart. ENGINE OIL (For the other countries) Use a premium quality 4-stroke motor oil to ensure longer service 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 radiator. 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.

2000-2001 Suzuki Quadmaster 500 Service & Repair Manual

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