1987-1990 Suzuki LT500R Quadzilla Service & Repair Manual

FOREWORD The SUZUKI L T500R was designed to offer superior perfonnance through two stroke power (Water-cooled engine with counter balancer), equipped with wishbone type front suspension and Full-ffoating rear suspension. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI Vehicles. Apprentice mechanics and udo it yourself" mechanics will also find this manual to be an extremely useful guide. The L T500R manufactured to standard specifications ;s the main subject matter of this manual. However, the L T500R machines distributed in your country might differ in minor respects from the standard-specification L T500R and, if they do, it is because some minor modifications (which are 'of no consequence in most cases as far as sef1licing is can· cemed) had to be made to comply with the statutory requirements of your country . This manual contains up·to·date information at the time of its issue. Later made modifi · cations and changes will be explained to each SUZUKI distributor in respective makers, from whom you may request updated information, if any.

VIEW OF SUZUKI LT500R ra7-MODEL) LEFT SIDE RIGHT SIDE

GROUP INDEX GENERAL INFORMATION TUNE-UP PROCEDURES ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION APPENDIX LT500RJ ('BB-MODEL) ..". ~~~~~~~~~~ LT500RK (,B9-MODEL) L T500RL ('90-MODEL) ftItI ~------------' '''

GENERAL INFORMATION r--------------- - CONTENTS -- ---- -------- --, VIN AND SERIAL NUMBER LOCATIONS "",,···············,,········· I- 1 FUEL , OIL AND COOLING SOLUTION RECOMMENDATIONS········ · ····················· · ········· · 1- 1 BREAKING-IN PROCEDURE ·· ··· ·· ........ ..... .... ....................... · 1- 2 SPECIAL MATERIALS ,,,,,,,,,,,,,,,,,,,,,,,,,,,, ,, ,,,,,,,,,,,, ,, ,,,,,,,,,,,, 1- 3 PRECAUTION AND GENERAL INSTRUCTIONS " " " .. " ·"""",, · 1- 6 SPECIFICATIONS···""····"··· · ··"·,, ·· ,,·,,,,·· .. ·,,··· ·· ,, .. · ,, .. ,, ",, ·· · 1- 7

1~1 GENERAL INFORMATION VIN AND SERIAL NUMBER LOCATIONS The VIN number Q) is stamped on the left frame member. The engine serial number 00 is l ocated on the crankcase. These numbers are required especially for register- ing the machine and ordering spare parts. FUEL, OIL AND COOLING SOLUTION RECOMMENDATIONS FUEL For U.S. model Use unleaded or low-lead type gasoline of at least 85 - 95 pump octane (A; M method) or 89 octane or higher rated by the research method. For other models Use gasoline with an octane number of 85 or higher (Research Method), preferable unleaded or low-lead. ENGINE OIL For U.S. model SUZUKI strongly recommends the use of SUZUKI CCI SUPER 2~CYClE MOTOR lUBRICANT. If this oil is not available use an equivalent high quality 2 Cycle Racing Lubricant. For other models For the oil to be mixed with gasoline, any of the following brands or its equivalent will do. • SHE ll SUPER M • CASTROl A747 • CASTRO l R30 CASTROl TTS (A545) CAUTION , • BELl~ RAY MC~ 100 • MOTUlCENTURY3002T • B.P. RACING Do not allo w two different brand s to get mixed in the fuel-oil mi xture. MIXTURE RATIO For proper engine performance 20 parts gasoline to , part oil is the correct gasoline to oil mixture ratio. For proper engine performance. it is essential that the above fuel oil mixture should be maintained. FUEL Oil MI XTURE RATIO OF 20 : 1 GASOLINE OIL GASOLINE OIL L ml Iqt) 1011 D.' 25 D. 0.8 1.0 50 10 1.6 I.. 75 1.' 2.4 2.0 100 2.0 3.2 2.' 12. 2.' ' .0 3.0 150 30 ' .8 3.' 175 3.5 5.6 '.0 200 '.0 6' ••• 22 • ' .5 7.2 '.0 250 5.0 8.0 • •• 215 ••• 8.8 6.0 300 6.0 ' .6 6.5 32. 6.' 10.4 7.0 350 7.0 11.2 7.' 37. 7.' 12.0 8.0 400 8.0 12.8 8.' 42. 85 13.6 '.0 '50 '.0 14.4 • •• 415 • •• 15.2 10.0 500 10.0 16.6 TRANSMISSION OIL Use a good quality SAE 20W/40 malti-grade motor oil.

• BRAKE FLUID Specification and Front DOT 30 r DOT4 classification: Rear DOT4 99000-23110 SUZUKI BRAKE FLUID COOLING SOLUTION Use an anti-freeze & Summer coolant compatible with aluminum radiator, mixed with distilled water only , WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI -FREEZE & SUMMER COOLANT The coolant performs as corrosion and rust inhibi- tor as well as anti -freeze. Therefore, the coolant should be used at all times even though the atmos- pheric temperature in your area does not go down to freezing point. SUZUK I recommends the use of SUZUKI GOLD · EN CR UISE A 1 200 anti-freeze & summer coolant. If this is not available, use an equivalent which is compatible with alu minum radiator. 99000- 24 120 Not available in U.S.A. SUZUKI GOLDEN CRUISER 1200 BREAKING-IN PROCEDURE During manufacture on ly the best possible materials are used and all machined pans are finished to a very high sta ndard but it is still necessary to allow the moving pans to " BR EAK - IN " before subject- ing the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exrcised during its early life. The general rules are as follows: GENER AL INFORM ATION 1-2 WARNING .- .. Since the brake system of this motorcycle is filled with e glycol-based brake fluid by the manufacturer. do not use or mix different types of fluid such as silicone-based and petroleum- based fluid for refilling the system. otherwise s erious damage will result . to Do not use any brake fluid taken from old. used, or unsealad containers . to Never re-use brake fluid left over from the previous servicing and stored for a long period. REOUIRED AMOUNT OF WATER/COOLANT Solution capacity (total) : 1 500 ml 11.59/ 1.32 USllmp qtl (reserve): 200 ml 10. 21 /0. 18 USllmp qtl For coolant mixture information , refer to cooling system section, page 4-1. CAUTION: Mixing of anti -freeze & summer coolant should be limited to 60 %. Mixing beyond it would reduce its efficiency. If the anti-freeze & summer coolant mixing ratio is below 30 %. rust inhibiting performance is greatly reduced. Every new unit is serviced with anti-leakage material . Bar 's leaks. 99000-24240 Not available in U.S.A. BAR'S LEAKS • Keep the these break-in engine speed limits: Up to 10 hours Less than 1/2 throttle • Do not maintain const ant engine speed for an extended time period duiring any portion of the break-in. Try to vary the throttle position .

1 -3 GENERAL INFORMATION SPECIAL MATERIALS The materials listed below are needed for maintenance work on the LT500R and should be kept on hand for ready use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual. Material For U.S.A. SUZUKI SUPER GREASE "A" 99000-25030 SUZUKI SILICONE GREASE 99000-25100 For other models SUZUKI SUPER GREASE "A" 99000-25010 SUZUKI SILICONE GREASE 99000-25100 SUZUKI BOND No. 1207B SUZUKI BOND No. 1215 p,rt • Steering shaft lower portion • Steering shaft dust seal • Steering shaft holder • Throttle lever • Brake pedal pivot shaft • Crankcase oil seal and bearing • Front wheel bearing and dust seal • Front suspension pivot bearing and dust seal • Clutch/parking brake lever sliding parts • Shock absorber bearing and dust seal • Rear wheel bearing and dust seal • Rear suspension pivot bearing and dust seal • Front brake caliper axle • Rear brake caliper axle • Rear caliper mounting bracket • Mating surfaces of the crankcase • Water pump mechanical seal • Rear sprocket flange • Rear brake disc flange p ... 2-18 1·40 2·18 7·40 2-18 7· 40 2-18 2-18 3·33 7- 4 2-18 7- 33 7·27 7·32 7· 51 2- 18 7-58 2-18 7-52 7- 14 7-22 7-52 3-39 4-11 7-60 7-60 e-~W~'M~-3~'~ '4 ~ O ~ ________ ~ ___ ~~~O~.~3'_"0~ ________ +-____________________ ~ ______ ~ SUZUKI BRAKE FLUID 99000-23110 (0.5U .~ ~e SUZUKI BRAKE FLUID 99000-231 10 (O.5L) • Brake fluid 1- 2 2-11

1987-1990 Suzuki LT500R Quadzilla Service & Repair Manual

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