Suzuki LT-F500FK1 2001 Workshop Service Manual for Repair

FOREWORD This manual contains an introductory description on the SUZUKI L T-F500FW 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 reliable service. .. This manual has been prepared on the basis of the latest specifications at the time of publica- tion. 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 vehicle. If you do not have the proper knowledge and tools, ask your authorized SUZUKI Motorcycle dealer to help you. AWARNING Inexperienced mechanics of mechanics with- out the proper tools and equipment may not be able to properly perform the services de- scribed in this manual. Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider. SUZUKI MOTOR CORPORATION Overseas Service Department GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SHAFT DRIVE AND DIFFERENTIAL GEARS FUEL AND LUBRICATION SYSTEM COOLING SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION L T-F500FX('99-MODELj L T-F500FY('OO-MODELj LT-F500FK1 ('01-MODEL) L T-F500FK2('02-MODEL)

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 find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel Item N'm kg - m ® 23 2.3 ® 50 5.0 © 100 10.0 Ib - ft 16.5 36.0 72.5 G) Front disc right side cover ® Front brake disc ® Front tire @ Front wheel ® Wheel rim valve assembly ® Wheel center cap ®

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indi- Apply THREAD LOCK SUPER "1360". ~ cates specified torque. • 99000-32130 Apply oil. Use engine oil unless otherwise te Apply or use brake fluid. ~ specified. Apply SUZUKI SUPER GREASE "A". Measure in voltage range. ~ 99000-25030 (For U.S.A.) ~ 99000-25010 (For others) Apply SUZUKI MOLY PASTE. Measure in resistance range. ~ 99000-25140 ~ Apply SUZUKI BOND "1207B". Measure in current range. e 99104-31140 (For U.S.A.) ~ 99000-31140 (For others) Apply SUZUKI BOND "1216". Measure in diode test range. .umJ 99104-31160 (For U.S.A.) ~ 99000-31160 (For others) Apply THREAD LOCK SUPER "1303". Measure in continuity test range. tJ130J ~ 99000-32030 Apply THREAD LOCK SUPER "1322". Use special tool. .. ';oOt • 99000-32110 Apply THREAD LOCK "1342". Use engine coolant. ~ em 99000-32050 99000-99032-11X (Except for U.S.A.)

GENERAL INFORMATION ~------------------CONTENTS--------------------~ WARNING/CAUTION/NOTE .............................................................................. 1- 1 GENERAL PRECAUTIONS ............................................................................... 1- 1 SUZUKI LT-F500FW ('9B-MODEL) .................................................................. 1- 3 SERIAL NUMBER LOCATION ......................................................................... 1- 3 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION ................... 1- 3 FUEL .................................................................................................................... 1- 3 ENGINE OIL ....................................................................................................... 1- 4 DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL ........................ 1- 4 BRAKE FLUID ................................................................................................... 1- 4 ENGINE COOLANT .......................................................................................... 1- 4 WATER FOR MIXING ...................................................................................... 1- 4 ANTI-FREEZE/ENGINE COOLANT ............................................................. 1- 5 LIQUID AMOUNT OF WATER/ENGINE COOLANT ................................ 1- 5 BREAK-IN PROCEDURES ................................................................................. 1- 5 INFORMATION LABELS .................................................................................... 1- 6 SPECIFICATIONS ................................................................................................ 1- 9 COUNTRY OR AREA CODES .......................................................................... 1-11

1·1 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 messages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. I A CAUTION I 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 safely principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS AWARNING * 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 outdoors. * 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 1·2 I A CAUTION I * 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 lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecting the battery, connect the positive cable first and then the negative cable, and cover the positive terminal with the terminal cover. * When performing service to electrical parts, disconnect the battery negative cable unless the service procedure requires the battery power. * When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, in a crisscross pattern. * Whenever you remove oil seals, gaskets, packing, a·rings, self·locking nuts, locking washers, cotter pins, circlips, and certain other parts as specified, 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 that 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, batteries, and tires. * To protect the earth's natural resources, properly dispose of used vehicle and parts.

1·3 GENERAL INFORMATION SUZUKI LT-F500FW ('98-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and actual vehicles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) CD is stamped on the right side of the rear frame pipe. The engine serial number ® is located on the rear 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 U.S.A. model) 1. Use only unleaded gasoline of at least 87 pump octane (R ; M) method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline 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 1-4 FUEL (For Canadian model) Use only unleaded gasoline of at least 87 pump octane (R ~ M) method or 91 octane or higher rated by the research method. FUEL (For the other models) Gasoline used should be graded 85 - 95 octane (Research Method) or higher. An unleaded gasoline type is recommended. ENGINE OIL (For U.S.A. model) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 10W/40. If an SAE 1 OW/40 oil is not available, select an alternative according to the right chart. ENGINE OIL (For the other models) Use a premium quality 4-stroke motor oil to ensure longer service life of your vehicle. Use only oils which are rated SF or SG under the API service classification. The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart. MULTIGRADE 'C TEMP. 'F DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL I , , , , , , -30 -20 -10 0 -22 -4 14 32 , , , -, , I " , , • I , 10 20 30 40 50 68 86104 Use SAE #90 hypoid gear oil which is rated GL-5 under API classification system. If you operate the vehicle where ambient temperature is below ODC (32 D F), use SAE #80 hypoid gear oil. BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this vehicle is filled with a 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 serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an 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.

1·5 GENERAL INFORMATION ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. Suzuki recommends the use of SUZUKI GOLDEN CRUISER 1200NA (except for U.S.A. model) anti- freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Solution capacity (total): 2 500 ml (2.6/2.2 US/Imp qt) For engine coolant mixture information, refer to cooling system section, page 6-4. I A CAUTION I Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing pOint. BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but 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. The general rules are as follows. 1. Keep to this break-in throttle position. Initial 500 km (300 miles) or 10 hours: Less than 112 throttle 2. After the engine has been operated for 500 km (300 miles) the vehicle can be subjected to full throttle operation for short periods of time.

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Suzuki LT-F500FK1 2001 Workshop Service Manual for Repair

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