Suzuki Vinson 500 LT-F500F Manual Transmission Complete Workshop Service Repair Manual 2003 2004 2005 2006 2007

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FOREWORD ThiS manual contains an introductory description on the SUZUKI L T-F500F and procedures for its inspection, service, and overhaul of its main compo- nents. Other information considered as genera lly 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 seNiee. This manual will help you know t he vehicle better so that you can assure your customers of fast and refi- able service. • This manual has been prepared on the basis of the fatest specifications at the time of publi- cat ion. If modifications have been made since then, differences.may exisl 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 no t represent the actual vehicle exactly in detail . • This manual is written for persons who have enough knowledge, skills and tools, including special tools, (or servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your au thorized SUZUKI motorcy- cle dealer to help you. A WARNING Inexperienced mechanics or mechanics without the proper lools 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 I PERIODIC MAINTENANCE I ENGINE DRIVETRAIN FUEL SYSTEM COOLING AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION

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SUPPLEMENTS .. LT-FSOOFK4 ('04-MODEL) LT-FSOOFKS ('OS-MODEL) L T-FSOOFK6 ('06- MODEL) I L T-FSOOFK7 ('07-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 litles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will aHow you to find th e 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. COMPONENT PARTS AND WORK TO BE DONE ~, I I I Under the name of each system or unit there is an exploded view which provides work instructions and other service information (e.g.; t ig htening torque, lubricating points, and locking agent points). Example: Rear suspension CD Aear ahodI. absorber (%I Swingarm e_" Ql Dust 1681 1Sl Bearing ® Rear ,hOck absortler moun~nll _"," ill Aear thock absofber mounting Ow,,"'" C Swingatm piYoI \odlnuI 4) Swingann pivot boll (LH) IS SwingiinTI pIYoI boll (AH) ITEM ® " C 10 I!> N·m kgf·m Ib-ft 35 ~S 25.S 60 ' .0 " .S 100 10.0 n.s 100 10,0 n.s 9.S 0.95 7.0 • ,. •

SYMBOL ~ listed in the table below are the symbols indicating instructions and other information necessary for servic- i ng. The meaning of each symbol is al so included in the table. SYMBOL DEFINITION SYMBOL DEFINITION ~ Torque control requ i red. Apply THREAD LOCK SUPER "1303". Data bes ide it indicates spe ci fied = 99000-32030 torque. Indicates service data. Apply THREAD LOCK SUPER "1322". - .. 99000·32110 (Excepl USA) l!r Apply oi l. Use eng ine oil unless • Apply THREAD LOCK "1342 ". otherwi se specified. 99000-32050 -m Apply hypoid gear oi l. .. Apply THREAD LOCK SUPER "1360". 99000·32130 -m Apply molybdenum oil solution. ~ Apply or use brake fluid. (mixture of engine oil and SUZUKI MOLY PASTE in a rati o of 1 : 1) ~ Apply SUZUKI SUPER GREASE "A". ~ Measure in voltage range. 99000·25030 (USA) 99000-25010 (Other s) J0I Apply SUZUKI SILICONE GREASE. ~ Measure in resistance range. 99000-25100 ~ Apply SUZUKI MOLY PASTE. ~ Measure in current range. 99000-25140 J0i Apply WATER RESISTANCE GREASE. ~ Measure in diode test range. 99 000-25160 ~ Apply SUZUKI BOND "1207B" ~ Measure in continuity test range. 99104-31140 (USA) Apply SUZUKI BOND "1215". ,looh Use special tool. em 99000·31110 (Except USA) Apply SUZUKI BOND "1216B". G Use engine coolant. a 99100·31230 99 000-99032-11 X (Excepl USA)

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GENERALINFORMATION 1·1 GENERAL INFORMA TION CONTENTS WARNINGICAUTIONINOTE ............................ .. ................................ 1- 2 GENERAL PRECAUTIONS ..................... .. ...... .. .. ............................... 1- 2 SUZUKI L T-F500FK3 (2003-MODEL) ............ .. .................................. 1- 4 SERIAL NUMBER LOCA TlON ...... .. .................... .. ............................. 1- 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDA TlON ............ 1- 4 FUEL . .. ............. ... .. .............. .. ........................ ............ .. ............. .... 1- 4 ENGINE OIL ... .... ...................... . .. ................... ............................... 1- 5 FRONT AND REAR DRIVE 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 GENERAlINFORMATlON WARNING/CAUTION/NOTE Please read this manual and follow its inst ructions carefuUy. To emphasize special information, the symbol and the words WARNING, CAUTI ON and NOTE have special meanings. Pay special attention to the mes· sages highlighted by these signal words. A WARNING Indicates 8 potential hazard that could result in death or inJury. I 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 safety principles. If you are unsure aboul 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. • •

Suzuki Vinson 500 LT-F500F Manual Transmission Complete Workshop Service Repair Manual 2003 2004 2005 2006 2007

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