Suzuki Vinson 500 2002-2007 Workshop Service Manual

FOREWORD This manual contains an introductory description on the SUZUKI L T-A500F and procedure s for its inspection, service, and overhaul of its ma in compo- nents. Other Information consi dered as generally known is not included. Read the GENERAL INFORMA TlON section to familiarize yourself with the vehicle and its mainte- nanCB. Use this section as well as other sections as a guide tor proper inspection and service. This manual will help you know the vehicle bett er so tha t y ou can assure y our customers of fast and reli- abl e service. • This manual has been prepared on the basis of the latest specifications at the time of publi- cation. 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 princ/ples of operation and work procedures. They may no t repre sent the actual vehicle exactly in detail. • This manual is written f or persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI vehicl es. If you do nor have the proper knowledge and tools, ask your authorized SUZUKI motorcy- cle dealer to help you. A WARNING Inexperienced mechanics or mechanics without the proper tools and eq ui pment may not be ab le to properly perform t he services described in this manual. Improper repair may result in i njury to the mechanic and may render the vehicle unsafe for the rider. GROUP INDEX GENERAL INFORMATION I PERIODIC MAINTENANCE I ENGINE I DRIVE TRAIN FUEL SYSTEM COOLING AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION

SUPPLEMENTS LT-ASOOFK3 ('03-MODEL) LT-ASOOFK4 ('04-MODEL) • LT-ASOOFKS (,OS-MODEL) LT-ASOOFK6 ('06-MODEL) LT-ASOOFK7 ('07-MODEL) 1

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The le1<1 of this manual is divided into section s. 2. The section ti tl es 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 yo u need. COMPONENT PARTS AND WORK TO BE DONE , , 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 age nt points). Example: Rear suspension ill Rear shock absorber I%l Swingarm (3} Spacer ® Dl,Istseal Gl Bearing ® Rear shock absorber monting upper nut 1& Rear shocll absorber monting lower /lUI C Swingarm piYOl locknut 13) Swingarm piVOl boll (LH) ~ Swingarm pivol boll (RH) ©~ftt @ @ J@I (5l ITEM ® " C " " J0 ~~ <Ill N.m kgf-m Ib-It " 3.' 24.5 00 6 .0 43.5 "" 10.0 72.5 100 10.0 72. 5 9.5 10 '0 • • • • • • .,:'-.-' •

• SYMBOL Listed in the table below are the symbols indicating instru ctions and other information necessary for servic- ing. The meaning of each symbol is also included in the table . SYMBOL DEFINITION SYMBOL DEFINITION ~ To r que control r equ i red. • Apply THREAD LOCK SUPER "1305". Data beside it indicates specified 99000-321 00 torque. Indicates service data. Ap pl y THREAD LOCK SUPER "1322". - • 99000-32110 (Except USA) 1r Apply oiL Use engi ne oil unless ~ Apply THREAD LOCK "1342". otherwise specified . 99000-32050 if App ly hypoid gear oil. = Apply THREAD LOCK SUPER "1360". 99000-32130 --m App ly molybdenum oil solution . I Ap pl y or use brake fluid. (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1) ,0 Apply SUZUKI SUPER GREASE "A". ~ Measure in voltage range. 99000-25030 (USA) 99000-25010 (Others) ~ Apply SUZUKI SILICONE GREASE. ~ Measure in resistance range. 99000-25100 ~ Apply SUZUKI MOLY PASTE. ~ Measure in cu rr ent range. 99000-25 140 ~ Apply WATER RESISTANCE GREASE. ~ Measure in diode lest ran ge. 99000-25160 ~ Apply SUZUKI BOND "1207B" ~ Measure in co nt inuity test range. 99104-31140 (USA) Apply SUZUKI BOND "1215". .foot. Use special 1001. -<IE] 99000-31 11 0 (Except USA) Apply SUZUKI BOND "1216B". eJ Use engine coola nt. e 99100-31230 99000-99032- 11 X (Except USA) = Apply THREAD LOCK SUPER "1303". 99000-32030

GENERAL I NF ORM ATI ON 1-1 GENERAL INFORMA TION CONTENTS WARNINGICAUTION INOTE ...... .. ........... .. .. ........... .. . .. ....................... 1- 2 GENERAL PRECAUTIONS .. ..................... .... .. . .. .. .......... .. .................. 1- 2 SUZUKI LT -A500F K2 (2002-MODELj ... .... ... .. ....... ........... ..........•...... 1- 4 SERIAL NUMBER LOCATION .... .............................................. .... ..... 1- 4 FUEL, DIL 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 INFORMA TlON LABELS .......... .... ... .... .. ................. .. .......... .. ........... ... 1- 7 SPECIFICATIONS ........................ .. .... .. .......... .... . .. ......... .. .............. .... 1- 8 COUNTRY AND AREA CODES ..... .. ..... .. .. ........... .. . .. ............ .. ... .. ... ... 1- 10

1-2 GENE RALINFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instruf:lions carefull y. To emphasize special informa ti on, 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 . I CAUTION I Indicates a potenti al hazard that could res ult in vehicle damage. NOTE: fndicates speciaf 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 re lat ing to the servicing, or lack of servi ci ng, of the vehicle. In addit ion to the WARNINGS and CAUTIONS stated, you must use good judgement an d basic mechanical safety principles. If yo u are unsure about how to pe rf orm a part icular service operat io n, ask a mo re experienced mechan ic for advi ce. GENERAL PRECAUTIONS A WARNING • Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of th e 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 th e 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, all, engine coolant, exhaust or brake systems, check all of the lines, and fittings related to the system for leaks. • • • •