Maintenance And Lubrication; Service Data; Differential; Parking Brake - Suzuki kq500 Service Manual

General Information ................................ 0A-1
General Description .............................................0A-1
Symbols .............................................................. 0A-1
Abbreviations ...................................................... 0A-1
SAE-to-Former SUZUKI Term ............................ 0A-2
Vehicle Side View ............................................... 0A-3
Vehicle Identification Number ............................. 0A-3
Fuel and Oil Recommendation ........................... 0A-3
Engine Coolant Recommendation ...................... 0A-4
BREAK-IN Procedures........................................ 0A-4
Country and Area Codes .................................... 0A-5
Wire Color Symbols ............................................ 0A-5
Warning, Caution and Information Labels
Location ............................................................ 0A-6
Component Location ...........................................0A-7
Electrical Components Location ......................... 0A-7
Specifications.......................................................0A-9
Specifications ...................................................... 0A-9
Special Tools and Equipment ...........................0A-11
Special Tool ...................................................... 0A-11
Maintenance and Lubrication................. 0B-1
Precautions...........................................................0B-1
Precautions for Maintenance .............................. 0B-1
General Description .............................................0B-1
Recommended Fluids and Lubricants................. 0B-1
Scheduled Maintenance ......................................0B-1
Periodic Maintenance Schedule Chart................ 0B-1
Lubrication Points ............................................... 0B-2
Repair Instructions ..............................................0B-3
Air Cleaner Element Inspection and Cleaning .... 0B-3
Exhaust Pipe Bolt and Muffler Bolt Inspection .... 0B-4
Valve Clearance Inspection and Adjustment ...... 0B-4
Spark Plug Replacement .................................... 0B-6
Spark Plug Inspection and Cleaning ................... 0B-6
Spark Arrester Cleaning...................................... 0B-7
Section 0
General Information
CONTENTS
Fuel Line Inspection ............................................0B-8
Engine Oil and Filter Replacement .....................0B-8
Front Differential Gear Oil Inspection................0B-10
Front Differential Gear Oil Replacement ...........0B-11
Final Gear Oil Inspection...................................0B-12
Final Gear Oil Replacement..............................0B-12
Throttle Cable Play Inspection and
Adjustment ......................................................0B-13
Throttle Body Inspection ...................................0B-13
Cooling System Inspection................................0B-13
Drive V-belt Inspection and Replacement.........0B-15
Drive Shaft Boots Inspection.............................0B-16
Front Brake System Inspection .........................0B-16
Rear Brake Pedal / Rear Brake (Parking
Brake) Lever Inspection and Adjustment ........0B-17
Rear Brake Friction Plate Wear Limit
Inspection........................................................0B-19
Tire Inspection...................................................0B-19
Steering System Inspection ..............................0B-20
Toe Adjustment .................................................0B-20
Suspensions Inspection ....................................0B-21
Chassis Bolt and Nut Inspection .......................0B-21
Compression Pressure Check ..........................0B-25
Oil Pressure Check ...........................................0B-25
SDS Check........................................................0B-25
Automatic Clutch Inspection..............................0B-25
Specifications .....................................................0B-26
Tightening Torque Specifications......................0B-26
Special Tools and Equipment ...........................0B-26
Recommended Service Material .......................0B-26
Special Tool ......................................................0B-27
Service Data ............................................. 0C-1
Specifications .......................................................0C-1
Service Data........................................................0C-1
Tightening Torque List ........................................0C-7
Table of Contents 0- i
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