User Manuals: Suzuki LT-F500F 2002 Utility ATV Parts

User Manuals: Suzuki LT-F500F 2002 Utility ATV Parts

Manuals and User Guides for Suzuki LT-F500F 2002 Utility ATV Parts. We have 1 Suzuki LT-F500F 2002 Utility ATV Parts manual available for free PDF download: Service Manual

Suzuki LT-F500F 2002 Service Manual

Suzuki LT-F500F 2002 Service Manual (382 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 23 MB

Table of Contents

General Information 1

5
- Table of Contents
  5
- Warning/Caution/Note
  6
- General Precautions
  6
- Suzuki Lt-F500Fk3 (2003-Model)
  8
- Serial Number Location
  8
- Fuel, Oil and Engine Coolant Recommendation
  8
  - Fuel
    8
  - Engine Oil
    9
  - Front and Rear Drive Gear Oil
    9
  - Brake Fluid
    9
  - Engine Coolant
    9
- BREAK-Ln PROCEDURES
  10
- Information Labels
  11
- Specifications
  12
- Country and Area Codes
  14
Periodic Maintenance

15
- Periodic Maintenance Schedule
  16
  - Periodic Maintenance Chart
    16
- Maintenance and Tune-Up Procedures
  17
  - Air Cleaner
    17
  - Exhaust Pipe Nuts and Muffler Bolts
    18
  - Valve Clearance
    19
  - Spark Plug
    20
  - Fuel Line
    21
  - Throttle Cable Play
    22
  - Engine Idle Speed
    22
  - Engine Oil and Oil Filter
    23
  - Differential Gear and Final Bevel Gear Oil
    25
  - Engine Coolant
    26
  - Radiator Hoses
    27
  - Clutch
    28
  - Spark Arrester
    28
  - Brakes
    29
  - Brake Fluid
    30
  - Brake Hoses
    32
  - Tires
    32
  - Steering System
    33
  - Suspensions
    34
  - Chassis Nuts and Bolts
    35
  - General Lubrication
    37
- Compression Pressure Check
  38
  - Compression Test Procedure
    38
- Oil Pressure Check
  39
  - Oil Pressure Test Procedure
    39
- Initial Engagement and Clutch Lock-Up Inspection
  40
  - Initial Engagement Inspection
    40
  - Clutch Lock-Up Inspection
    41
- Parking Inspection
  42
Engine

43
- Engine Components Removable with Engine in Place
  44
  - Engine Left Side
    44
  - Engine Right Side
    44
  - Engine Center
    44
- Engine Removal and Installation
  45
  - Engine Removal
    45
  - Engine Installation
    50
- Engine Disassembly
  54
  - Engine Top Side
    54
  - Engine Bottom Side
    58
- Engine Components Inspection and Servicing
  67
  - Cylinder Head Cover
    67
  - Cylinder Head
    68
  - Camshaft
    78
  - Cam Chain Tension Adjuster
    80
  - Cylinder
    80
  - Piston
    81
  - Conrod/Crankshaft
    83
  - Clutch
    84
  - Transmission
    87
  - Gearshift Fork
    90
  - Transfer Gearshift Cam
    91
  - Oil Pump
    93
  - Crankcase
    93
  - Generator Cover
    98
  - Clutch Cover
    102
  - Recoil Starter
    103
  - Drive Train (Inboard Side)
    106
  - Shim Adjustment
    115
  - Reassembly Information
    118
  - Crankshaft
    119
- Engine Reassembly
  120
  - Engine Bottom Side
    120
  - Gearshift Cam and Fork
    121
  - Transfer
    134
  - Engine Top Side
    141
Drive Train

150
- Drive Train
  151
  - Front Driving System
    151
  - Front Drive (Differential) Removal
    152
  - Front Drive (Differential) Disassembly
    152
  - Front Drive (Differential) Inspection
    156
  - Front Drive (Differential) Reassembly
    159
  - Front Drive (Differential) Installation
    165
  - Shim Adjustment
    166
  - Reassembly Information
    169
- Rear Driving System
  170
  - Rear Drive Removal
    171
  - Rear Drive Disassembly
    172
  - Rear Drive Inspection
    177
  - Rear Drive Reassembly
    180
  - Rear Drive Installation
    185
  - Shim Adjustment
    187
  - Reassembly Information
    190
Fuel System

192
- Fuel Tank
  193
  - Construction
    193
  - Fuel Line Inspection
    194
  - Removal
    194
  - Remounting
    194
- Fuel Valve
  195
  - Removal and Inspection
    195
  - Fuel Strainer
    195
  - Remounting
    195
- Fuel Level Gauge
  196
  - Removal
    196
  - Inspection
    196
  - Remounting
    196
- Carburetor
  197
  - Construction
    197
  - Specifications
    198
  - I.D. No. Location
    198
  - Removal
    199
  - Disassembly
    200
  - Cleaning
    203
  - Inspection
    203
  - Reassembly
    204
  - Remounting
    205
Cooling and Lubrication System

206
- Engine Coolant
  207
- Cooling Circuit
  208
  - Cooling Circuit Inspection
    208
- Radiator and Hoses
  209
  - Radiator Removal
    209
  - Radiator Remounting
    209
  - Radiator Reservoir Tank Removal and Remounting
    209
  - Radiator Cap Inspection
    210
  - Radiator Inspection and Cleaning
    210
  - Radiator Hose Inspection
    211
- Cooling Fan
  212
  - Removal
    212
  - Inspection
    212
  - Installation
    213
- Cooling Fan Thermo-Switch
  214
  - Removal
    214
  - Inspection
    214
  - Installation
    214
- Engine Coolant Temperature Switch
  215
  - Removal
    215
  - Inspection
    215
  - Installation
    215
- Thermostat
  216
  - Removal
    216
  - Inspection
    216
  - Installation
    216
- Water Pump
  218
  - Removal
    218
  - Inspection
    218
  - Disassembly
    219
  - Reassembly and Installation
    220
- Lubrication System
  222
  - Oil Pressure
    222
  - Oil Filter
    222
  - Oil Pressure Regulator
    222
  - Oil Sump Filter
    222
  - Oil Pump
    222
  - Engine Lubrication System Chart
    223
  - Engine Lubrication System
    224
Chassis

225
- Exterior Parts
  226
  - Construction
    226
  - Removal
    228
  - Remounting
    234
- Front and Rear Wheels
  235
  - Construction
    235
  - Removal
    235
  - Remounting
    235
- Tires
  236
  - Tire Replacement
    236
- Front Drive Shaft
  238
  - Construction
    238
  - Removal
    238
  - Inspection and Disassembly
    238
  - Remounting
    242
- Front Brake
  243
  - Construction
    243
  - Brake Pad Replacement
    244
  - Brake Fluid Replacement
    245
  - Brake Caliper Removal and Disassembly
    245
  - Brake Caliper Inspection
    247
  - Brake Caliper Reassembly and Remounting
    248
  - Brake Disc Removal and Disassembly
    250
  - Brake Disc Inspection
    251
  - Brake Disc Reassembly and Remounting
    251
  - Master Cylinder Removal and Disassembly
    252
  - Master Cylinder Inspection
    254
  - Master Cylinder Reassembly and Remounting
    254
- Front Suspension
  256
  - Construction
    256
  - Removal and Disassembly
    257
  - Inspection
    259
  - Reassembly and Remounting
    262
- Steering
  265
  - Construction
    265
  - Removal and Disassembly
    266
  - Inspection
    268
  - Reassembly and Remounting
    270
  - Toe-In Adjustment
    272
- Front Wheel, Front Brake, Front Suspension and Steering Reassembling Information
  273
- Rear Brake
  274
  - Construction
    274
  - Brake Pad Replacement
    275
  - Brake Fluid Replacement
    276
  - Brake Caliper Removal and Disassembly
    276
  - Brake Caliper Inspection
    278
  - Brake Caliper Reassembly and Remounting
    279
  - Brake Disc Removal and Disassembly
    281
  - Brake Disc Inspection
    281
  - Brake Disc Reassembly and Remounting
    282
  - Master Cylinder Removal and Disassembly
    283
  - Master Cylinder Inspection
    284
  - Master Cylinder Reassembly and Remounting
    285
- Rear Suspension
  287
  - Construction
    287
  - Removal
    288
  - Inspection and Disassembly
    289
  - Reassembly and Remounting
    290
- Rear Axle
  292
  - Construction
    292
  - Removal
    293
  - Inspection and Disassembly
    293
  - Reassembly and Remounting
    295
- Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm and Rear Axle Shaft Reassembling Information
  297
- Gearshift Lever
  298
  - Construction
    298
  - Removal and Disassembly
    299
  - Inspection
    300
  - Reassembly and Remounting
    301
- Cables
  303
  - Removal and Installation
    303
  - Cable Play Adjustment
    307
Electrical System

309
- Cautions in Servicing
  310
  - Connectors
    310
  - Couplers
    310
  - Clamps
    310
  - Fuses
    310
  - Semi-Conductor Equipped Parts
    310
  - Battery
    311
  - Connecting the Battery
    311
  - Wiring Procedure
    311
  - Using the Multi Circuit Tester
    311
- Location of Electrical Components
  312
- Charging System
  314
  - Troubleshooting
    314
  - Inspection
    316
- Starter System
  319
  - Troubleshooting
    319
  - Starter Motor Removal and Disassembly
    320
  - Starter Motor Inspection
    321
  - Starter Motor Reassembly and Remounting
    322
  - Starter Relay Inspection
    323
  - Neutral Relay Inspection
    324
  - Parking Brake Switch
    324
- Ignition System
  325
  - Troubleshooting
    325
  - Inspection
    327
- 2Wd/4Wd Selecting System
  329
  - Description
    329
  - Troubleshooting
    330
  - Inspection
    331
- Speedometer
  333
  - Parts Names
    333
  - Operating Procedure
    334
  - Inspection
    336
- Lamps
  338
  - Headlight and Auxiliary Light
    338
  - Brake Light/Taillight
    340
- Switches
  341
- Battery
  343
  - Specifications
    343
  - Initial Charging
    343
  - Servicing
    345
  - Recharging Operation
    345
Servicing Information

346
- Troubleshooting
  347
  - Engine
    347
  - Drive Train
    351
  - Carburetor
    351
  - Chassis
    352
  - Brakes
    353
  - Radiator (Cooling System)
    353
  - Electrical
    354
  - Battery
    355
- Wiring Diagram
  356
- Wiring Harness, Cable, and Hose Routing
  357
  - Wiring Harness Routing
    357
  - Cable Routing
    360
  - Carburetor Hose Routing
    361
  - Cooling System Hose Routing
    363
  - Front Driving System
    364
  - Front Brake Hose Routing
    365
  - Rear Brake Hose Routing
    366
  - Oil Return Tank Hose Routing
    367
- Special Tools
  368
- Tightening Torque
  371
  - Engine
    371
  - Differential
    372
  - Chassis
    372
  - Tightening Torque Chart
    373
- Service Data
  374

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