Suzuki Vinson LT-A500F Manuals

Suzuki Vinson LT-A500F Manuals

Manuals and User Guides for Suzuki Vinson LT-A500F. We have 1 Suzuki Vinson LT-A500F manual available for free PDF download: Service Manual

Suzuki Vinson LT-A500F Service Manual

Suzuki Vinson LT-A500F Service Manual (351 pages)

4x4

Brand: Suzuki | Category: Offroad Vehicle | Size: 21.32 MB

Table of Contents

Group Index
2
Component Parts and Work to be Done
3
Symbols
4
Table of Contents
5
General Information
5
Warning/Caution/Note
6
General Precautions
6
Suzuki Lt-A500Fy (2000-Model)
8
Serial Number Location
8
Fuel, Oil, and Engine Coolant Recommendations
8
- Engine Oil
  9
- Differential Gear and Final Bevel Gear Oil
  9
- Brake Fluid
  9
- Engine Coolant
  9
Break-In Procedures
10
Information Labels
11
Dimensions and Dry Mass
12
Specifications
12
Country and Area Codes
14
- Periodic Maintenance
  15
- Periodic Maintenance Chart
  16
- Periodic Maintenance Schedule
  16
- Air Cleaner
  17
- Maintenance and Tune-Up Procedures
  17
- Exhaust Pipe Nuts and Muffler Bolts
  18
- Valve Clearance
  19
  - Carbon Deposits
    20
  - Electrode
    20
  - Spark Plug
    20
  - Spark Plug Gap
    20
- Fuel Hose
  21
- Spark Plug Installation
  21
- Throttle Cable Play
  21
- Engine Idle Speed
  22
- Engine Oil and Oil Filter
  22
  - Engine Oil Replacement
    22
  - Oil Filter Replacement
    23
- Differential Gear and Final Bevel Gear Oil
  24
  - Engine Coolant Level Check
    25
  - Engine Coolant Replacement
    25
- Drive Belt
  26
- Radiator Hoses
  26
- Spark Arrester
  28
- Brake Pads
  29
- Brakes
  29
  - Rear Brake Lever
    29
  - Rear Brake Pedal and Lever
    29
  - Brake Fluid Level
    30
  - Brake Shoes
    30
  - Air Bleeding the Brake Fluid Circuit
    31
- Brake Hoses
  31
  - Tire Pressure
    32
  - Tire Tread Condition
    32
  - Vehicle Load Capacity Limit
    32
- Steering
  33
- Suspensions
  33
- Toe-In
  33
- Chassis Nuts and Bolts
  34
- General Lubrication
  36
- Compression Pressure Check
  37
- Compression Test Procedure
  37
  - High Oil Pressure
    38
  - Low Oil Pressure
    38
- Oil Pressure Check
  38
- Oil Pressure Test Procedure
  38
- Initial Engagement and Clutch Lock-Up Inspection
  39
- Initial Engagement Inspection
  39
- Clutch Lock-Up Inspection
  40
  - Engine
    41
  - Engine Components Removable with Engine in Place
    42
- Engine Removal and Remounting
  43
- Engine Remounting
  48
- Engine Disassembly
  51
- Cylinder Head Cover
  63
- Cylinder Head Cover Distortion
  63
- Engine Components Inspection and Service
  63
  - Rocker Arm Shaft O.D.
    63
  - Cylinder Head Disassembly
    64
  - Rocker Arm I.D.
    64
  - Cylinder Head Distortion
    65
  - Valve Stem Runout
    65
  - Valve Face Wear
    66
  - Valve Head Radial Runout
    66
  - Valve Stem Deflection
    66
  - Valve Stem Wear
    66
  - Valve Guide Servicing
    67
  - Valve Seat Servicing
    68
  - Valve Seat Width
    68
  - Initial Seat Cut
    69
  - Final Seat Cut
    70
  - Top Narrowing Cut
    70
  - Valve Seat Sealing Condition Inspection
    71
  - Valve Spring
    71
  - Valve Stem End Condition
    71
- Cylinder Head
  72
- Camshaft/Automatic Decompression Assembly
  73
  - Cam Wear
    74
  - Camshaft Journal Wear
    74
  - Camshaft Runout
    75
- Cylinder
  75
- Cylinder Distortion
  75
- Piston and Piston Ring
  75
  - Piston Ring Free End Gap and Piston Ring End Gap
    76
  - Piston-Ring-To-Groove Clearance
    76
  - Conrod Deflection and Big End Side Clearance
    77
  - Conrod Small End I.D.
    77
  - Piston Pin and Pin Bore
    77
  - Clutch Shoes
    78
  - Clutch Wheel
    78
  - Crankshaft Runout
    78
  - One-Way Clutch
    78
- Starter Clutch
  79
- Drive Belt
  80
- Movable Drive Face and Driven Face
  80
  - Movable and Fixed Drive Face
    81
  - Movable Drive Face Disassembly
    81
  - Oil Seal
    81
  - Roller and Sliding Surface
    81
  - Movable Driven Face Disassembly
    83
  - Movable and Fixed Driven Face
    84
  - Movable Driven Face Spring
    84
  - O-Ring and Oil Seal
    84
  - Drive Belt Inspection
    86
- Oil Pump
  87
- Gearshift Fork and Gear
  88
  - Transmission Disassembly
    89
  - Transmission Reassembly
    90
  - Countershaft Bearings
    93
  - Right Driveshaft Bearing
    93
  - Crankshaft Bearing
    94
  - Left Driveshaft Bearing
    94
  - Output Shaft Bearings
    94
  - Left Balancer Shaft Bearing
    95
  - Right Balancer Shaft Bearing
    95
  - Left Clutch Housing Bearing
    96
  - Water Pump Bearing
    96
  - Drive Belt Cover Bearing
    97
  - Starter Cup Bearing
    97
  - Countershaft Oil Seal
    98
- Oil Seals
  98
  - Clutch Housing Oil Seal
    99
  - Gearshift Shaft Oil Seal
    99
  - Starter Cup Oil Seal
    99
- Engine Reassembly
  101
- Transmission Output Shaft
  101
- Water Pump Driven Gear
  101
- Crankshaft
  102
- Balancer Shaft
  103
- Secondary Driven Output Shaft
  103
- Gearshift Cam and Fork
  104
- Crankcase
  105
- Gearshift Cam Stopper Bolt
  106
- Water Pump Drive Gear
  106
- Oil Pump
  107
- Starter Clutch and Generator Rotor
  107
- Cam Chain
  108
- Clutch Shoe
  108
- One Way Clutch
  108
- Clutch Housing
  109
- Movable Drive/Driven Face and Drive Belt
  109
- Neutral Switch
  109
- Generator Rotor Cover
  111
- Oil Filter
  111
- Piston Ring
  111
- Speedometer Gearbox
  111
- Piston and Cylinder
  113
- Cylinder Head
  114
- Camshaft/Automatic Decompression Assembly
  115
- Cam Chain Tension Adjuster
  116
- Cylinder Head Cover
  116
- Valve Clearance
  117
- Recoil Starter
  118
  - Recoil Starter Reassembly
    119
  - Shaft Drive and Differential
    120
  - Secondary Bevel Gears Construction
    121
- Disassembly
  122
- Removal
  122
- Rear Secondary Driven Output Shaft
  123
- Inspection
  124
- Reassembly
  124
  - Front Secondary Driven Output Shaft
    125
  - Backlash
    126
- Shim Adjustment
  126
- Tooth Contact
  127
- Final Assembly and Remounting
  128
- Reassembly Information
  129
- Differential Bevel Gears Construction
  130
- Removal
  131
- Disassembly
  132
  - Differential Driven Bevel Gear and Differential Assembly
    134
  - Differential Drive Bevel Gear Housing
    135
- Inspection
  135
- Reassembly and Adjustment
  137
- Differential Gear Bearing Case Shim Clearance
  141
- Remounting
  146
- Final Bevel Gears Construction
  148
- Removal and Disassembly
  149
- Inspection
  151
- Reassembly and Adjustment
  153
  - Final Gear Bearing Case Shim Clearance
    155
  - Final Assembly
    158
  - Remounting
    159
  - Fuel and Lubrication System
    161
- Fuel Line Inspection
  162
  - Fuel Tank Construction
    162
  - Fuel Tank Removal
    162
  - Fuel Tank Remounting
    163
- Fuel Strainer
  164
- Fuel Valve Removal and Inspection
  164
- Remounting
  164
  - Fuel Level Gauge Inspection
    165
  - Fuel Level Gauge Remounting
    165
  - Fuel Level Gauge Removal
    165
  - Carburetor Construction
    166
- I.D. NO. Location
  167
- Specifications
  167
- Disassembly
  168
- Removal
  168
- Pilot Screw Removal
  170
- Cleaning
  171
  - Float Height Adjustment
    172
  - Needle Valve Inspection
    172
  - Pilot Screw
    173
- Reassembly
  173
- Remounting
  173
- Engine Lubrication System Chart
  174
  - Cooling System
    175
  - Cooling System Description
    176
  - Cooling System Construction
    177
- Inspection
  180
- Radiator, Cooling Fan, and Engine Coolant Reservoir
  180
  - Cooling Fan Removal
    181
  - Cooling Fan Remounting
    182
- Cooling Fan Thermo Switch
  183
- Removal
  183
  - Cooling Fan Thermo Switch Inspection
    184
  - Cooling Fan Thermo Switch Installation
    184
  - Engine Coolant Temperature Switch Inspection
    185
  - Engine Coolant Temperature Switch Installation
    185
  - Engine Coolant Temperature Switch Removal
    185
  - Thermostat Inspection
    186
  - Thermostat Removal
    186
  - Thermostat Installation
    187
  - Water Pump Inspection
    188
  - Water Pump Removal and Disassembly
    188
  - Mechanical Seal
    189
  - Chassis
    190
  - Chassis Exterior Parts
    191
  - Front Carrier
    193
  - Front Grip Bar
    193
  - Seat Removal
    193
  - Front Fender Side Covers
    194
  - Fuel Tank Cover
    194
  - Radiator Cover
    194
  - Front Fender
    195
  - Rear Carrier
    195
  - Rear Fender
    196
  - Front and Rear Wheels Construction
    198
- Tire Replacement
  199
  - Front Drive Shaft Construction
    201
  - Front Drive Shaft Disassembly
    201
  - Front Drive Shaft Removal
    201
  - Front Drive Shaft Inspection and Reassembly
    203
  - Front Drive Shaft Remounting
    205
  - Brake Hose no
    206
  - Front Brake Construction
    206
- Brake Pad Replacement
  207
- Brake Caliper Removal and Disassembly
  208
- Brake Fluid Replacement
  208
- Brake Caliper Inspection
  209
  - Brake Caliper Pistons
    209
  - Brake Caliper Holder
    210
- Brake Caliper Reassembly and Remounting
  210
  - Piston Seals
    210
  - Rubber Parts
    210
- Brake Disc Removal and Disassembly
  211
- Brake Disc Inspection
  212
- Brake Disc Reassembly and Remounting
  212
- Master Cylinder Removal and Disassembly
  214
- Master Cylinder Inspection
  215
- Master Cylinder Reassembly and Remounting
  215
  - Piston and Rubber Parts
    215
  - Front Suspension Construction
    217
  - Front Suspension Removal and Disassembly
    218
  - Front Shock Absorber
    219
- Inspection
  219
  - Knuckle End
    219
  - Brake Disc Cover
    220
  - Bushing
    220
  - Drive Shaft Cover
    220
  - Wishbone Arm
    220
  - Dust Seal
    221
  - Hub Bearings
    221
- Reassembly and Remounting
  222
  - Steering Construction
    225
  - Steering Removal and Disassembly
    226
  - Steering Inspection
    228
  - Steering Shaft and Holder
    228
  - Steering Reassembly and Remounting
    229
  - Steering Shaft
    229
  - Handlebar
    230
  - Tie Rod
    230
- Toe-In Adjustment
  231
- Front Wheel, Front Brake, Front Suspension, and Steering Reassembling Information
  232
  - Rear Brake Construction
    233
  - Rear Brake Removal and Disassembly
    233
  - Brake Drum Inspection
    235
- Reassembly and Remounting
  236
- Reassembly and Remounting
  241
  - Rear Axle Shaft Construction
    242
  - Rear Axle Housing
    243
  - Rear Axle Shaft Inspection
    243
  - Rear Axle Shaft Removal and Disassembly
    243
  - Hub Bearing
    244
  - Rear Axle Shaft
    244
- Reassembly and Remounting
  245
- Rear Shock Absorber Standard Position
  246
- Rear Wheel, Rear Brake, Rear Suspension, and Rear Axle Shaft Reassembling Information
  247
  - Selection Shift Lever Removal and Disassembly
    248
  - Shift Levers Construction
    248
  - Selection Shift Lever Inspection
    249
  - Range Lever Removal and Disassembly
    250
  - Range Lever Inspection
    251
  - Range Lever Reassembly and Remounting
    251
  - Cables Installation and Adjustment
    252
  - Range Lever Cable
    254
  - Electrical System
    256
- Cautions in Servicing
  257
- Clamps
  257
- Connectors
  257
- Couplers
  257
- Fuses
  257
- Semi-Conductor Equipped Parts
  257
- Connecting the Battery
  258
- Wiring Procedure
  258
- Using the Multi Circuit Tester
  259
- Location of Electrical Components
  260
  - Charging System Description
    262
  - Charging System Troubleshooting
    263
  - Battery Current Leakage
    264
  - Charging Output
    264
- Inspection
  264
  - Ac Generator No-Load Performance
    265
  - Stator Coil Resistance
    265
  - Regulator/Rectifier
    266
  - Starter System Description
    267
  - Starter System Troubleshooting
    267
- Starter Motor Removal and Disassembly
  268
  - Armature Coil Inspection
    269
  - Carbon Brushes
    269
  - Commutator
    269
- Starter Motor Inspection
  269
- Starter Motor Reassembly and Remounting
  270
- Starter Relay Inspection
  271
- Neutral Relay Inspection
  272
- Inspection
  275
  - Ignition Coil Resistance
    276
  - Pickup Coil and Power Source Coil Peak Voltage
    276
- Back-Up Light Relay (for E-17)
  277
  - Pickup Coil and Power Source Coil Resistance
    277
  - Speedometer Removal
    278
  - Speedometer Disassembly
    279
  - Bulb Replacement
    280
- Headlight
  280
- Lamps
  280
- Taillight
  281
  - Dimmer Switch
    282
  - Ignition Switch
    282
  - Starter Button
    282
- Switches
  282
  - Battery Removal
    283
  - Battery Specifications
    283
  - Filling Electrolyte
    283
- Initial Charging
  283
- Recharging Operation
  285
- Servicing
  285
- Servicing Information
  286
- Engine
  287
- Troubleshooting
  287
- Shaft Drive
  290
- Chassis
  291
- Battery
  294
- Wiring Diagram
  295
- Wire Harness Routing
  297
- Wire Harness, Cable and Hose Routing
  297
- Cable Routing
  299
- Differential and Final Bevel Gear Hose Routing
  301
- Rear Brake Breather Hose Routing
  302
- Fuel System Hose Routing
  303
- Cooling System Hose Routing
  304
- Front Brake Hose Routing
  305
- Heat Shield Adhesive Position
  306
- Special Tools
  307
  - Tightening Torque
    310
  - Tightening Torque Chart
    312
- Service Data
  313
- Lt-A500Fk1
  320
- Final Bevel Gears
  333
- Removal and Disassembly
  334
- Inspection
  336
- Reassembly and Adjustment
  339
- Remounting
  344
- Wiring Diagram
  346
- Cooling System Hose Routing
  348

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