2002-2007 Suzuki 500 LTA Service Manual
Manual is the same as the one used by professional mechanics in workshops.
Service Manual contains detailed instructions and step by step diagrams for all workshop procedures; everything from basic inspections and adjustments to rebuilding the engine, as well as electrical diagrams, torque settings, fluid capacities, etc.
Manual chapters:
01 GENERAL INFORMATION
02 PERIODIC MAINTENANCE
03 ENGINE
04 DRIVE TRAIN
05 FUEL SYSTEM
06 COOLING AND LUBRICATION SYSTEM
07 CHASSIS
08 ELECTRICAL SYSTEM
09 SERVICING INFORMATION
10 LT-A500FK3 ('03-MODEL)
11 LT-A500FK4 ('04-MODEL)
12 LT-A500FK5 ('05-MODEL)
13 LT-A500FK6 ('06-MODEL)
14 LT-A500FK7 ('07-MODEL)
Manual is indexed and searchable.
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"2002-2007 Suzuki 500 LTA Service Manual" manual can be saved to any computer hard drive, flash storage, burned to a CD or DVD ROM or any other digital media.This Manual PDF file is:
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Full list of manual chapters:
FOREWORD
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
COMPONENT PARTS AND WORK TO BE DONE
SYMBOL
01 GENERAL INFORMATION
WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SUZUKI LT-A500FK2 (2002-MODEL)
SERIAL NUMBER LOCATION
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL
ENGINE OIL
FRONT AND REAR DRIVE GEAR OIL
BRAKE FLUID
ENGINE COOLANT
BREAK-lN PROCEDURES
INFORMATION LABELS
SPECIFICATIONS
COUNTRY AND AREA CODES
02 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
MAINTENANCE AND TUNE-UP PROCEDURES
AIR CLEANER
EXHAUST PIPE NUTS AND MUFFLER BOLTS
VALVE CLEARANCE
SPARK PLUG
FUEL HOSE
THROTTLE CABLE PLAY
ENGINE IDLE SPEED
ENGINE OIL AND OIL FILTER
DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL
ENGINE COOLANT
RADIATOR HOSES
DRIVE BELT
SPARK ARRESTER
BRAKES
BRAKE FLUID
BRAKE HOSES
TIRES
STEERING
SUSPENSIONS
CHASSIS NUTS AND BOLTS
GENERAL LUBRICATION
COMPRESSION PRESSURE CHECK
COMPRESSION TEST PROCEDURE
OIL PRESSURE CHECK
OIL PRESSURE TEST PROCEDURE
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION
INITIAL ENGAGEMENT INSPECTION
CLUTCH LOCK-UP INSPECTION
03 ENGINE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE
ENGINE LEFT SIDE
ENGINE RIGHT SIDE
ENGINE CENTER
ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
ENGINE INSTALLATION
ENGINE DISASSEMBLY
ENGINE TOP SIDE
ENGINE BOTTOM SIDE
ENGINE COMPONENTS INSPECTION AND SERVICING
CYLINDER HEAD COVER
CYLINDER HEAD
CAMSHAFT
CAM CHAIN TENSION ADJUSTER
CYLINDER
PISTON
CONROD/CRANKSHAFT
CLUTCH
MOVABLE DRIVE FACE AND DRIVEN FACE
DRIVE BELT
OIL PUMP
TRANSFER
SHIFT FORK
GEARSHIFT CAM
CRANKSHAFT
DRIVE TRAIN (INBOARD SIDE)
SHIM ADJUSTMENT
CRANKCASE
DRIVE BELT COVER
GENERATOR COVER
RECOIL STARTER
ENGINE REASSEMBLY
ENGINE BOTTOM SIDE
ENGINE TOP SIDE
04 DRIVE TRAIN
FRONT DRIVING SYSTEM
FRONT DRIVE (DIFFERENTIAL) REMOVAL
FRONT DRIVE (DIFFERENTIAL) DISASSEMBLY
FRONT DRIVE (DIFFERENTIAL) INSPECTION
FRONT DRIVE (DIFFERENTIAL) REASSEMBLY
FRONT DRIVE (DIFFERENTIAL) INSTALLATION
SHIM ADJUSTMENT
REASSEMBLY INFORMATION
REAR DRIVING SYSTEM
REAR DRIVE REMOVAL
REAR DRIVE DISASSEMBLY
REAR DRIVE INSPECTION
REAR DRIVE REASSEMBLY
REAR DRIVE INSTALLATION
SHIM ADJUSTMENT
REASSEMBLY INFORMATION
05 FUEL SYSTEM
FUEL TANK
CONSTRUCTION
FUEL LINE INSPECTION
REMOVAL
REMOUNTING
FUEL VALVE
REMOVAL AND INSPECTION
FUEL STRAINER
REMOUNTING
FUEL LEVEL GAUGE
REMOVAL
INSPECTION
REMOUNTING
CARBURETOR
CONSTRUCTION
SPECIFICATIONS
I.D. NO. LOCATION
REMOVAL
DISASSEMBLY
CLEANING
INSPECTION
REASSEMBLY
REMOUNTING
06 COOLING AND LUBRICATION SYSTEM
ENGINE COOLANT
COOLING CIRCUIT
COOLING CIRCUIT INSPECTION
RADIATOR AND HOSES
RADIATOR REMOVAL
RADIATOR REMOUNTING
RADIATOR RESERVOIR TANK
RADIATOR CAP INSPECTION
RADIATOR INSPECTION AND CLEANING
RADIATOR HOSE INSPECTION
COOLING FAN
REMOVAL
INSPECTION
INSTALLATION
COOLING FAN THERMO-SWITCH
REMOVAL
INSPECTION
INSTALLATION
ENGINE COOLANT TEMPERATURE SWITCH
REMOVAL
INSPECTION
INSTALLATION
THERMOSTAT
REMOVAL
INSPECTION
INSTALLATION
WATER PUMP
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND INSTALLATION
LUBRICATION SYSTEM
OIL PRESSURE
OIL FILTER
OIL PRESSURE REGULATOR
OIL STRAINER
OIL PUMP
ENGINE LUBRICATION SYSTEM CHART
ENGINE LUBRICATION SYSTEM
07 CHASSIS
EXTERIOR PARTS
CONSTRUCTION
REMOVAL
REMOUNTING
FRONT AND REAR WHEELS
CONSTRUCTION
REMOVAL
REMOUNTING
TIRES
TIRE REPLACEMENT
FRONT DRIVE SHAFT
CONSTRUCTION
REMOVAL
INSPECTION AND REASSEMBLY
REMOUNTING
FRONT BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT
BRAKE CALIPER REMOVAL AND DISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND REMOUNTING
BRAKE DISC REMOVAL AND DISASSEMBLY
BRAKE DISC INSPECTION
BRAKE DISC REASSEMBLY AND REMOUNTING
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND REMOUNTING
FRONT SUSPENSION
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
STEERING
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
TOE-IN ADJUSTMENT
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION
REAR BRAKE
CONSTRUCTION
BRAKE PAD REPLACEMENT
BRAKE FLUID REPLACEMENT
BRAKE CALIPER REMOVAL AND DISASSEMBLY
BRAKE CALIPER INSPECTION
BRAKE CALIPER REASSEMBLY AND REMOUNTING
BRAKE DISC REMOVAL AND DISASSEMBLY
BRAKE DISC INSPECTION
BRAKE DISC REASSEMBLY AND REMOUNTING
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND REMOUNTING
REAR SUSPENSION
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
REAR AXLE
CONSTRUCTION
REMOVAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING
REAR WHEEL, REAR BRAKE, REAR SUSPENSION, REAR SWINGARM AND REAR AXLE SHAFT REASSEMBLING INFORMATION
GEARSHIFT LEVER
CONSTRUCTION
REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
CABLES
INSTALLATION
CABLE PLAY ADJUSTMENT
08 ELECTRICAL SYSTEM
CAUTIONS IN SERVICING
CONNECTORS
COUPLERS
CLAMPS
FUSES
SEMI-CONDUCTOR EQUIPPED PARTS
BATTERY
CONNECTING THE BATTERY
WIRING PROCEDURE
USING THE MULTI CIRCUIT TESTER
LOCATION OF ELECTRICAL COMPONENTS
CHARGING SYSTEM
TROUBLESHOOTING
INSPECTION
STARTER SYSTEM
TROUBLESHOOTING
STARTER MOTOR REMOVAL AND DISASSEMBLY
STARTER MOTOR INSPECTION
STARTER MOTOR REASSEMBLY AND REMOUNTING
STARTER RELAY INSPECTION
NEUTRAL RELAY INSPECTION
IGNITION/STARTER CONTROL RELAY
PARKING BRAKE SWITCH
IGNITION SYSTEM
TROUBLESHOOTING
INSPECTION
2WD/4WD SELECTING SYSTEM
DESCRIPTION
TROUBLESHOOTING
INSPECTION
SPEEDOMETER
PARTS NAMES
OPERATING PROCEDURE
INSPECTION
LAMPS
HEADLIGHT AND AUXILIARY LIGHT
BRAKE LIGHT/TAILLIGHT
DIODE
SWITCHES
BATTERY
SPECIFICATIONS
INITIAL CHARGING
SERVICING
RECHARGING OPERATION
09 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
DRIVE TRAIN
CARBURETOR
CHASSIS
BRAKES
RADIATOR (COOLING SYSTEM)
ELECTRICAL
BATTERY
WIRING DIAGRAM
WIRING HARNESS, CABLE, AND HOSE ROUTING
WIRING HARNESS ROUTING
CABLE ROUTING
CARBURETOR HOSE ROUTING
COOLING SYSTEM HOSE ROUTING
FRONT BRAKE HOSE ROUTING
REAR BRAKE HOSE ROUTING
SPECIAL TOOLS
TIGHTENING TORQUE
ENGINE
DIFFERENTIAL
CHASSIS
TIGHTENING TORQUE CHART
SERVICE DATA
10 LT-A500FK3 ('03-MODEL)
SPECIFICATIONS
ENGINE
TRANSFER
GEARSHIFT CAM
DRIVE BEVEL GEAR BEARING
PROPELLER SHAFT INSTALLATION
CHASSIS
PARKING INTERLOCK CABLE ADJUSTMENT
FRONT WHEEL, FRONT BRAKE, FRONT SUSPENSION AND STEERING REASSEMBLING INFORMATION
REAR BRAKE
WIRING DIAGRAM
REAR BRAKE HOSE ROUTING
SERVICE DATA
11 LT-A500FK4 ('04-MODEL)
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
FRONT WHEEL, FRONT SUSPENSION AND STEERING ASSEMBLY
HANDLEBAR GRIP INSTALLATION
FUEL METER INSPECTION
FUEL LEVEL GAUGE INSPECTION
FUEL LEVEL GAUGE INSTALLATION
WIRING DIAGRAM
WIRE HARNESS ROUTING
CABLE ROUTING
12 LT-A500FK5 ('05-MODEL)
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
FRONT AND REAR BRAKE CALIPER MOUNTING BOLTS
WIRING HARNESS ROUTING
13 LT-A500FK6 ('06-MODEL)
SPECIFICATIONS
SERVICE DATA
TIGHTENING TORQUE
WIRING DIAGRAM
14 LT-A500FK7 ('07-MODEL)
SPECIFICATIONS
SERVICE DATA
FRONT BRAKE HOSE ROUTING
REAR BRAKE HOSE ROUTING
