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Table of Contents
- 2. Group index
- 3. Component Parts and Work To Be Done
- 4. Symbols
- 5. General Information
- 6. Warning/caution/note
- 8. Suzuki lt-a500fy (2000-model)
- 9. Engine Oil
- 10. Break-in procedures
- 11. Information labels
- 12. Specifications
- 14. Country and area codes
- 15. Periodic maintenance
- 16. Periodic maintenance schedule
- 17. Maintenance and tune-up procedures
- 18. Exhaust pipe nuts and muffler bolts
- 19. Valve clearance
- 20. Spark plug
- 21. Spark plug installation
- 22. Engine idle speed
- 23. Oil filter replacement
- 24. DIFFERENTIAL GEAR AND FINAL BEVEL GEAR O...
- 25. Engine coolant level check
- 26. Radiator hoses
- 28. Spark Arrester
- 29. Brakes
- 30. Brake shoes
- 31. Air bleeding the brake fluid circuit
- 32. Tire tread condition
- 33. Steering
- 34. Chassis nuts and bolts
- 36. General lubrication
- 37. Compression pressure check
- 38. Oil pressure check
- 39. Initial engagement and clutch lock-up in...
- 40. Clutch lock-up inspection
- 41. Engine
- 42. Engine components removable with engine ...
- 43. Engine removal and remounting
- 48. Engine remounting
- 51. Engine disassembly
- 63. Engine components inspection and service
- 64. Rocker arm i.d.
- 65. Cylinder head distortion
- 66. Valve head radial runout
- 67. Valve guide servicing
- 68. Valve seat width
- 69. Initial seat cut
- 70. Top narrowing cut
- 71. Valve seat sealing condition inspection
- 72. CYLINDER HEAD
- 73. Camshaft/automatic decompression assembl...
- 74. Cam wear
- 75. Cylinder
- 76. Piston-ring-to-groove clearance
- 77. Piston pin and pin bore
- 78. Crankshaft runout
- 79. Starter clutch
- 80. Movable drive face and driven face
- 81. Movable drive face disassembly
- 83. Movable driven face disassembly
- 84. O-ring and oil seal
- 86. Drive Belt Inspection
- 87. Oil Pump
- 88. Gearshift fork and gear
- 89. Transmission disassembly
- 90. Transmission reassembly
- 93. Countershaft bearings
- 94. Left driveshaft bearing
- 95. Right balancer shaft bearing
- 96. Water pump bearing
- 97. Drive belt cover bearing
- 98. Oil seals
- 99. Gearshift shaft oil seal
- 101. Engine reassembly
- 102. Crankshaft
- 103. Balancer shaft
- 104. Gearshift cam and fork
- 105. Crankcase
- 106. Gearshift cam stopper bolt
- 107. Starter clutch and generator rotor
- 108. Cam chain
- 109. Neutral switch
- 111. Oil filter
- 113. Piston and cylinder
- 114. Cylinder head
- 115. CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBL...
- 116. Cam chain tension adjuster
- 117. VALVE CLEARANCE
- 118. Recoil starter
- 119. Recoil starter reassembly
- 120. Shaft Drive and Differential
- 121. Secondary bevel gears construction
- 122. REMOVAL
- 123. Rear secondary driven output shaft
- 124. INSPECTION
- 125. Front secondary driven output shaft
- 126. Shim adjustment
- 127. Tooth contact
- 128. Final assembly and remounting
- 129. Reassembly information
- 130. Differential bevel gears construction
- 131. REMOVAL
- 132. DISASSEMBLY
- 134. Differential driven bevel gear and diffe...
- 135. Differential drive bevel gear housing
- 137. REASSEMBLY AND ADJUSTMENT
- 141. Differential gear bearing case shim clea...
- 146. REMOUNTING
- 148. Final bevel gears construction
- 149. REMOVAL AND DISASSEMBLY
- 151. INSPECTION
- 153. REASSEMBLY AND ADJUSTMENT
- 155. Final gear bearing case shim clearance
- 158. Final assembly
- 159. Remounting
- 161. Fuel and lubrication system
- 162. Fuel tank construction
- 163. Fuel tank remounting
- 164. Fuel valve removal and inspection
- 165. Fuel level gauge removal
- 166. Carburetor construction
- 167. I.D. NO. Location
- 168. REMOVAL
- 170. Pilot screw removal
- 171. CLEANING
- 172. Needle valve inspection
- 173. Pilot screw
- 174. Engine lubrication system chart
- 175. Cooling System
- 176. Cooling system description
- 177. Cooling system construction
- 180. Radiator, cooling fan, and engine coolan...
- 181. Cooling Fan Removal
- 182. Cooling Fan Remounting
- 183. Cooling fan thermo switch
- 184. Cooling fan thermo switch inspection
- 185. Engine coolant temperature switch remova...
- 186. Thermostat removal
- 187. Thermostat installation
- 188. Water pump removal and disassembly
- 189. Mechanical Seal
- 190. Chassis
- 191. Chassis exterior parts
- 193. Seat Removal
- 194. Radiator Cover
- 195. Front Fender
- 196. Rear Fender
- 198. Front and rear Wheels construction
- 199. Tire Replacement
- 201. Front drive shaft construction
- 203. Front drive shaft inspection and reassem...
- 205. Front drive shaft remounting
- 206. Front brake construction
- 207. Brake pad replacement
- 208. Brake fluid replacement
- 209. Brake caliper inspection
- 210. Brake caliper reassembly and remounting
- 211. Brake disc removal and disassembly
- 212. Brake disc inspection
- 214. Master cylinder removal and disassembly
- 215. Master cylinder reassembly and remountin...
- 217. Front suspension construction
- 218. Front suspension removal and disassembly
- 219. Front shock absorber
- 220. Wishbone Arm
- 221. Dust Seal
- 222. Reassembly and remounting
- 225. Steering construction
- 226. Steering removal and disassembly
- 228. Steering inspection
- 229. Steering Reassembly and Remounting
- 230. Tie Rod
- 231. Toe-In Adjustment
- 232. Front wheel, front brake, front suspensi...
- 233. Rear brake construction
- 235. Brake Drum Inspection
- 236. REASSEMBLY AND REMOUNTING
- 239. Rear suspension construction
- 240. Rear suspension removal and disassembly
- 241. REASSEMBLY AND REMOUNTING
- 242. Rear axle shaft construction
- 243. Rear axle shaft removal and disassembly
- 244. Rear axle shaft
- 245. REASSEMBLY AND REMOUNTING
- 246. Rear shock absorber standard position
- 247. Rear wheel, rear brake, rear suspension,...
- 248. Shift levers construction
- 249. Selection shift lever inspection
- 250. Range Lever Removal and Disassembly
- 251. Range Lever Inspection
- 252. Cables Installation and Adjustment
- 254. Range Lever Cable
- 256. Electrical System
- 257. Cautions in servicing
- 258. Connecting the battery
- 259. Using the multi circuit tester
- 260. Location of electrical components
- 262. Charging system description
- 263. Charging system troubleshooting
- 264. Battery current leakage
- 265. Stator coil resistance
- 266. Regulator/rectifier
- 267. Starter system description
- 268. Starter motor removal and disassembly
- 269. Starter motor inspection
- 270. Starter motor reassembly and remounting
- 271. Starter relay inspection
- 272. Neutral relay inspection
- 273. Ignition system description
- 275. Ignition coil primary peak voltage
- 276. Ignition coil resistance
- 277. Back-up light relay (for e-17)
- 278. Speedometer removal
- 279. Speedometer disassembly
- 280. Lamps
- 281. Taillight
- 282. Switches
- 283. Battery removal
- 285. Servicing
- 286. Servicing Information
- 287. Troubleshooting
- 290. SHAFT DRIVE
- 291. CHASSIS
- 294. BATTERY
- 295. Wiring diagram
- 297. Wire harness, cable and hose routing
- 299. Cable routing
- 301. Differential and Final Bevel Gear Hose R...
- 302. Rear brake breather hose routing
- 303. Fuel system hose routing
- 304. Cooling System Hose Routing
- 305. Front brake hose routing
- 306. Heat Shield Adhesive Position
- 307. Special tools
- 310. Tightening torque
- 312. Tightening torque chart
- 313. Service data
- 320. LT-A500FK1
- 333. FINAL BEVEL GEARS
- 334. REMOVAL AND DISASSEMBLY
- 336. INSPECTION
- 339. REASSEMBLY AND ADJUSTMENT
- 344. REMOUNTING
- 346. WIRING DIAGRAM
- 348. COOLING SYSTEM HOSE ROUTING
Page 1 of 350
Table of Contents
- 2. Group index
- 3. Component Parts and Work To Be Done
- 4. Symbols
- 5. General Information
- 6. Warning/caution/note
- 8. Suzuki lt-a500fy (2000-model)
- 9. Engine Oil
- 10. Break-in procedures
- 11. Information labels
- 12. Specifications
- 14. Country and area codes
- 15. Periodic maintenance
- 16. Periodic maintenance schedule
- 17. Maintenance and tune-up procedures
- 18. Exhaust pipe nuts and muffler bolts
- 19. Valve clearance
- 20. Spark plug
- 21. Spark plug installation
- 22. Engine idle speed
- 23. Oil filter replacement
- 24. DIFFERENTIAL GEAR AND FINAL BEVEL GEAR O...
- 25. Engine coolant level check
- 26. Radiator hoses
- 28. Spark Arrester
- 29. Brakes
- 30. Brake shoes
- 31. Air bleeding the brake fluid circuit
- 32. Tire tread condition
- 33. Steering
- 34. Chassis nuts and bolts
- 36. General lubrication
- 37. Compression pressure check
- 38. Oil pressure check
- 39. Initial engagement and clutch lock-up in...
- 40. Clutch lock-up inspection
- 41. Engine
- 42. Engine components removable with engine ...
- 43. Engine removal and remounting
- 48. Engine remounting
- 51. Engine disassembly
- 63. Engine components inspection and service
- 64. Rocker arm i.d.
- 65. Cylinder head distortion
- 66. Valve head radial runout
- 67. Valve guide servicing
- 68. Valve seat width
- 69. Initial seat cut
- 70. Top narrowing cut
- 71. Valve seat sealing condition inspection
- 72. CYLINDER HEAD
- 73. Camshaft/automatic decompression assembl...
- 74. Cam wear
- 75. Cylinder
- 76. Piston-ring-to-groove clearance
- 77. Piston pin and pin bore
- 78. Crankshaft runout
- 79. Starter clutch
- 80. Movable drive face and driven face
- 81. Movable drive face disassembly
- 83. Movable driven face disassembly
- 84. O-ring and oil seal
- 86. Drive Belt Inspection
- 87. Oil Pump
- 88. Gearshift fork and gear
- 89. Transmission disassembly
- 90. Transmission reassembly
- 93. Countershaft bearings
- 94. Left driveshaft bearing
- 95. Right balancer shaft bearing
- 96. Water pump bearing
- 97. Drive belt cover bearing
- 98. Oil seals
- 99. Gearshift shaft oil seal
- 101. Engine reassembly
- 102. Crankshaft
- 103. Balancer shaft
- 104. Gearshift cam and fork
- 105. Crankcase
- 106. Gearshift cam stopper bolt
- 107. Starter clutch and generator rotor
- 108. Cam chain
- 109. Neutral switch
- 111. Oil filter
- 113. Piston and cylinder
- 114. Cylinder head
- 115. CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBL...
- 116. Cam chain tension adjuster
- 117. VALVE CLEARANCE
- 118. Recoil starter
- 119. Recoil starter reassembly
- 120. Shaft Drive and Differential
- 121. Secondary bevel gears construction
- 122. REMOVAL
- 123. Rear secondary driven output shaft
- 124. INSPECTION
- 125. Front secondary driven output shaft
- 126. Shim adjustment
- 127. Tooth contact
- 128. Final assembly and remounting
- 129. Reassembly information
- 130. Differential bevel gears construction
- 131. REMOVAL
- 132. DISASSEMBLY
- 134. Differential driven bevel gear and diffe...
- 135. Differential drive bevel gear housing
- 137. REASSEMBLY AND ADJUSTMENT
- 141. Differential gear bearing case shim clea...
- 146. REMOUNTING
- 148. Final bevel gears construction
- 149. REMOVAL AND DISASSEMBLY
- 151. INSPECTION
- 153. REASSEMBLY AND ADJUSTMENT
- 155. Final gear bearing case shim clearance
- 158. Final assembly
- 159. Remounting
- 161. Fuel and lubrication system
- 162. Fuel tank construction
- 163. Fuel tank remounting
- 164. Fuel valve removal and inspection
- 165. Fuel level gauge removal
- 166. Carburetor construction
- 167. I.D. NO. Location
- 168. REMOVAL
- 170. Pilot screw removal
- 171. CLEANING
- 172. Needle valve inspection
- 173. Pilot screw
- 174. Engine lubrication system chart
- 175. Cooling System
- 176. Cooling system description
- 177. Cooling system construction
- 180. Radiator, cooling fan, and engine coolan...
- 181. Cooling Fan Removal
- 182. Cooling Fan Remounting
- 183. Cooling fan thermo switch
- 184. Cooling fan thermo switch inspection
- 185. Engine coolant temperature switch remova...
- 186. Thermostat removal
- 187. Thermostat installation
- 188. Water pump removal and disassembly
- 189. Mechanical Seal
- 190. Chassis
- 191. Chassis exterior parts
- 193. Seat Removal
- 194. Radiator Cover
- 195. Front Fender
- 196. Rear Fender
- 198. Front and rear Wheels construction
- 199. Tire Replacement
- 201. Front drive shaft construction
- 203. Front drive shaft inspection and reassem...
- 205. Front drive shaft remounting
- 206. Front brake construction
- 207. Brake pad replacement
- 208. Brake fluid replacement
- 209. Brake caliper inspection
- 210. Brake caliper reassembly and remounting
- 211. Brake disc removal and disassembly
- 212. Brake disc inspection
- 214. Master cylinder removal and disassembly
- 215. Master cylinder reassembly and remountin...
- 217. Front suspension construction
- 218. Front suspension removal and disassembly
- 219. Front shock absorber
- 220. Wishbone Arm
- 221. Dust Seal
- 222. Reassembly and remounting
- 225. Steering construction
- 226. Steering removal and disassembly
- 228. Steering inspection
- 229. Steering Reassembly and Remounting
- 230. Tie Rod
- 231. Toe-In Adjustment
- 232. Front wheel, front brake, front suspensi...
- 233. Rear brake construction
- 235. Brake Drum Inspection
- 236. REASSEMBLY AND REMOUNTING
- 239. Rear suspension construction
- 240. Rear suspension removal and disassembly
- 241. REASSEMBLY AND REMOUNTING
- 242. Rear axle shaft construction
- 243. Rear axle shaft removal and disassembly
- 244. Rear axle shaft
- 245. REASSEMBLY AND REMOUNTING
- 246. Rear shock absorber standard position
- 247. Rear wheel, rear brake, rear suspension,...
- 248. Shift levers construction
- 249. Selection shift lever inspection
- 250. Range Lever Removal and Disassembly
- 251. Range Lever Inspection
- 252. Cables Installation and Adjustment
- 254. Range Lever Cable
- 256. Electrical System
- 257. Cautions in servicing
- 258. Connecting the battery
- 259. Using the multi circuit tester
- 260. Location of electrical components
- 262. Charging system description
- 263. Charging system troubleshooting
- 264. Battery current leakage
- 265. Stator coil resistance
- 266. Regulator/rectifier
- 267. Starter system description
- 268. Starter motor removal and disassembly
- 269. Starter motor inspection
- 270. Starter motor reassembly and remounting
- 271. Starter relay inspection
- 272. Neutral relay inspection
- 273. Ignition system description
- 275. Ignition coil primary peak voltage
- 276. Ignition coil resistance
- 277. Back-up light relay (for e-17)
- 278. Speedometer removal
- 279. Speedometer disassembly
- 280. Lamps
- 281. Taillight
- 282. Switches
- 283. Battery removal
- 285. Servicing
- 286. Servicing Information
- 287. Troubleshooting
- 290. SHAFT DRIVE
- 291. CHASSIS
- 294. BATTERY
- 295. Wiring diagram
- 297. Wire harness, cable and hose routing
- 299. Cable routing
- 301. Differential and Final Bevel Gear Hose R...
- 302. Rear brake breather hose routing
- 303. Fuel system hose routing
- 304. Cooling System Hose Routing
- 305. Front brake hose routing
- 306. Heat Shield Adhesive Position
- 307. Special tools
- 310. Tightening torque
- 312. Tightening torque chart
- 313. Service data
- 320. LT-A500FK1
- 333. FINAL BEVEL GEARS
- 334. REMOVAL AND DISASSEMBLY
- 336. INSPECTION
- 339. REASSEMBLY AND ADJUSTMENT
- 344. REMOUNTING
- 346. WIRING DIAGRAM
- 348. COOLING SYSTEM HOSE ROUTING
File size: 20.34 MB
Created: March 11, 2023
Last updated: April 09, 2023
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