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LT-F500F 2002
Suzuki LT-F500F 2002 User Manual
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7-42
CH
ASS
IS
REMOVAL AND DI
S
A
S
SEMBLY
•
Rem
ov
e the fr
ont fen
der
. (
!
7-
6
)
•
Rem
ov
e the fr
ont w
hee
l. (
!
7-1
1)
•
Remove the master cyli
nder asse
mbly. (
!
7-
28
)
•
Rem
ov
e the th
ro
ttle lever
case.
•
Di
sconne
ct th
e
rear
brake
cab
le
1
and rem
ove the
hand
lebar
switch
2
.
•
Remove the auxi
liary li
ght cover
3
.
•
Remove the sp
eedometer co
ver
4
.
•
Remove the speed
ometer assembly
5
.
265
267
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
5
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Suzuki LT-F500F 2002 Specifications
General
Brand
Suzuki
Model
LT-F500F 2002
Category
Offroad Vehicle
Language
English
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