Suzuki Vinson LT-A500F Manual de usuario

SUZUKI

LT-A500F

SERVICE

MANUAL

FOREWORD

This

manual contains an introductory description on

the

SUZUKI

LT-A500F and procedures for its

inspection, service, and overhaul of its main compo-

nents.

Other

information

considered as generally known is

not included.

Read

the

GENERAL

INFORMATION section to

familiarize

yourself

with

the vehicle and its mainte-

nance.

Use this section as well as other sections as

aguide for proper inspection and service.

This

manual

will

help you know the vehicle better so

that

you can assure your customers of fast and

reli-

able service.

This

manual has been prepared on the

basis

of the latest specifications at the

time

of publication. If modifications have been

made since then, differences may exist

between

the content of this manual and the

actual vehicle.

*Illustrations in this manual are

used

to show

the basic principles of operation and work

procedures.

They may not represent the

actual vehicle exactly in detail.

This

manual is

written

for persons who have

enough knowledge, skills and tools, includ-

ing special tools, for servicing

SUZUKI

vehi-

cles.

If you do not have the proper

knowledge and tools, ask your authorized

SUZUKI

motorcycle dealer to help you.

WARNING

Inexperiencedmechanicsormechanics

without

thepropertoolsandequipment

maynotbeabletoproperly

perform

the

services

describedinthismanual.

Improper

repairmayresultininjurytothe

mechanicandmayrenderthevehicle

unsafefortherider.

GROUP

INDEX

GENERAL

INFORMATION

PERIODIC

MAINTENANCE

ENGINE

SHAFT

DRIVE AND

DIFFERENTIAL

GEARS

FUEL

AND LUBRICATION

SYSTEM

COOLING

SYSTEM

CHASSIS

ELECTRICAL

SYSTEM

SERVICING

INFORMATION

LT-A500FK1

('01-MODEL)

SUZUKI

MOTORCORPORATION

Motorcycle

Service

Department

SUZUKI

MOTOR

CORPORATION

1999

HOWTOUSETHISMANUAL

TOLOCATE

WHAT

YOUARELOOKING

FOR:

The

text

this

manualisdividedintosections.

Thesection

titles

are

listed

inthe

GROUP

INDEX.

3.Holdingthemanualasshownattheright

will

allowyou

findthe

first

pageofthesectioneasily.

Thecontentsare

listed

the

first

page

eachsec-

tion

tohelpyoufindtheitemandpageyouneed.

COMPONENTPARTSANDWORKTOBEDONE

Underthename

eachsystem

unitthere

isan

explodedviewwhichprovidesworkinstructions

and

other

serviceinformation(e.g.;

tightening

torque,

lubricating

points,andlockingagentpoints).

Example:Frontbrake

Mastercylinderreservoircap

Diaphragm

Mastercylinderclamp

Boot

Piston/cupset

©Cup

Spring

Mastercylinder

BrakehoseNo.1

BrakehoseNo.2

BrakehoseNo.3

Brakepipejoint

Brakepipe,

Piston

Pistonseal

Dust

seal

Brakecaliper

Brakecaliperholder

Brakepad

PadSpring

Mastercylinderclampbolt

Brakehoseunionbolt

Brakepipenut

Airbleedervalve

Brakecalipermountingbolt

Brakepadmountingpin

ITEM Nm

kgf-m

Ib-ft

10 1.0 7.0

23 2.3 16.5

16 1.6 11.5

7.5 0.75 5.0

26 2.6 19.0

18 1.8 13.0

SYMBOL

Listed

thetablebelow

are

thesymbolsindicating

instructions

and

otherinformationnecessary

for

servic-

ing.

The

meaning

eachsymbol

alsoincluded

thetable.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Torquecontrolrequired.

Databesideitindicatesspecified

torque.

Apply

THREADLOCKSUPER

"1305".

99000-32100

Indicates

servicedata. Apply

THREADLOCKSUPER

"1322".

99000-32110

(Except

USA)

Apply

oil.

Use

engineoilunless

otherwise

specified. Apply

THREADLOCK

"1342".

99000-32050

Applymolybdenumoilsolution,

(mixture

engineoil

andSUZUKI

MOLYPASTEin

ratio

: 1)

Apply

use

brake

fluid.

Apply

SUZUKISUPERGREASE

"A".

99000-25030

(For

USA)

99000-25010

(For

theothercountries)

Measure

voltagerange.

Apply

SUZUKI

SILICONEGREASE.

99000-25100

Measure

resistancerange.

Apply

SUZUKIMOLYPASTE.

99000-25140

Measure

currentrange.

Apply

WATERRESISTANCEGREASE

99000-25160

Measure

diode

test

range.

^12Q7B]

Apply

SUZUKIBOND

"1207B".

99104-31140

(For

USA)

99000-31140

(For

theothercountries)

Measure

continuity

test

range.

^1215]

Apply

SUZUKIBOND

"1215".

99000-31110

(Except

USA)

Usespecial

tool.

^1216]

Apply

SUZUKIBOND

"1216".

99104-31160

(For

USA)

99000-31160

(For

theothercountries)

Useenginecoolant.

99000-99032-11X

(Except

USA)

Apply

THREADLOCKSUPER

"1303".

99000-32030

GENERAL

INFORMATION

GENERAL

INFORMATION

CONTENTS

WARNING/CAUTION/NOTE 1- 2

GENERAL

PRECAUTIONS 7-2

SUZUKI LT-A500FY (2000-MODEL) 1- 4

SERIAL

NUMBER LOCATION 1- 4

FUEL,

OIL, AND ENGINE COOLANT RECOMMENDATIONS 1- 4

FUEL

1- 4

ENGINE OIL 1- 5

DIFFERENTIAL

GEAR

AND FINAL

BEVEL

GEAR

OIL 1- 5

BRAKE

FLUID 1- 5

ENGINE COOLANT 1-5

BREAK-IN

PROCEDURES 1- 6

INFORMATION

LABELS

1- 7

SPECIFICATIONS

1- 8

COUNTRY AND AREA CODES 1-10

1-2

GENERAL

INFORMATION

WARNING/CAUTION/NOTE

Pleasereadthismanualandfollowitsinstructionscarefully.

emphasizespecialinformation,thesymbol

andthewords

WARNING,

CAUTION

and

NOTE

havespecialmeanings.Payspecialattentiontothemes-

sageshighlightedbythesesignalwords.

WARNING

Indicatesa potentialhazard

that

couldresultindeathorinjury.

ACAUTIOINT

Indicatesa potentialhazard

that

couldresultinvehicledamage.

NOTE:

Indicates

special information to make maintenance

easier

or instructions clearer.

Pleasenote,however,thatthewarningsandcautionscontained

thismanualcannotpossiblycoverall

potential

hazardsrelatingtotheservicing,

lackofservicing,ofthevehicle.Inadditiontothe

WARNINGS

and

CAUTIONS

stated,youmustusegoodjudgementandbasicmechanicalsafetyprinciples.

you

are

unsureabouthowtoperform

particularserviceoperation,ask

moreexperiencedmechanicforadvice.

GENERAL

PRECAUTIONS

WARNING

*Properserviceandrepairproceduresare

important

forthesafetyoftheservicemechanic

andthesafetyandreliabilityofthevehicle.

*Whentwoormorepersonsworktogether,pay

attention

tothesafetyofeachother.

*Whenitisnecessarytoruntheengineindoors,makesure

that

exhaustgasisforcedout-

doors.

*Whenworking

with

toxicorflammablematerials,makesure

that

theareayouworkiniswell

ventilatedand

that

you

allofthemanufacturer'sinstructions.

*Neverusegasolineasa cleaningsolvent.

*Toavoid

getting

burned,donottouchtheengine,engineoil,radiator,andexhaustsystem

until

theyhavecooled.

After

servicingthefuel,oil,enginecoolant,exhaustorbrake

systems,

checkallofthelines,

and

fittings

relatedtothesystemforleaks.

GENERAL

INFORMATION1-3

ACAUTION

*Ifpartsreplacementis

necessary,

replacethepartswithSUZUKIGenuinePartsortheir

equivalent.

*Whenremovingpartsthat aretobereused,keepthemarrangedinanorderlymannerso

that theymaybereinstalledintheproperorder.

*Besuretousespecialtoolswheninstructed.

*Makesurethat allpartsusedinreassemblyareclean.Lubricatethemwhenspecified.

*Usethespecifiedlubricants,bonds,or

sealants.

*Whenremovingthebattery,

disconnect

the0 batteryleadwirefirst,thenthe0 batterylead

wire.

*Whenreconnectingthebattery,connectthe0 batteryleadwirefirst,thenthe0 battery

leadwire.Finally,coverthe© batteryterminalwiththeterminalcover.

*Whenperformingservicetoelectricalparts,disconnectthe0 batteryleadwire,

unless

the

service

procedurerequiresthebatterypower.

*Whentighteningcylinderheadand

crankcase

nutsandbolts,tightenthelarger

sizes

first.

Always

tightenthenutsandboltsfromtheinsideworkingout,diagonallyandtothe

speci-

fiedtorque.

*Wheneveryouremoveoil

seals,

gaskets,packing,O-rings,self-lockingnuts,locking

wash-

ers,

cotterpins,

circlips,

andotherspecifiedparts,besuretoreplacethemwithnew

ones.

Also,

beforeinstallingthesenewparts,besuretoremoveany

left

overmaterialfromthe

mating

surfaces.

*Neverreusea circlip.Wheninstallinga newcirclip,takecarenottoexpandtheendgap

largerthanrequiredtoslipthecirclipovertheshaft.Afterinstallinga circlip,alwaysensure

itiscompletelyseatedinitsgrooveandsecurelyfitted.

*Usea torquewrenchtotightenfastenerstothespecifiedtorque.Wipeoffgreaseandoilifa

threadissmearedwiththem.

*After

reassembling,

checkpartsfortightnessandproperoperation.

*Toprotecttheenvironment,donotunlawfullydisposeofusedmotoroil,enginecoolant,all

otherfluids,batteries,andtires.

*Toprotecttheearth'snatural

resources,

properlydisposeofusedvehiclesandparts.

1-4

GENERAL

INFORMATION

SUZUKILT-A500FY(2000-MODEL)

RIGHT

SIDE

LEFT

SIDE

Differencebetweenphotographs andtheactualvehicles

depends

onthemarkets.

SERIAL

NUMBERLOCATION

TheframeserialnumberorV.I.N.(VehicleIdentification

Number)

isstampedontherightsideoftherear

framepipe.

The

engineserialnumber

located

the

left

side

thecrankcase.

These

numbersare

requiredespeciallyforregisteringthemachineandorderingspareparts.

FUEL,

OIL,ANDENGINECOOLANTRECOMMENDATION

FUEL

(ForUSA)

•

Useonlyunleadedgasoline

ofat

least

pump

octane

(R * M )

method

91octane

higherrated

bytheResearchMethod.

•

SUZUKI

recommendsthatcustomersusealcohol-freeunleadedgasolinewheneverpossible.

•

Use

blendedgasolinecontaining

MTBE

(MethylTertiaryButylEther)ispermitted.

•

Use

blendedgasoline/alcoholfuelispermitted,providedthatthefuelcontainsnotmorethan10%eth-

anol.

Gasoline/alcoholfuelmaycontainupto5%methanolifappropriatecosolventsandcorrosioninhib-

itors

arepresentinit.

•

Iftheperformance

thevehicle

unsatisfactorywhileusingblendedgasoline/alcohol

fuel,

youshould

switch

toalcohol-freeunleadedgasoline.

•

Failuretofollowtheseguidelinescouldpossiblyvoidapplicablewarrantycoverage.Check

with

yourfuel

suppliertomakesurethatthefuelyouintendtousemeetstherequirementslistedabove.

GENERAL

INFORMATION

1-5

FUEL

(ForCANADA)

Useonlyunleadedgasoline

ofat

least

pumpoctane

(

R *^

) or

91octane

higherrated

the

ResearchMethod.

FUEL

(Fortheothercountries)

Useunleadedgasolinethatisgraded91octaneorhigherbytheResearchMethod.

ENGINE

OIL(ForUSA)

SUZUKI

recommendstheuse

SUZUKI

PERFORMANCE

MOTOR

OILoroilsthatmeetAPIserviceclassifications

SGandthathave

viscosityrating

ofSAE

10W/40.

engine

oil

with

ratingofSAE

10W/40

isnotavailable,selectanalter-

nativeaccordingtothechart.

ENGINE

OIL(Fortheothercountries)

Use

premiumquality4-strokemotoroiltoensurelongerser-

vice

life

yourvehicle.

Use

onlyoilsthatmeetAPIservice

classifications

SForSGand

thathave

viscosityrating

SAE

10W/40.

engineoil

with

rating

ofSAE

10W/40

not

available,selectanalternativeaccordingtothechart.

DIFFERENTIAL

GEAR

ANDFINAL

BEVEL

GEAR

OIL

UsehypoidgearoilthatmeetstheAPIserviceclassificationGL-5andisratedSAE#90.Use

hypoidgear

oil

with

rating

SAE#80ifthevehicleisoperatedwheretheambienttemperatureisbelow

0°C

(32°F).

BRAKE

FLUID

Specification

and

classification:

DOT4

AWARNING

This

vehicle

uses

glycol-basedbrakefluid.Donotuseormixdifferenttypes

brakefluid

such

silicone-based

andpetroleum-basedfluidsforrefillingthe

system,

otherwiseserious

damagewillresulttothebrake

system.

Neveruseanybrakefluidtakenfromold,

used,

orunsealedcontainers.

Neverreusebrakefluid

left

overfromthelastservicingorwhichhasbeenstoredfor

long

periodoftime.

ENGINE

COOLANT

Sinceantifreezealsohascorrosion-andrust-inhibitingproperties,alwaysuseenginecoolantcontaining

antifreeze,eveniftheatmospherictemperaturedoesnotgobelowthefreezingpoint.

Useanantifreezedesignedforaluminumradiators.

SUZUKI

recommendstheuse

SUZUKI

COOLANT

antifreeze.Ifthisisnotavailable,useanequivalentantifreezeforaluminumradiators.

Mix onlydistilledwater

with

theantifreeze.Othertypesofwatercancorrodeandclogthealuminumradia-

tor.

Mixdistilledwaterandantifreezeata ratioof50:50

40:60.

Formoreinformation,refertopage6-5intheCoolingSystemsection.

MULTIGRADE

Mt.wgi.mr.iva^

°C

TEMP

•

-30

-20-10

0 10203040

°F -22

-41432506886

104

1-6

GENERAL

INFORMATION

ACAUTION

The

percentageofantifreezeinthecoolantshouldbebetween50to60%.Ifthepercentageof

antifreezeisaboveorbelowthisrangethecoolant'sfrostprotectionandrust-inhibiting

capa-

bilities

will

bereduced.Alwayskeeptheantifreezecontentabove50%eveniftheatmospheric

temperaturedoesnotgobelowthefreezingpoint.

BREAK-IN

PROCEDURES

Duringmanufacturingonlythebestpossiblematerialsareusedandallmachinedpartsarefinishedto

veryhighstandard.

Itis

still

necessary

allowthemovingparts

"BREAK-IN"

beforesubjecting

the

enginetomaximumstresses.Thefutureperformanceand

reliability

oftheenginedependsonthecareand

restraint

exercisedduringitsearly

life.

Refertothefollowingbreak-inenginespeedrecommendations.

•

Keeptothesebrake-inenginespeed

limits.

Break-in

engine

speeds

Initial

500km(300miles):

Less

than12

throttle

•

Upon

reaching

odometerreading

500km(300miles)youcansubjectthevehicleto

full

throttle

operation,

forshortperiodsof

time.

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