Suzuki LT 500R 1987 Service Repair Manual

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Tipo: Atv

Proveedor:

SKU: 92795

Etiquetas: 1987 Atv LT 500R Misc Motorcycles Suzuki

Variantes de producto

Descripción

The 1987 Suzuki LT500R, affectionately known as the "King Quad," is a high-performance All-Terrain Vehicle (ATV) engineered for recreational and competitive use. Suzuki's pursuit of power and durability is evident in this model, which was developed as a potent successor to earlier sport ATVs, emphasizing powerful engine output and agile handling for aggressive riding. This liquid-cooled, 2-stroke ATV, with its 499cc engine and 6-speed manual transmission, offered exceptional performance for its era, positioning it as a formidable competitor in the sport ATV market. This comprehensive service and repair manual provides detailed information for owners and technicians alike. It covers all major systems of the 1987 Suzuki LT500R, including complete engine disassembly and assembly, cooling system service, fuel system tuning, ignition system troubleshooting, transmission and drivetrain maintenance, suspension and brake system overhauls, and electrical system diagnostics. The manual includes step-by-step repair instructions, exploded view diagrams, wiring schematics, and troubleshooting guides to ensure optimal performance, reliability, and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

LT500R

Year:

Nickname:

King Quad

Vehicle Type:

All-Terrain Vehicle (ATV)

Codes

Vin Code:

Refer to VIN plate location in manual

👋 Introduction

Market Position

Market Segment:

High-performance sport ATV for recreational and competitive use.

Target Audience:

Enthusiasts and owners seeking detailed maintenance and repair information.

Competitive Analysis

Competitors 1987:

Yamaha Banshee, Kawasaki Tecate-4, Honda TRX250R

Key Features

Performance Focus:

Emphasized powerful engine and agile handling for aggressive riding.

Engineering Philosophy:

Suzuki's pursuit of power and durability in the ATV market.

📋 Manual Details

Coverage Areas

Manual Type:

Service Manual / Repair Manual

Language:

English

Format:

Digital Download (PDF)

Page Count

Page Count:

Estimated 200+ pages (based on typical service manual scope)

Manual Type

Manual Classification:

Comprehensive Diagnostic and Repair Guide

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, tuning, troubleshooting, including top-end and bottom-end components.

Cooling System:

Radiator, fan, thermostat, coolant flow, troubleshooting coolant leaks.

Fuel System:

Carburetor (Mikuni VM series) tuning, cleaning, jetting, fuel pump, fuel lines, fuel tank maintenance.

Ignition System:

CDI unit, ignition coil, spark plug specifications, timing, troubleshooting ignition failures.

Transmission:

Clutch operation, gear shifting mechanism, gearbox disassembly and assembly, lubrication.

Drivetrain:

Chain drive system, sprockets, swingarm, rear axle maintenance and adjustment.

Suspension:

Front suspension (telescopic forks), rear suspension (shock absorber, linkage), adjustment, service, and overhaul.

Brakes:

Front and rear brake systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, caliper and master cylinder service.

Electrical System:

Lighting, battery, wiring diagrams, stator, starter motor (if applicable), troubleshooting electrical faults.

Chassis Frame:

Frame inspection, steering system, wheel bearings, hubs.

Bodywork:

Fender removal, seat service, plastic panel maintenance.

Procedures Included

Maintenance:

Regular maintenance checks, lubrication points, filter replacement, battery care.

Troubleshooting:

Diagnostic charts for common performance issues, starting problems, and system failures.

Repair:

Step-by-step instructions for component removal, replacement, and reassembly for all major systems.

Overhaul:

Detailed procedures for complete engine and gearbox rebuilds.

Adjustments:

Carburetor tuning, clutch adjustment, chain tensioning, suspension settings.

Diagnostics:

Electrical system diagnostics, performance tuning guidance.

Technical Depth

Depth Level:

Comprehensive, covering everything from basic adjustments to complete engine rebuilds.

Diagrams Illustrations:

Includes detailed exploded view diagrams, wiring schematics, and step-by-step illustrated procedures.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text for quick access to information.

Print Quality

Image Resolution:

High resolution for clear viewing of diagrams and text.

Printability:

Printable for home or workshop use.

Binding Type

Binding Type:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke, Reed Valve, Liquid-Cooled

Displacement:

499 cc (30.45 cubic inches)

Bore X Stroke:

85.0 mm x 88.0 mm (3.35 in x 3.46 in)

Compression Ratio:

6.2:1

Carburetor:

Mikuni VM34SS, Single

Ignition:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower:

Approx. 45-50 HP (manufacturer specific, unconfirmed exact figure)

Torque:

Not officially published, but high for its class.

Fuel System

Fuel Type:

Unleaded gasoline (91-93 octane recommended)

Fuel Mixture:

Pre-mix 2-stroke oil (e.g., Yamalube 2R or equivalent) at 50:1 ratio.

🔧 Transmission

Standard

Transmission Type:

6-Speed Manual with Reverse

Clutch Type:

Wet, Multi-Disc

Final Drive:

O-ring sealed chain (520 pitch recommended)

Features

Gear Ratios:

Refer to manual for specific gear ratios.

📐 Dimensions

Exterior

Length:

Approx. 71.9 inches (1825 mm)

Width:

Approx. 45.7 inches (1160 mm)

Height:

Approx. 45.7 inches (1160 mm)

Wheelbase:

Approx. 49.6 inches (1260 mm)

Weights

Dry Weight:

Approx. 370 lbs (168 kg)

Fuel Capacity:

3.2 US gal (12.1 L)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet ANSI safety standards for ATVs of its era.

Active Features

Throttle Limiter:

Thumb throttle with governor (adjustable)

Braking System:

Dual hydraulic front disc brakes, single hydraulic rear disc brake.

Passive Features

Handlebar Design:

Handlebar with padded crossbar and handguards for control and protection.

Footwells:

Wide footwells with grip pattern for rider stability.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic functionality for its era)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

Performance Tech

Engine Cooling:

Liquid-cooled for consistent performance under load.

Ignition System Type:

CDI system for reliable spark generation.

🔧 Maintenance

Service Intervals

Oil Change Engine:

Check and top-up 2-stroke oil as needed. Refer to manual for specific transmission oil change intervals.

Air Filter Cleaning:

Clean every 10-20 hours of operation, depending on conditions.

Spark Plug Replacement:

Replace every 20-30 hours or as needed based on performance.

Chain Lubrication:

Lubricate chain every 20-30 hours, adjust tension as needed.

Fluid Specifications

Engine Oil Type:

High-quality 2-stroke synthetic blend oil, ratio 50:1 (refer to manual for specific recommendations).

Transmission Oil Type:

API GL-4, SAE 80W/90 Gear Oil (Capacity: 0.8 L / 0.85 US qt)

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid

Coolant Type:

Permanent type antifreeze coolant (50/50 mix with distilled water)

Known Issues

Carburetor Fouling:

Can be prone to fouling due to rich jetting or poor fuel quality; requires regular cleaning/tuning.

Engine Overheating:

If not properly maintained or if cooling system has leaks.

Clutch Wear:

Normal wear and tear; requires adjustment or replacement over time depending on usage.

Suspension Seals:

Fork seals can leak over time; requires periodic inspection and replacement.

📚 Vehicle History

Brand Heritage

Suzuki Atv History:

Suzuki has a long-standing reputation for performance-oriented motorcycles and ATVs.

Model Evolution

Lt500R Development:

Developed as a high-performance successor to earlier Suzuki sport ATVs, aiming for top-tier power and handling.

Production

Production Years:

1987-1989

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Performance Awards:

Highly regarded in its time for performance and racing capabilities within the ATV community.