The Suzuki LT500R QuadZilla, produced from 1987 to 1990, stands as a testament to Suzuki's prowess in the high-performance all-terrain vehicle market. This powerful 2-stroke ATV, featuring a liquid-cooled 499cc engine and a 6-speed manual transmission, was engineered for aggressive sport riding and off-road capability. Known for its potent power delivery and agile handling, the QuadZilla competed effectively in its segment, offering enthusiasts a thrilling and capable machine. Its robust construction and performance-oriented design made it a significant model in Suzuki's ATV history, appealing to riders seeking an adrenaline-fueled experience.
This comprehensive service manual provides essential information for the maintenance, repair, and restoration of 1987-1990 Suzuki LT500R QuadZilla ATVs. Covering all major systems, including the engine, cooling, fuel, electrical, drivetrain, chassis, and brakes, it offers detailed step-by-step procedures, diagnostic guidance, and factory specifications. From routine maintenance and tune-ups to complete engine overhauls and component replacements, this manual is an invaluable resource for owners, technicians, and mechanics. It includes critical data such as torque specifications, fluid types, and troubleshooting tips for common issues, ensuring the QuadZilla can be kept in optimal working condition.
Vehicle Type:
All-Terrain Vehicle (ATV)
Generation:
First Generation
Production Years Covered:
1987, 1988, 1989, 1990
Model Codes:
LT500R (1987), LT500RJ (1988), LT500RK (1989), LT500RL (1990)
Market Position:
The Suzuki LT500R QuadZilla was a high-performance sport ATV in its era, known for its powerful engine and aggressive styling. This manual serves as an indispensable tool for owners and enthusiasts seeking to maintain, repair, and restore these iconic machines.
Competitive Analysis:
Competed against other high-performance 2-stroke ATVs of the late 1980s, offering significant power and agility. This manual provides the critical technical data needed to keep these machines running at their peak, a key differentiator for enthusiasts.
Key Features:
Comprehensive coverage for multiple model years, detailed step-by-step instructions, clear illustrations and diagrams, troubleshooting guide, factory-level repair information, DIY friendly. Instant download capability.
Coverage:
Complete service, repair, and maintenance for 1987-1990 Suzuki LT500R QuadZilla ATVs.
Manual Type:
Service Manual / Repair Manual / Workshop Manual / Factory Manual
Format:
Digital Download (PDF, ZIP, RAR, EXE)
Systems:
Engine (rebuild, tune-up, diagnostics), Cooling System, Fuel Systems (carburetor, fuel pump, EFI for applicable models), Electrical System (ignition, charging system, battery, wiring diagrams), Chassis, Suspension (front forks, rear shock/strut), Drivetrain (transmission, clutch, drive shaft, rear axle), Brakes (front and rear), Steering, Bodywork (fenders, plastics), Wheels and Tires.
Procedures:
Periodic maintenance, tune-up procedures, engine overhaul, troubleshooting common problems, repair and replacement of all major components, carburetor adjustment, suspension setup, electrical diagnostics, brake servicing, lubrication, fluid changes, installation procedures, preventative maintenance.
Depth:
Comprehensive from basic maintenance and adjustments to complete engine rebuilds, transmission overhauls, and advanced electrical diagnostics. Includes torque specifications, clearances, fluid types and capacities, and detailed step-by-step instructions with illustrations.
File Format Details:
PDF format, compatible with all PDF readers. May be zipped/compressed requiring extraction software (WinZip, WinRAR). Digital delivery, no physical copy. File size can be up to 5GB. Printable and savable.
Print Quality:
High-resolution digital scan, suitable for printing. Zoomable illustrations and diagrams.
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
499cc (499 cubic centimeters)
Bore X Stroke:
85.0 mm x 87.0 mm (approximate)
Compression Ratio:
7.4:1 (approximate, check manual for specific year variations)
Horsepower:
Approx. 45-50 HP (varies slightly by year and tune)
Torque:
Refer to manual for specific torque figures.
Carburetor:
Mikuni VM34SS (typically)
Fuel Injection:
Not standard on all models; early models are carbureted. Some later iterations or modifications might exist.
Cooling Type:
Liquid-cooled
Oil Type:
2-stroke engine oil, specific mix ratio with gasoline or oil injection system (refer to manual for exact specifications and pre-mix ratio).
Transmission Type:
6-speed manual with clutch
Optional Transmission:
N/A
Features:
Constant mesh, foot-operated gear shifter.
Transmission Oil Type:
Refer to manual for specific transmission oil type and capacity (typically gear oil).
Overall Length:
Refer to manual for exact dimensions.
Overall Width:
Refer to manual for exact dimensions.
Overall Height:
Refer to manual for exact dimensions.
Dry Weight:
Approx. 350-370 lbs (159-168 kg, varies by year)
Fuel Capacity:
Approx. 2.6 gallons (9.8 liters, check manual for exact figure)
Safety Ratings:
N/A (ATVs typically do not receive standardized crash ratings like cars).
Active Safety Features:
Disc brakes (front and rear), robust suspension system designed for off-road stability.
Passive Safety Features:
Durable frame construction, integrated grab bars.
Infotainment System:
N/A (Basic ATV instrumentation: speedometer, odometer, neutral indicator, high beam indicator).
Driver Assistance Features:
N/A
Connectivity Options:
N/A
Periodic Maintenance Schedule:
The manual provides detailed schedules for checks and services at specific mileage or usage intervals, including oil changes, filter replacements, chain adjustment, spark plug checks, and brake inspections.
Engine Oil Type:
High-quality 2-stroke engine oil, specifically formulated for air-cooled or liquid-cooled 2-stroke engines. Refer to manual for recommended viscosity grade and brand/type, and the exact fuel-to-oil pre-mix ratio or if an oil injection system is used.
Coolant Type:
Ethylene glycol-based antifreeze coolant (typically 50/50 mix with distilled water). Refer to manual for specific coolant type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
Common Problems:
Overheating due to cooling system issues, carburetor tuning difficulties, clutch wear, 2-stroke engine wear (piston rings, cylinder), suspension component wear, electrical gremlins. The manual details troubleshooting for these and other potential issues.
Torque Specifications:
Extensive list of torque specifications for engine components, suspension, brakes, wheels, and chassis fasteners is included in the manual.
Valve Clearance:
N/A (This is a 2-stroke engine, it does not have valves in the traditional sense).
Brand Heritage:
Suzuki has a long-standing reputation for performance and reliability in the powersports industry, including a strong history in ATV manufacturing.
Model Evolution:
The LT500R QuadZilla was a significant machine for Suzuki, representing their entry into the high-performance, large-displacement sport ATV market. It was known for its potent 2-stroke engine inherited from Suzuki's motorcycle lineage.
Production Period:
Early production focused on the LT500R, with model year designations (RJ, RK, RL) indicating minor updates and variations over its initial production run from 1987 to 1990.
Industry Recognitions:
The LT500R QuadZilla was recognized in its time as a potent and capable sport ATV, often praised for its performance and power. Specific awards are not typically cataloged for individual ATV models of this era.
