Segment:
High-performance sport ATV
Reputation:
Known as the 'QuadZilla,' a powerful and iconic machine in its era
Competitors Era:
Competed against other high-performance 2-stroke ATVs from brands like Yamaha (Banshee), Kawasaki (Tecate), and Honda (CR250R-based ATVs)
Engine Type:
2-stroke, liquid-cooled
Performance Focus:
Emphasis on raw power and off-road performance
Durability:
Designed for demanding off-road use
Manual Benefit:
Empowers owners to perform their own repairs and maintenance, saving money and extending vehicle life
Vehicle Years Covered:
1987, 1988, 1989, 1990
Vehicle Models Covered:
Suzuki LT500R QuadZilla, Suzuki LTR500 QuadZilla
Type:
Repair and Service Manual
Designation:
Factory Service Manual / Workshop Manual / Repair Guide
Primary Language:
English
Delivery Method:
Digital Download
File Compression:
ZIP (may require WinZip or WinRAR)
Compatibility:
Windows, Linux, Mac, PC & MAC compatible
Print Permissions:
Printable
Save Permissions:
Savable to multiple devices
File Size Note:
Can be large (up to 5GB), check storage space
Engine:
Complete engine overhaul, troubleshooting, rebuild, specific components (cylinder, piston, conrod, crankshaft, flywheel, magneto, stator, etc.)
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel tank, mixture screw adjustments
Ignition System:
Ignition system troubleshooting, magneto, coil, spark plug, ignition timing
Transmission:
Transmission overhaul, repair, troubleshooting, gearshift mechanism, primary reduction gear
Drive Train:
Drive shaft, swingarm, rear axle, suspension components (struts, bogey)
Brakes:
Front and rear brake system diagnosis, repair, pads, rotors
Cooling System:
Radiator, coolant, fluid specifications, coolant change procedures
Electrical System:
Charging system, battery, rectifier, wiring diagrams (schematic), switches, lights
Body And Frame:
Frame, plastics, fenders, seat, hull, panels, installation procedures
Suspension Steering:
Front forks, triple trees, steering system, wheel alignment, wheel bearing maintenance
Maintenance:
Preventative maintenance, scheduled service, fluid changes, lubrication, filter replacements
Troubleshooting:
Comprehensive troubleshooting guides, common issues, error codes, no spark diagnosis
Repair:
Step-by-step repair instructions for all major components and systems
Rebuild:
Complete engine rebuild, transmission rebuild, carburetor rebuild (if applicable/mentioned)
Diagnostics:
Diagnostic procedures for electrical and mechanical issues
Installation:
Installation instructions for various parts and accessories
Depth Level:
Highly detailed, covering all aspects for repair, service, restoration, maintenance, rebuilding, and diagnosis
Target Audience:
Professional technicians, mechanics, workshops, and DIY enthusiasts
Illustration Quality:
Illustrated with clear step-by-step instructions
Special Features:
Exploded views, detailed component breakdowns, torque specifications, fluid specifications, reference charts
Engine Type:
2-stroke, liquid-cooled, reed valve
Displacement:
499cc (approx.)
Bore X Stroke:
Not specified in product info, but typically around 69.0 mm x 68.4 mm for this engine family.
Compression Ratio:
Manual will contain specific figure (e.g., 6.8:1 or similar for its era).
Horsepower:
Estimated 45-55 HP (stock, varies by tune and source)
Torque:
Manual will provide specific torque figures.
Carburetor:
Mikuni TMX30 or similar (check manual for exact type and jetting data)
Fuel Injection System:
The product description mentions 'efi' and 'fuel injection', which is unusual for the standard LT500R which typically used a carburetor. This might indicate a specific variant or a slight inaccuracy in the description. The manual would clarify this definitively.
Fuel Type:
Unleaded gasoline (manual will specify octane rating)
Oil Type:
2-stroke engine oil, premix or oil injection system (manual will specify)
Valve Clearance:
Not applicable for a 2-stroke engine without valves in the traditional sense (refer to port timing in manual).
Starter System:
Kick start (Kicker)
Length:
Manual will contain exact dimensions, likely around 73 inches.
Width:
Manual will contain exact dimensions, likely around 47 inches.
Height:
Manual will contain exact dimensions, likely around 44 inches.
Dry Weight:
Manual will specify, typically around 380-400 lbs.
Weight Distribution:
Manual will provide information on weight distribution for service purposes.
Cargo Capacity:
Not applicable for this type of vehicle.
Oil Change Engine:
Manual will provide specific intervals for engine oil (if applicable to gearbox oil) and 2-stroke oil.
Air Filter Cleaning:
Recommended based on operating conditions, detailed in the manual.
Spark Plug Check:
Recommended at regular intervals, with specific torque and gap settings in the manual.
Chain Lubrication Tension:
Regularly recommended, with procedures and specifications in the manual.
Engine Oil Type:
Manual specifies 2-stroke oil grade and type (e.g., API TC, JASO FD).
Transmission Oil:
Manual specifies type and viscosity for gearbox oil (e.g., SAE 80W/90 GL-4).
Coolant Type:
Manual specifies type of antifreeze/coolant and mixture ratio.
Brake Fluid:
Manual specifies DOT 3 or DOT 4 brake fluid.
2 Stroke Maintenance:
2-stroke engines require regular top-end maintenance (piston, rings) due to higher wear rates; manual details this.
Carburetor Cleaning:
Carburetors can be prone to clogging if fuel is not fresh or if stored improperly; manual guides cleaning and tuning.
Cooling System Efficiency:
Ensuring proper coolant flow and radiator cleanliness is crucial for preventing overheating.
Suspension Wear:
As a performance ATV, suspension components can experience wear over time; manual provides adjustment and replacement procedures.
