Product Positioning:
Essential resource for owners and technicians seeking dealer-level repair and maintenance capabilities for the Suzuki LT500R Quad Zilla.
Manual Value Proposition:
Provides comprehensive, dealer-equivalent information at a fraction of the cost, empowering DIY enthusiasts and professionals alike.
Unique Selling Points:
Detailed illustrations, step-by-step instructions, extensive coverage of all systems, printable format.
Powertrain Systems:
Engine, Gearbox, Clutch, Transmission, Lubrication System, Cooling System, Fuel System, Ignition System, Electric Starter
Chassis Systems:
Frame, Body Panels, Fenders, Exhaust System, Front Wheel, Steering System, Rear Wheel System, Wheels & Tires
Electrical Systems:
Alternator, Starter Clutch, Battery/Charging System, Lights/Meters/Switches, Wiring Diagrams
Suspension Braking:
Suspension (Front and Rear), Braking System
Diagnostic Repair:
All diagnostic and repair procedures covered
Maintenance Rebuild:
Repair, Maintain, Rebuild, Refurbish, Restore
Depth Of Coverage:
Detailed illustrations, step-by-step instructions, comprehensive technical information and specifications
Engine Rebuild Procedures:
Includes detailed steps for engine removal/installation, disassembly, inspection, and reassembly of internal components (crankcase, piston, cylinder, crankshaft, valves).
Transmission Overhaul:
Covers gearbox and clutch inspection, repair, and overhaul, including transmission system components.
Suspension And Steering Service:
Detailed procedures for servicing the front wheel and steering system, as well as the rear suspension system.
Electrical System Diagnostics:
Comprehensive coverage of the electrical system including alternator, starter clutch, battery/charging system, ignition system, lighting, and detailed wiring diagrams for troubleshooting.
Troubleshooting Guides:
Includes a dedicated troubleshooting section to help diagnose and resolve common problems.
Chassis And Body Repair:
Procedures for working on the frame, body panels, fenders, and exhaust system.
Specifications And Data:
Provides essential technical specifications, torque values, clearances, and data required for accurate repairs and adjustments.
Engine Type:
2-stroke, Liquid-cooled, Single-cylinder
Displacement:
499 cc (30.4 cu. in.)
Bore X Stroke:
86.0 mm x 86.0 mm (3.39 in. x 3.39 in.)
Horsepower Estimate:
Approximately 45-50 HP (exact figures vary by tuning and year)
Torque Estimate:
Not explicitly stated but significant for its class.
Carburetor:
Mikuni VM34SS (or similar, specification varies by year/market)
Fuel Type:
Unleaded gasoline (Octane rating to be specified in manual)
Fuel Injection System:
Not applicable ( carbureted )
Lubrication Type:
Premix or Oil Injection (specify in manual)
Cooling Method:
Liquid-cooled
Overall Length:
Not specified in product info, typical for class 70-80 inches.
Overall Width:
Not specified in product info, typical for class 45-50 inches.
Overall Height:
Not specified in product info, typical for class 40-45 inches.
Dry Weight:
Approx. 370-400 lbs (168-181 kg) depending on year and specific components.
Fuel Capacity:
Approx. 3.2 gallons (12 liters)
Atv Safety Considerations:
High-performance ATV; requires experienced rider, protective gear, and adherence to safe riding practices. Manual covers operational safety.
Braking System:
Hydraulic disc brakes, front and rear
Frame Construction:
Steel frame design, detailed in chassis section.
Infotainment System:
Not Applicable (Basic instrumentation only)
Driver Assistance Features:
Not Applicable
Connectivity Features:
Not Applicable
Ignition System Type:
CDI (Capacitor Discharge Ignition) system with variable timing.
Lighting System:
Headlights, taillights, brake lights, and instrument cluster lighting.
Oil Change Interval:
Refer to manual for specific intervals based on usage; typically every 20-40 hours of operation for gearbox oil.
Air Filter Cleaning:
Frequent cleaning and inspection recommended, especially in dusty conditions, as per manual guidelines.
Spark Plug Replacement:
Refer to manual for recommended service intervals and correct spark plug type (e.g., NGK BR9ES).
Engine Oil Type:
2-stroke engine oil (premix or injector oil type as specified in manual, e.g., API TC grade).
Gearbox Oil Type:
Suzuki recommends specific gear oil for the transmission, likely a SAE 80W API GL-4 or GL-5.
Coolant Type:
Ethylene glycol-based antifreeze mixture (refer to manual for specific mixture ratio and type).
Common Wear Points:
Clutch wear, piston ring wear, carburetor jetting issues, electrical connector corrosion, exhaust system leaks. Manual provides diagnostic procedures for these.
Performance Tuning:
Manual provides baseline specifications for engine tuning, carburetor settings, and ignition timing.
