Positioning:
A high-performance, sport-oriented ATV, the LT500R was a significant player in the racing and recreational ATV market of its era.
Key Competitors:
Yamaha Banshee, Honda TRX250R/300EX, Kawasaki Tecate-4.
Performance Focus:
Renowned for its powerful two-stroke engine and agile handling, appealing to riders seeking a thrilling and competitive experience.
Target User:
Enthusiast owners, mechanics, and DIY repairers working on the Suzuki LT500R Quadzilla.
Primary Coverage:
Mechanical, electrical, and bodywork repair and maintenance for the Suzuki LT500R Quadzilla.
Secondary Coverage:
Troubleshooting, diagnostics, specifications, and diagrams.
Type:
Comprehensive Service and Repair Manual
Format:
Digital (likely PDF)
Format:
Digital Download (e.g., .zip containing PDF files)
Quality:
High resolution, suitable for printing with clear diagrams and text.
Type:
N/A (Digital Format)
Type:
N/A (Digital Format)
Engine System:
Engine overhaul, top-end, bottom-end, cooling, lubrication, ignition, starting, charging.
Fuel System:
Carburetor system (Mikuni VM), fuel tank, fuel lines, fuel pump.
Transmission System:
Clutch operation, gearbox disassembly, assembly, lubrication, and adjustment.
Drivetrain System:
Shaft drive, rear differential, axle components, wheel hubs.
Suspension System:
Front and rear suspension components, shock absorbers, linkage, bearings.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, pads, rotors, bleeding procedures.
Electrical System:
Wiring diagrams, lighting, ignition system, battery, charging system, starter motor, control circuits.
Frame And Body:
Frame inspection, body panels, fenders, seat, handlebars, controls.
Cooling System:
Radiator, coolant, fan, hoses, thermostat.
Exhaust System:
Muffler, pipe, gaskets, heat shields.
Maintenance Procedures:
Routine checks, oil changes, filter replacements, spark plug service, chain adjustment, brake adjustments.
Troubleshooting Procedures:
Diagnosing common and uncommon problems with detailed step-by-step guides.
Repair Procedures:
Detailed instructions for component disassembly, repair, and reassembly.
Diagnostic Procedures:
Component testing, electrical circuit diagnosis, engine performance checks.
Special Tool Requirements:
Identification of necessary special tools for specific repair operations.
Depth Level:
Comprehensive: from basic maintenance to full engine and transmission rebuilds.
Diagnostics Coverage:
In-depth diagnostic procedures for engine, electrical, and mechanical systems.
Rebuild Instructions:
Detailed instructions for overhauling major components like the engine and gearbox.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
499cc (499 cm³)
Bore X Stroke:
86.0 mm x 86.0 mm
Ignition System:
CDI (Capacitor Discharge Ignition)
Starting System:
Electric Starter
Horsepower Estimated:
Approximately 45-50 HP (stock)
Torque Estimated:
Not widely published, but significant low-end torque for a 2-stroke.
Carburetor:
Mikuni VM38SS (single carburetor)
Fuel Type:
Unleaded gasoline with 2-stroke oil premix (typical ratio 50:1 or as specified).
System:
Suzuki Posi-Force oil injection system.
Length:
Approx. 76.2 inches (1935 mm)
Width:
Approx. 48.0 inches (1219 mm)
Height:
Approx. 44.1 inches (1120 mm)
Dry Weight:
Approx. 388 lbs (176 kg)
Fuel Capacity:
3.2 US gal (12 L)
Oil Capacity:
1.1 US qt (1.0 L) (Engine oil)
Wheelbase:
Approx. 49.2 inches (1250 mm)
Ground Clearance:
Approx. 9.1 inches (230 mm)
Engine Oil Change:
Every 20-40 hours of operation or annually (refer to manual for specific recommendations based on usage).
Air Filter Cleaning:
As needed, depending on operating conditions (frequently in dusty environments).
Spark Plug Replacement:
Every 100-200 hours or annually (check and clean more frequently).
Clutch Adjustment:
Regularly check and adjust as per manual specifications.
Engine Oil:
Suzuki recommends a specific 2-stroke engine oil (e.g., Suzuki Premium 2-Stroke Oil) for the oil injection system. For premixing, refer to manual for recommended ratio and oil type (e.g., high-quality synthetic 2-stroke oil).
Gear Oil:
Refer to manual for specific gear oil viscosity (e.g., SAE 80W/90 API GL-4).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (check manual for exact specification).
Coolant:
Permanent type antifreeze coolant, 50/50 mix with distilled water.
Common Problems:
Carburetor tuning and maintenance, electrical system reliability (especially older components), clutch wear, potential for reed valve damage if improperly maintained.
Performance Degradation:
Loss of power due to carbon buildup, worn piston rings, or improper fuel/air mixture.
Suspension Wear:
Wear in bushings and bearings, needing regular lubrication and replacement.
Heritage Summary:
Suzuki has a long history of producing reliable and performance-oriented motorcycles and ATVs.
Lt500R Introduction:
Introduced in the mid-1980s as Suzuki's flagship high-performance ATV, often referred to as the 'Quadzilla'.
Key Updates:
Received updates for performance and reliability throughout its production run, though specific year-by-year changes are detailed in the manual.
Production Period:
Approximately 1987-1989, with variations in different markets.
Market Impact:
Established Suzuki as a major contender in the high-performance ATV segment, especially in racing circuits.
