Suzuki Vinson LT-A500F User manual

SUZUKI
LT-A500F
SERVICE MANUAL

FOREWORD
This manual contains an introductory description on
the SUZUKI LT-A500F and procedures for its
inspection, service, and overhaul of its main compo-
nents.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its mainte-
nance. Use this section as well as other sections as
aguide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.
* This manual has been prepared on the
basis of the latest specifications at the time
of publication. If modifications have been
made since then, differences may exist
between the content of this manual and the
actual vehicle.
*Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, includ-
ing special tools, for servicing SUZUKI vehi-
cles. If you do not have the proper
knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
A WARNING
Inexperiencedmechanicsormechanics
without thepropertoolsandequipment
maynotbeabletoproperly perform the
services describedinthismanual.
Improper repairmayresultininjurytothe
mechanicandmayrenderthevehicle
unsafefortherider.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
SHAFT DRIVE AND
DIFFERENTIAL GEARS
FUEL AND LUBRICATION
SYSTEM
COOLING SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
LT-A500FK1 ('01-MODEL)
SUZUKI MOTORCORPORATION
Motorcycle Service Department
© COPYRIGHT SUZUKI MOTOR CORPORATION 1999

HOWTOUSETHISMANUAL
TOLOCATE WHAT YOUARELOOKING
FOR:
1. The text of this manualisdividedintosections.
2. Thesection titles are listed inthe GROUP INDEX.
3.Holdingthemanualasshownattheright will allowyou
to findthe first pageofthesectioneasily.
4. Thecontentsare listed on the first page of eachsec-
tion tohelpyoufindtheitemandpageyouneed.
COMPONENTPARTSANDWORKTOBEDONE
Underthename of eachsystem or unitthere isan explodedviewwhichprovidesworkinstructions and
other serviceinformation(e.g.; tightening torque, lubricating points,andlockingagentpoints).
Example:Frontbrake
© Mastercylinderreservoircap
© Diaphragm
© Mastercylinderclamp
© Boot
© Piston/cupset
©Cup
® Spring
© Mastercylinder
© BrakehoseNo.1
® BrakehoseNo.2
® BrakehoseNo.3
© Brakepipejoint
© Brakepipe, RH
@ Brakepipe, LH
@ Piston
© Pistonseal
® Dust seal
© Brakecaliper
® Brakecaliperholder
© Brakepad
© PadSpring
® Mastercylinderclampbolt
® Brakehoseunionbolt
© Brakepipenut
© Airbleedervalve
© Brakecalipermountingbolt
© Brakepadmountingpin
H
ITEM Nm
kgf-m
Ib-ft
®
10 1.0 7.0
®
23 2.3 16.5
©
16 1.6 11.5
®
7.5 0.75 5.0
©
26 2.6 19.0
©
18 1.8 13.0

SYMBOL
Listed in thetablebelow are thesymbolsindicating instructions and otherinformationnecessary for servic-
ing. The meaning of eachsymbol is alsoincluded in thetable.
SYMBOL DEFINITION
SYMBOL DEFINITION
H
Torquecontrolrequired.
Databesideitindicatesspecified
torque.
Apply THREADLOCKSUPER "1305".
99000-32100
Indicates servicedata. Apply
THREADLOCKSUPER "1322".
99000-32110 (Except USA)
Apply oil. Use engineoilunless
otherwise specified. Apply
THREADLOCK "1342".
99000-32050
if
Applymolybdenumoilsolution,
(mixture of engineoil andSUZUKI
MOLYPASTEin a ratio of 1 : 1)
Apply or use brake fluid.
Apply SUZUKISUPERGREASE "A".
99000-25030 (For USA)
99000-25010 (For theothercountries)
Measure in voltagerange.
Apply SUZUKI SILICONEGREASE.
99000-25100
Measure in resistancerange.
Apply SUZUKIMOLYPASTE.
99000-25140
Measure in currentrange.
Apply WATERRESISTANCEGREASE
99000-25160
Measure in diode test range.
^12Q7B]
Apply SUZUKIBOND "1207B".
99104-31140 (For USA)
99000-31140 (For theothercountries)
II
Measure in continuity test range.
^1215]
Apply SUZUKIBOND "1215".
99000-31110 (Except USA)
Usespecial tool.
^1216]
Apply SUZUKIBOND "1216".
99104-31160 (For USA)
99000-31160 (For theothercountries)
Useenginecoolant.
99000-99032-11X (Except USA)
Apply THREADLOCKSUPER "1303".
99000-32030

GENERAL INFORMATION
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE 1- 2
GENERAL PRECAUTIONS 7-2
SUZUKI LT-A500FY (2000-MODEL) 1- 4
SERIAL NUMBER LOCATION 1- 4
FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS 1- 4
FUEL 1- 4
ENGINE OIL 1- 5
DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL 1- 5
BRAKE FLUID 1- 5
ENGINE COOLANT 1-5
BREAK-IN PROCEDURES 1- 6
INFORMATION LABELS 1- 7
SPECIFICATIONS 1- 8
COUNTRY AND AREA CODES 1-10

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Pleasereadthismanualandfollowitsinstructionscarefully. To emphasizespecialinformation,thesymbol
andthewords WARNING, CAUTION and NOTE havespecialmeanings.Payspecialattentiontothemes-
sageshighlightedbythesesignalwords.
A WARNING
Indicatesa potentialhazard that couldresultindeathorinjury.
ACAUTIOINT
Indicatesa potentialhazard that couldresultinvehicledamage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Pleasenote,however,thatthewarningsandcautionscontained in thismanualcannotpossiblycoverall
potential hazardsrelatingtotheservicing, or lackofservicing,ofthevehicle.Inadditiontothe WARNINGS
and CAUTIONS stated,youmustusegoodjudgementandbasicmechanicalsafetyprinciples. If you are
unsureabouthowtoperform a particularserviceoperation,ask a moreexperiencedmechanicforadvice.
GENERAL PRECAUTIONS
A WARNING
*Properserviceandrepairproceduresare important forthesafetyoftheservicemechanic
andthesafetyandreliabilityofthevehicle.
*Whentwoormorepersonsworktogether,pay attention tothesafetyofeachother.
*Whenitisnecessarytoruntheengineindoors,makesure that exhaustgasisforcedout-
doors.
*Whenworking with toxicorflammablematerials,makesure that theareayouworkiniswell
ventilatedand that you follow allofthemanufacturer'sinstructions.
*Neverusegasolineasa cleaningsolvent.
*Toavoid getting burned,donottouchtheengine,engineoil,radiator,andexhaustsystem
until theyhavecooled.
* After servicingthefuel,oil,enginecoolant,exhaustorbrake systems, checkallofthelines,
and fittings relatedtothesystemforleaks.

GENERAL INFORMATION1-3
ACAUTION
*Ifpartsreplacementis necessary, replacethepartswithSUZUKIGenuinePartsortheir
equivalent.
*Whenremovingpartsthat aretobereused,keepthemarrangedinanorderlymannerso
that theymaybereinstalledintheproperorder.
*Besuretousespecialtoolswheninstructed.
*Makesurethat allpartsusedinreassemblyareclean.Lubricatethemwhenspecified.
*Usethespecifiedlubricants,bonds,or sealants.
*Whenremovingthebattery, disconnect the0 batteryleadwirefirst,thenthe0 batterylead
wire.
*Whenreconnectingthebattery,connectthe0 batteryleadwirefirst,thenthe0 battery
leadwire.Finally,coverthe© batteryterminalwiththeterminalcover.
*Whenperformingservicetoelectricalparts,disconnectthe0 batteryleadwire, unless the
service procedurerequiresthebatterypower.
*Whentighteningcylinderheadand crankcase nutsandbolts,tightenthelarger sizes first.
Always tightenthenutsandboltsfromtheinsideworkingout,diagonallyandtothe speci-
fiedtorque.
*Wheneveryouremoveoil seals, gaskets,packing,O-rings,self-lockingnuts,locking wash-
ers, cotterpins, circlips, andotherspecifiedparts,besuretoreplacethemwithnew ones.
Also, beforeinstallingthesenewparts,besuretoremoveany left overmaterialfromthe
mating surfaces.
*Neverreusea circlip.Wheninstallinga newcirclip,takecarenottoexpandtheendgap
largerthanrequiredtoslipthecirclipovertheshaft.Afterinstallinga circlip,alwaysensure
itiscompletelyseatedinitsgrooveandsecurelyfitted.
*Usea torquewrenchtotightenfastenerstothespecifiedtorque.Wipeoffgreaseandoilifa
threadissmearedwiththem.
*After reassembling, checkpartsfortightnessandproperoperation.
*Toprotecttheenvironment,donotunlawfullydisposeofusedmotoroil,enginecoolant,all
otherfluids,batteries,andtires.
*Toprotecttheearth'snatural resources, properlydisposeofusedvehiclesandparts.

1-4 GENERAL INFORMATION
SUZUKILT-A500FY(2000-MODEL)
RIGHT SIDE LEFT SIDE
* Differencebetweenphotographs andtheactualvehicles depends onthemarkets.
SERIAL NUMBERLOCATION
TheframeserialnumberorV.I.N.(VehicleIdentification Number) © isstampedontherightsideoftherear
framepipe. The engineserialnumber © is located on the left side of thecrankcase. These numbersare
requiredespeciallyforregisteringthemachineandorderingspareparts.
FUEL, OIL,ANDENGINECOOLANTRECOMMENDATION
FUEL (ForUSA)
• Useonlyunleadedgasoline ofat least 87 pump octane (R * M ) method or 91octane or higherrated
bytheResearchMethod.
• SUZUKI recommendsthatcustomersusealcohol-freeunleadedgasolinewheneverpossible.
• Use of blendedgasolinecontaining MTBE (MethylTertiaryButylEther)ispermitted.
• Use of blendedgasoline/alcoholfuelispermitted,providedthatthefuelcontainsnotmorethan10%eth-
anol. Gasoline/alcoholfuelmaycontainupto5%methanolifappropriatecosolventsandcorrosioninhib-
itors arepresentinit.
• Iftheperformance of thevehicle is unsatisfactorywhileusingblendedgasoline/alcohol fuel, youshould
switch toalcohol-freeunleadedgasoline.
• Failuretofollowtheseguidelinescouldpossiblyvoidapplicablewarrantycoverage.Check with yourfuel
suppliertomakesurethatthefuelyouintendtousemeetstherequirementslistedabove.

GENERAL INFORMATION 1-5
FUEL (ForCANADA)
Useonlyunleadedgasoline ofat least 87 pumpoctane (
R *^
) or 91octane or higherrated by the
ResearchMethod.
FUEL (Fortheothercountries)
Useunleadedgasolinethatisgraded91octaneorhigherbytheResearchMethod.
ENGINE OIL(ForUSA)
SUZUKI recommendstheuse of SUZUKI PERFORMANCE 4
MOTOR OILoroilsthatmeetAPIserviceclassifications SF or
SGandthathave a viscosityrating ofSAE 10W/40. If engine
oil with a ratingofSAE 10W/40 isnotavailable,selectanalter-
nativeaccordingtothechart.
ENGINE OIL(Fortheothercountries)
Use a premiumquality4-strokemotoroiltoensurelongerser-
vice life of yourvehicle. Use onlyoilsthatmeetAPIservice
classifications SForSGand thathave a viscosityrating of
SAE 10W/40. If engineoil with a rating ofSAE 10W/40 is not
available,selectanalternativeaccordingtothechart.
DIFFERENTIAL GEAR ANDFINAL BEVEL GEAR OIL
UsehypoidgearoilthatmeetstheAPIserviceclassificationGL-5andisratedSAE#90.Use a hypoidgear
oil with a rating of SAE#80ifthevehicleisoperatedwheretheambienttemperatureisbelow 0°C (32°F).
BRAKE FLUID
Specification and classification: DOT4
AWARNING
This vehicle uses a glycol-basedbrakefluid.Donotuseormixdifferenttypes of brakefluid
such as silicone-based andpetroleum-basedfluidsforrefillingthe system, otherwiseserious
damagewillresulttothebrake system.
Neveruseanybrakefluidtakenfromold, used, orunsealedcontainers.
Neverreusebrakefluid left overfromthelastservicingorwhichhasbeenstoredfor a long
periodoftime.
ENGINE COOLANT
Sinceantifreezealsohascorrosion-andrust-inhibitingproperties,alwaysuseenginecoolantcontaining
antifreeze,eveniftheatmospherictemperaturedoesnotgobelowthefreezingpoint.
Useanantifreezedesignedforaluminumradiators. SUZUKI recommendstheuse of SUZUKI COOLANT
antifreeze.Ifthisisnotavailable,useanequivalentantifreezeforaluminumradiators.
Mix onlydistilledwater with theantifreeze.Othertypesofwatercancorrodeandclogthealuminumradia-
tor.
Mixdistilledwaterandantifreezeata ratioof50:50 - 40:60.
Formoreinformation,refertopage6-5intheCoolingSystemsection.
MULTIGRADE
Mt.wgi.mr.iva^
°C
TEMP •
-30 -20-10 0 10203040
°F -22
-41432506886 104

1-6 GENERAL INFORMATION
ACAUTION
The percentageofantifreezeinthecoolantshouldbebetween50to60%.Ifthepercentageof
antifreezeisaboveorbelowthisrangethecoolant'sfrostprotectionandrust-inhibiting capa-
bilities will bereduced.Alwayskeeptheantifreezecontentabove50%eveniftheatmospheric
temperaturedoesnotgobelowthefreezingpoint.
BREAK-IN PROCEDURES
Duringmanufacturingonlythebestpossiblematerialsareusedandallmachinedpartsarefinishedto a
veryhighstandard. Itis still necessary to allowthemovingparts to "BREAK-IN" beforesubjecting the
enginetomaximumstresses.Thefutureperformanceand reliability oftheenginedependsonthecareand
restraint exercisedduringitsearly life. Refertothefollowingbreak-inenginespeedrecommendations.
• Keeptothesebrake-inenginespeed limits.
Break-in engine speeds
Initial 500km(300miles): Less than12 throttle
• Upon reaching an odometerreading of 500km(300miles)youcansubjectthevehicleto full throttle
operation, forshortperiodsof time.