Suzuki LT-A500XP User manual

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99011-31H60-03ALT-A500XP
Part No. 99011-31H60-03A September, 2008 EN Printed in USA
LT-A500XP
TK
K9
5 mm
No.1180 LT-A500XP (99011-31H60-03A)
5 mm
No.1180 LT-A500XP (99011-31H60-03A)
5 mm
No.1180 LT-A500XP (99011-31H60-03A)
5 mm
No.1180 LT-A500XP (99011-31H60-03A)
OWNER’S MANUAL
This owner’s manual contains
important safety information.
Please read it carefully.
Never allow anyone under 16
years old to ride this ATV.
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate :
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with
another vehicle
• with a passenger - passengers affect balance
and steering and increase risk of losing control
ALWAYS :
• use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns
• avoid paved surfaces - pavement may seriously
affect handling and control
LOCATE AND READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

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No.1180 LT-A500XP (99011-31H60-03A)
California Proposition 65 Warning
WARNING
Engine exhaust, some of its constituents, and certain product com-
ponents contain or emit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
This manual should be considered a permanent part of the ve-
hicle and should remain with the vehicle when resold or other-
wise transferred to a new owner or operator. The manual con-
tains important safety information and instructions which should
be read carefully before operating the vehicle.
This hang tag is not to be removed before sale.
This ATV is for
RECREATIONAL or
UTILITY USE,
NO OPERATOR UNDER AGE 16.
OPERATOR ONLY-NO PASSENGERS
This category G (GENERAL USE) ATV is for off road
use only, for recreation and utility purposes.
Training courses to teach ATV riding are available.
For information contact your dealer.
Check with your dealer to find out about state or
local laws regarding ATV operation.

IMPORTANT
WARNING /CAUTION /NOTE
Please read this manual and fol-
low its instructions carefully. To
emphasize special information,
the symbol and the words
WARNING, CAUTION and NOTE
have special meanings. Pay spe-
cial attention to the messages
highlighted by these signal words:
NOTE: Indicates special informa-
tion to make maintenance easier
or instructions clearer.
• WARNINGs and CAUTIONs
are arranged like this:
WARNING
Indicates a potential hazard
that could result in death or
injury.
CAUTION
Indicates a potential hazard
that could result in vehicle
damage.
 WARNING-or-CAUTION
This first part will identify a
POTENTIAL HAZARD.
This second part will describe
WHAT CAN HAPPEN if you
ignore the WARNING or CAU-
TION.
This third part will describe
HOW TO AVOID THE HAZARD.

FOREWORD
• This owner’s manual contains
important safety and mainte-
nance information. Read it
carefully before you ride your
new ATV. Failure to follow the
warnings contained in this
manual can result in INJURY
or DEATH.
• Do not allow anyone under
age 16 to ride this ATV.
• In the USA, anyone who pur-
chases a new Suzuki ATV, and
everyone in the purchaser’s
immediate family who is old
enough to ride the ATV pur-
chased (see label), is entitled
to take a training course at no
additional charge. Others can
take the training course for a
small fee. When a non-busi-
ness purchaser or age-appro-
priate family member
completes training, the pur-
chaser will receive a $100
check if it is their first ATV or a
$50 check if they have owned
an ATV before. Limit one
check per ATV purchased. Ask
an authorized Suzuki dealer
for details or call 1-800-887-
2887 for training information.
• It is important that this manual
remain with the vehicle when
you sell it. The next owner will
need this manual also. Store
the owner’s manual in the box
under the seat.
• Review the “Tips and Practice
Guide” handbook supplied
with this owner’s manual
(owner’s in U.S.A.). This spe-
cial handbook contains a vari-
ety of safety tips, helpful hints,
and practice exercises that can
increase your riding enjoyment
and safety.
• All information, illustrations
and specifications contained in
this manual are based on the
latest product information
available at the time of publica-
tion. Due to improvements or
other changes, there may be
some discrepancies between
information in this manual and
your ATV. Suzuki reserves the
right to make production
changes at any time, without
notice and without incurring
any obligation to make the
same or similar changes to
vehicles previously built or
sold.
• Suzuki Motor Corporation
believes in conservation and
protection of Earth’s natural
resources. To that end, we
encourage every vehicle
owner to recycle, trade in, or
properly dispose of, as appro-
priate, used motor oil, coolant,
other fluids, batteries and tires.

• The proper care and mainte-
nance that your ATV requires
is outline in this manual. By fol-
lowing these instructions
explicitly you will ensure a long
trouble-free operating life for
your ATV. This ATV also con-
forms to the U.S. Environmen-
tal Protection Agency (EPA)
and California Air Resources
Board (CARB) emission regu-
lations which apply to new
ATVs. The proper adjustment
of engine components is nec-
essary for this ATV to comply
with the EPA and CARB regu-
lations. Therefore, please fol-
low the maintenance
instructions closely to ensure
emission compliance. Your
authorized Suzuki dealer has
experienced technicians that
are trained to provide your
machine with the best possible
service with the right tools and
equipment.
© COPYRIGHT SUZUKI MOTOR
CORPORATION 2008
NOTICE TO OWNERS
AN ATV IS NOT A TOY AND
CAN BE HAZARDOUS TO
OPERATE – An ATV handles dif-
ferently from other vehicles
including motorcycles and cars. A
collision or rollover can occur
quickly, even during routine
maneuvers such as turning and
driving on hills or over obstacles,
if you fail to take proper precau-
tions.
SEVERE INJURY OR DEATH can
result if you do not follow these
instructions:
• Read this manual and all
labels carefully and follow the
operating procedures
described.
• Never operate an ATV without
proper instruction. Take a
training course. Beginners
should receive training from a
licensed instructor. Contact an
authorized ATV dealer or in the
USA call 1-800-887-2887 to
find out about the training
courses nearest you.
• Always follow this age recom-
mendation:
– A child under 16 years old
should never operate an ATV
with engine size greater than
90 cc.
• Never carry a passenger on an
ATV.

• Always avoid operating an ATV
on paved surfaces, including
sidewalks, paths, parking lots,
drive ways, and streets.
• Never operate an ATV on any
public street, road or highway,
even a dirt or gravel one.
• Never operate an ATV without
wearing an approved motorcy-
cle helmet that fits properly.
You should also wear eye pro-
tection (goggles or face
shield), gloves, boots, long-
sleeved shirt or jacket, and
long pants.
• Never consume alcohol or
drugs before or while operat-
ing this ATV.
• Never operate at excessive
speeds. Always go at a speed
that is proper for the terrain,
visibility and operating condi-
tions, your skill and experi-
ence.
• Never attempt wheelies,
jumps, or other stunts.
• Always inspect your ATV each
time you use it to make sure it
is in safe operating condition.
Always follow the inspection
and maintenance procedures
and schedules described in
this manual.
• Always keep both hands on
the handlebars and both feet
on the footrests of the ATV
during operation.
• Always go slowly and be extra
careful when operating on
unfamiliar terrain. Always be
alert to changing terrain condi-
tions when operating the ATV.
• Never operate on excessively
rough, slippery or loose terrain
until you have learned and
practiced the skills necessary
to control the ATV on such ter-
rain. Always be especially cau-
tious on these kinds of terrain.
• Always follow proper proce-
dures for turning as described
in this manual. Practice turning
at low speeds before attempt-
ing to turn at faster speeds. Do
not turn at excessive speed.
• Never operate the ATV on hills
too steep for the ATV or for
your abilities. Practice on
smaller hills before attempting
larger hills.
• Always follow proper proce-
dures for climbing hills as
described in this manual.
Check the terrain carefully
before you start up any hill.
Never climb hills with exces-
sively slippery or loose sur-
faces. Shift your weight
forward. Never open the throt-
tle suddenly or make sudden
gear changes. Never go over
the top of any hill at high
speed.

• Always follow proper proce-
dures for going down hills and
for braking on hills as
described in this manual.
Check the terrain carefully
before you start down any hill.
Shift your weight backward.
Never go down a hill at high
speed. Avoid going down a hill
at an angle that would cause
the vehicle to lean sharply to
one side. Go straight down the
hill where possible.
• Always follow proper proce-
dures for crossing the side of a
hill as described in this man-
ual. Avoid hills with excessively
slippery or loose surfaces.
Shift your weight to the uphill
side of the ATV. Never attempt
to turn the ATV around on any
hill until you have mastered the
turning technique described in
this manual on level ground.
Avoid crossing the side of a
steep hill if possible.
• Always use proper proce-
dures if you stall or roll back-
wards when climbing a hill. To
avoid stalling, use the proper
gear and maintain a steady
speed when climbing a hill. If
you stall or roll backwards, fol-
low the special procedure for
braking described in this man-
ual. Dismount on the uphill
side or to a side if pointed
straight uphill. Turn the ATV
around and remount, following
the procedure described in this
manual.
• Always check for obstacles
before operating in a new
area. Never attempt to operate
over large obstacles, such as
large rocks or fallen trees.
Always follow proper proce-
dures when operating over
obstacles as described in this
manual.
• Always be careful when skid-
ding or sliding. Learn to safely
control skidding or sliding by
practicing at low speeds and
on level, smooth terrain. On
extremely slippery surfaces,
such as ice, go slowly and be
very cautious in order to
reduce the chance of skidding
or sliding out of control.
• Never operate an ATV in fast
flowing water or in water
deeper than that specified in
this manual. Remember that
wet brakes may have reduced
stopping ability. Test your
brakes after leaving water. If
necessary, apply them several
times to let friction dry out the
linings.
• Always be sure there are no
obstacles or people behind
you when you operate in
reverse. When it is safe to pro-
ceed in reverse, go slowly.
• Always use tires of the size
and type specified in this man-
ual. Always maintain proper
tire pressure as described in
this manual.
• Never modify an ATV through
improper installation or use of
accessories.

• Never exceed the stated load
capacity for an ATV. Cargo
should be properly distributed
and securely attached.
Reduce speed and follow
instructions in this manual for
carrying cargo or pulling a
trailer. Allow greater distance
for braking.
FOR MORE INFORMATION
ABOUT ATV SAFETY, Owners in
the USA can call the Consumer
Product Safety Commission at 1-
800-638-2772, or the ATV Distrib-
utors’ Safety Hotline at 1-800-
852-5344.
WARNING
Indicates a potential hazard
that could result in injury or
death.

TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
10
FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS
CONTROLS, EQUIPMENT AND ADJUSTMENTS
RIDING YOUR ATV
ACCESSORY USE AND VEHICLE LOADING
INSPECTION AND MAINTENANCE
TROUBLESHOOTING
PREPARATION FOR WINTER RIDING
TRANSPORTING
CLEANING PROCEDURE AND STORAGE PROCEDURE
CONSUMER INFORMATION
SPECIFICATIONS
INDEX

1-1
1
FUEL, OIL AND ENGINE COOLANT
RECOMMENDATIONS
FUEL .................................................................................................................... 1-2
ENGINE OIL ......................................................................................................... 1-3
ENGINE COOLANT SOLUTION ......................................................................... 1-5
FRONT DIFFERENTIAL GEAR OIL .................................................................... 1-6
FINAL GEAR OIL ................................................................................................ 1-6

1-2
FUEL, OIL AND
ENGINE COOLANT
RECOMMENDATIONS
FUEL
Your vehicle requires regular
unleaded gasoline, with a mini-
mum pump octane rating of 87
((R+M)/2 method). In some areas,
the only fuels that are available
are oxygenated fuels.
Oxygenated fuels which meet the
minimum octane requirement and
the requirements described below
may be used in your ATV without
jeopardizing the New Vehicle Lim-
ited Warranty or the Emission
Control System Warranty.
NOTE: Oxygenated fuels are
fuels which contain oxygen-carry-
ing additives such as MTBE or
alcohol.
Gasoline containing MTBE
Unleaded gasoline containing
MTBE (Methyl Tertiary Butyl
Ether) may be used in your ATV if
the MTBE content is not greater
than 15%. This oxygenated fuel
does not contain alcohol.
Gasoline/Ethanol Blends
Blends of unleaded gasoline and
ethanol (grain alcohol), also
known as “GASOHOL”, may be
used in your ATV if the ethanol
content is not greater than 10%.
Gasoline/Methanol
Fuels containing 5% or less meth-
anol (wood alcohol) may be suit-
able for use in your ATV if they
contain co-solvents and corro-
sion inhibitors.
DO NOT USE fuels containing
more than 5% methanol under
any circumstances. Fuel system
damage or ATV performance
problems resulting from the use of
such fuels are not the responsibil-
ity of Suzuki and may not be cov-
ered under the New Vehicle
Limited Warranty or the Emission
Control System Warranty.
Fuel Pump Labeling
In some states, pumps that dis-
pense oxygenated fuels are
required to be labeled for the type
and percentage of oxygen, and
whether important additives are
present. Such labels may provide
enough information for you to
determine if a particular blend of
fuel meets the requirements listed
above. In other states, pumps
may not be clearly labeled as to
the content or type of oxygen and
additives. If you are not sure that
the fuel you intend to use meets
these requirements, check with
the service station operator or the
fuel supplier.

1-3
NOTE:
• To help minimize air pollution,
Suzuki recommends that you
use oxygenated fuels.
• Be sure that any oxygenated
fuel you use has octane rat-
ings of at least 87 pump
octane ((R+M)/2 method).
• If you are not satisfied with the
driveability of your ATV when
you are using an oxygenated
fuel, or if engine pinging is
experienced, substitute
another brand as there are dif-
ferences between brands.
ENGINE OIL
Oil quality is a major contributor to
your engine’s performance and
life. Always select good quality
engine oil. Suzuki recommends
the use of SUZUKI PERFOR-
MANCE 4 MOTOR OIL or equiva-
lent engine oil. Use oil with an API
(American Petroleum Institute)
classification of SF/SG or SH/SJ,
or with a JASO classification of
MA.
API: American Petroleum Institute
JASO: Japanese Automobile
Standards Organization
SAE Engine Oil Viscosity
Suzuki recommends the use of
SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available,
select an alternative according to
the following chart.
NOTE: In very cold weather
(below 14°F (–10°C)), use SAE
5W-30 for good starting and
smooth operation.
CAUTION
Spilled gasoline containing
alcohol can harm your ATV.
Alcohol can damage painted
surfaces.
Be careful not to spill any fuel
when filling the fuel tank. Wipe
spilled gasoline up immedi-
ately.
SAE API JASO
10W-40 SF or SG –
10W-40 SH or SJ MA

1-4
JASO T903
The JASO T903 standard is an
index to select engine oils for 4-
stroke motorcycle and ATV
engines. Motorcycle and ATV
engines lubricate clutch and
transmission gears with engine
oil. JASO T903 specifies perfor-
mance requirements for motorcy-
cle and ATV clutches and
transmissions.
There are two classes, MA and
MB. The oil container shows the
classification as follows.
1Code number of oil sales company
2Oil classification
Energy Conserving
Suzuki does not recommend the
use of “ENERGY CONSERVING”
oils. Some engine oils which have
an API classification of SH or
higher have an “ENERGY CON-
SERVING” indication in the API
classification doughnut mark.
These oils can affect engine life
and clutch performance.
Not recommended Recommended
E
N
E
R
G
Y
C
O
N
S
E
R
V
I
N
G
A
P
I
S
E
R
V
I
C
E
S
J
SAE
10W-40
A
P
I
S
E
R
V
I
C
E
S
J
SAE
10W-40

1-5
ENGINE COOLANT SOLUTION
Use engine coolant that is com-
patible with an aluminum radiator,
mixed with distilled water at a
50:50 mixture ratio for engine
coolant solution. An engine cool-
ant mixture other than 50:50 can
affect cooling efficiency or rust
inhibiting performance.
Engine Coolant
Engine coolant should be used at
all times in your ATV radiator,
even if the temperature in your
area does not go down to the
freezing point. Engine coolant
acts as a rust inhibitor and water
pump lubricant as well as an anti-
freeze solution.
WARNING
Engine coolant is harmful or
fatal if swallowed or inhaled.
Do not drink antifreeze or cool-
ant solution. If swallowed, do
not induce vomiting. Immedi-
ately contact a poison control
center or a physician. Avoid
inhaling mist or hot vapors; if
inhaled, remove to fresh air. If
coolant gets in eyes, flush eyes
with water and seek medical
attention. Wash thoroughly
after handling. Solution can be
poisonous to animals.
Keep out of the reach of chil-
dren and animals.
CAUTION
Spilled engine coolant can
harm your ATV.
Engine coolant can damage
painted surfaces.
Be careful not to spill any fluid
when filling the radiator. Wipe
spilled engine coolant up
immediately.

1-6
Water for Mixing
Use distilled water only. Water
other than distilled water can cor-
rode and clog the aluminum radia-
tor.
Required amount of engine cool-
ant/water solution capacity (total):
2500 ml (2.6 US qt)
FRONT DIFFERENTIAL GEAR
OIL
Use a SAE 90 hypoid gear oil
which is rated GL-5 under the API
classification system. If you nor-
mally operate the vehicle where
ambient temperature is below 0°C
(32°F), use a SAE 80 hypoid gear
oil.
FINAL GEAR OIL
Use Mobil Fluid 424 or an equiva-
lent.
Engine coolant 1250 ml
(1.3 US qt)
Water 1250 ml
(1.3 US qt)

2-1
2
CONTROLS, EQUIPMENT AND
ADJUSTMENTS
LOCATION OF PARTS ....................................................................................... 2-2
KEY ...................................................................................................................... 2-5
IGNITION SWITCH .............................................................................................. 2-6
INSTRUMENT PANEL ......................................................................................... 2-7
SHIFT LEVER .................................................................................................... 2-12
SELECTION SWITCH ........................................................................................ 2-14
LEFT HANDLEBAR ........................................................................................... 2-16
RIGHT HANDLEBAR ........................................................................................ 2-19
THROTTLE LIMITER ......................................................................................... 2-19
REAR BRAKE PEDAL ...................................................................................... 2-20
FUEL TANK CAP .............................................................................................. 2-20
SEAT LOCK ....................................................................................................... 2-22
BOX .................................................................................................................... 2-23
FRONT FENDER BOX ...................................................................................... 2-23
FRONT AND REAR SUSPENSION ADJUSTMENT ......................................... 2-24
FLAG BRACKET ............................................................................................... 2-25

2-2
CONTROLS, EQUIPMENT AND ADJUSTMENTS
LOCATION OF PARTS
1Rear brake lever
2Left handlebar switches
3Speedometer and indicator lights
4Ignition switch
5Front brake fluid reservoir
6Front brake lever
7Shift lever
8Throttle lever
92WD/4WD/DIFF LOCK selection switch

2-3
0Battery
AFuel tank cap
BSeat lock
CFootrests

2-4
DRear brake pedal