1987-1990 Suzuki LT500R Service Manual

Complete service manual for the 1987-1990 Suzuki LT500R ATV. Covers all maintenance, repair, and troubleshooting procedures. PN 9900B-23110

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Suzuki Models Covered & Key Technical Specifications

Models: Suzuki LT500R, LT500RJ, LT500RK, LT500RL
Sub-models / Variants: 87-Model, 88-Model, 89-Model, 90-Model
Build Years: 1987–1990
Serial Numbers: Effective Engine No.: From 103220
Technical Data:

  • Engine: 499 cc (30.4 cu. in), 2-stroke, water-cooled, single cylinder
  • Carburetor: MIKUNI TM38SS
  • Drive System: 5-speed constant mesh transmission, chain drive
  • Fuel System: Premix 20:1
  • Dry Mass: 178 kg (392 lbs)
  • Coolant Capacity: 1500 ml total capacity
Technical Specifications
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Document Number / Seller:
30342 / Susan Murphy
File Size:
27.18 MB
File Type:
PDF
Language:
English
Pages:
248
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Apr 23, 2025

Suzuki Manual Features & Content Preview

Suzuki LT500R 1987–1990 Service Manual Overview

  • Covers 1987–1990 Suzuki LT500R ATV models including the LT500RJ, LT500RK, and LT500RL variants
  • Original OEM publication P/N 9900B-23110
  • Contains 47 exploded-view diagrams and 18 torque reference tables
  • Delivered as a direct download the moment payment clears
  • Indexed PDF search covers every chapter and appendix
  • Stored against your account so you can retrieve it after a hard-drive loss
  • This official 248-page publication serves as the primary technical reference for the 1987–1990 Suzuki LT500R series, documenting factory-specified rebuild and maintenance parameters for the water-cooled two-stroke engine and full-floating suspension system.

Manual Content Summary

This factory service manual provides essential technical documentation for the Suzuki LT500R. The document structure begins with detailed general information, including VIN locations, fluid recommendations, and break-in procedures. Subsequent chapters detail the periodic maintenance schedule, engine disassembly and reassembly, cooling system diagnostics, fuel system specifications, and comprehensive chassis maintenance requirements. Detailed sections for the 1988, 1989, and 1990 model years are included to account for specific model-year variations.

Technical Data Preview

The technical data section provides critical reference values for mechanics. Cylinder head bolt torque is documented at 26–30 N·m (18.8–21.7 lb-ft). The cooling system capacity is specified at 1500 ml total volume. Spark plug gap for the standard model is listed at 0.55–0.65 mm (0.022–0.026 in) in the ignition data table. Gear-shift fork groove width is specified as 5.0–5.1 mm (0.197–0.201 in). Piston pin outer diameter service limit is 17.980 mm (0.7079 in) as listed in the engine inspection charts. For engine reassembly, the primary drive gear nut requires 100–130 N·m (72.5–94.0 lb-ft) of torque. Reference only — always consult a certified technician before performing service on this equipment.

An official 248-page Suzuki OEM service manual covering the 1987–1990 LT500R, documenting engine, chassis, electrical, and cooling system specifications for the LT500RJ, LT500RK, and LT500RL builds.

Document Reference: 9900B-23110

Manual FAQ, Purchase & Download Details

Is the LT500R electrical wiring schematic included? keyboard_arrow_down

Chapter 6 of the manual contains electrical system information which includes wiring diagrams and reference values for the covered models.

Can I find technical information for the engine and transmission systems within this document? keyboard_arrow_down

Manual includes dedicated chapters for the engine, cooling system, fuel system, and transmission. These sections contain specifications, capacity details, and exploded views relevant to these systems.

Does the manual provide detailed specification tables for the 1987 to 1990 model years? keyboard_arrow_down

General Information section contains extensive specification tables covering dimensions, dry mass, engine details, transmission ratios, and chassis metrics for the 1987-1990 Suzuki LT500R production run.

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