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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Document Details

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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

Models Covered & Key Technical Specifications

Suzuki LT500R (9900B-23110) - 1987-1990 A Structured Vault for Mechanics | Complete Volume.

  • Factory Processing Speed: 499 cm3 (30.4 cu. in) signifies the engine displacement Capacity.
  • Certified Mass Specs: 178 kg (392 lbs) establishes the dry mass Metric.
  • Engineered Precision Specs: Inside 32° ± 3° defines the steering angle range Specification.
  • Verified Locking Torques: 20 N·m requires the proper torque for the front wheel set nuts Baseline.
  • Designated Measurement Bounds: 110 mm (4.3 in) sets the ground clearance Limit.
  • Integral Cycle Rate: 20:1 is the standard fuel and oil premixture Ratio.

Manual Description & Preview

Definitive Shop Wiring Manual: Suzuki LT500R (1987-1990) - Complete Workshop Repair & Maintenance Manual Resource-Library

Serial-Range: 1987-1990 // Subsystem-Focus: Engine / Chassis Logic // Diagnostic-Area: Maintenance & Repair. Featuring a modular arrangement of technical content, this manual provides a thorough overview of the Suzuki LT500R.

Technical notes are provided for engine component removal and reinstallation procedures.

Quality checks are addressed for the chassis, including front and rear suspension systems.

The transmission section documents gearshift patterns and clutch adjustments.

The troubleshooting chapter addresses common issues like no-spark and engine stalling.

Cooling system maintenance is addressed in detail, including radiator and water pump procedures.

This manual documents torque specifications for various components to ensure proper component alignment retention.

Performance-Element Diagnostic-Logic Validation-Data
Engine Specifications Carburetor Settings General Lubrication
Chassis Components Brake System Electrical System
Suspension Tuning Tire Maintenance Fuel System

FAQ

Assess the **critical** calibration settings for the carburetor keyboard_arrow_down

11.4 ± 1.0 mm (0.45 ± 0.04 in) is the specified float height for proper carburetor calibration.

What components have **required** clearance measurements keyboard_arrow_down

0.10 - 0.30 mm (0.004 - 0.012 in) is the standard clearance for the shift fork in its gear groove.

Confirm the **specified** torque specifications keyboard_arrow_down

40 - 60 N·m (4.0 - 6.0 kg·m / 29.0 - 43.5 lb-ft) is the specified torque for the rear sprocket mounting bolts.

What tools are **essential** safety precautions keyboard_arrow_down

A 6 mm "T" type hexagon wrench is essential for removing the kick starter lever.

Identify the **correct** lubrication requirements keyboard_arrow_down

SUZUKI SUPER GREASE "A" must be applied to the bearings and dust seals before installing the front suspension components.

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