Suzuki Vinson LT-A500F (2002-2007) - Repair, Service and Maintenance Manual

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SUZUKI VINSON LT-A500F (2002-2007) - SERVICE MANUAL

- English service manual, to Suzuki Vinson LT-A500F (2002-2007)


CONTENTS:

HOW TO USE THIS MANUAL

- To Locate What You Are Looking For:
- Component Parts And Work To Be Done
- Symbol


01 GENERAL INFORMATION

- Warning/Caution/Note
- General Precautions
- Suzuki Lt-A500fk2 (2002-Model)
- Serial Number Location
- Fuel, Oil And Engine Coolant Recommendation
- Fuel
- Engine Oil
- Front And Rear Drive Gear Oil
- Brake Fluid
- Engine Coolant
- Break-Ln Procedures
- Information Labels
- Specifications
- Country And Area Codes


02 PERIODIC MAINTENANCE

- Periodic Maintenance Schedule
- Periodic Maintenance Chart
- Maintenance And Tune-Up Procedures
- Air Cleaner
- Exhaust Pipe Nuts And Muffler Bolts
- Valve Clearance
- Spark Plug
- Fuel Hose
- Throttle Cable Play
- Engine Idle Speed
- Engine Oil And Oil Filter
- Differential Gear And Final Bevel Gear Oil
- Engine Coolant
- Radiator Hoses
- Drive Belt
- Spark Arrester
- Brakes
- Brake Fluid
- Brake Hoses
- Tires
- Steering
- Suspensions
- Chassis Nuts And Bolts
- General Lubrication
- Compression Pressure Check
- Compression Test Procedure
- Oil Pressure Check
- Oil Pressure Test Procedure
- Initial Engagement And Clutch Lock-Up Inspection
- Initial Engagement Inspection
- Clutch Lock-Up Inspection


03 ENGINE

- Engine Components Removable With Engine In Place
- Engine Left Side
- Engine Right Side
- Engine Center
- Engine Removal And Installation
- Engine Removal
- Engine Installation
- Engine Disassembly
- Engine Top Side
- Engine Bottom Side
- Engine Components Inspection And Servicing
- Cylinder Head Cover
- Cylinder Head
- Camshaft
- Cam Chain Tension Adjuster
- Cylinder
- Piston
- Conrod/Crankshaft
- Clutch
- Movable Drive Face And Driven Face
- Drive Belt
- Oil Pump
- Transfer
- Shift Fork
- Gearshift Cam
- Crankshaft
- Drive Train (Inboard Side)
- Shim Adjustment
- Crankcase
- Drive Belt Cover
- Generator Cover
- Recoil Starter
- Engine Reassembly
- Engine Bottom Side
- Engine Top Side


04 DRIVE TRAIN

- Front Driving System
- Front Drive (Differential) Removal
- Front Drive (Differential) Disassembly
- Front Drive (Differential) Inspection
- Front Drive (Differential) Reassembly
- Front Drive (Differential) Installation
- Shim Adjustment
- Reassembly Information
- Rear Driving System
- Rear Drive Removal
- Rear Drive Disassembly
- Rear Drive Inspection
- Rear Drive Reassembly
- Rear Drive Installation
- Shim Adjustment
- Reassembly Information


05 FUEL SYSTEM

- Fuel Tank
- Construction
- Fuel Line Inspection
- Removal
- Remounting
- Fuel Valve
- Removal And Inspection
- Fuel Strainer
- Remounting
- Fuel Level Gauge
- Removal
- Inspection
- Remounting
- Carburetor
- Construction
- Specifications
- I.D. No. Location
- Removal
- Disassembly
- Cleaning
- Inspection
- Reassembly
- Remounting


06 COOLING AND LUBRICATION SYSTEM

- Engine Coolant
- Cooling Circuit
- Cooling Circuit Inspection
- Radiator And Hoses
- Radiator Removal
- Radiator Remounting
- Radiator Reservoir Tank
- Radiator Cap Inspection
- Radiator Inspection And Cleaning
- Radiator Hose Inspection
- Cooling Fan
- Removal
- Inspection
- Installation
- Cooling Fan Thermo-Switch
- Removal
- Inspection
- Installation
- Engine Coolant Temperature Switch
- Removal
- Inspection
- Installation
- Thermostat
- Removal
- Inspection
- Installation
- Water Pump
- Removal And Disassembly
- Inspection
- Reassembly And Installation
- Lubrication System
- Oil Pressure
- Oil Filter
- Oil Pressure Regulator
- Oil Strainer
- Oil Pump
- Engine Lubrication System Chart
- Engine Lubrication System


07 CHASSIS

- Exterior Parts
- Construction
- Removal
- Remounting
- Front And Rear Wheels
- Construction
- Removal
- Remounting
- Tires
- Tire Replacement
- Front Drive Shaft
- Construction
- Removal
- Inspection And Reassembly
- Remounting
- Front Brake
- Construction
- Brake Pad Replacement
- Brake Fluid Replacement
- Brake Caliper Removal And Disassembly
- Brake Caliper Inspection
- Brake Caliper Reassembly And Remounting
- Brake Disc Removal And Disassembly
- Brake Disc Inspection
- Brake Disc Reassembly And Remounting
- Master Cylinder Removal And Disassembly
- Master Cylinder Inspection
- Master Cylinder Reassembly And Remounting
- Front Suspension
- Construction
- Removal And Disassembly
- Inspection
- Reassembly And Remounting
- Steering
- Construction
- Removal And Disassembly
- Inspection
- Reassembly And Remounting
- Toe-In Adjustment
- Front Wheel, Front Brake, Front Suspension And Steering Reassembling Information
- Rear Brake
- Construction
- Brake Pad Replacement
- Brake Fluid Replacement
- Brake Caliper Removal And Disassembly
- Brake Caliper Inspection
- Brake Caliper Reassembly And Remounting
- Brake Disc Removal And Disassembly
- Brake Disc Inspection
- Brake Disc Reassembly And Remounting
- Master Cylinder Removal And Disassembly
- Master Cylinder Inspection
- Master Cylinder Reassembly And Remounting
- Rear Suspension
- Construction
- Removal
- Inspection And Disassembly
- Reassembly And Remounting
- Rear Axle
- Construction
- Removal
- Inspection And Disassembly
- Reassembly And Remounting
- Rear Wheel, Rear Brake, Rear Suspension, Rear Swingarm And Rear Axle Shaft Reassembling Information
- Gearshift Lever
- Construction
- Removal And Disassembly
- Inspection
- Reassembly And Remounting
- Cables
- Installation
- Cable Play Adjustment


08 ELECTRICAL SYSTEM

- Cautions In Servicing
- Connectors
- Couplers
- Clamps
- Fuses
- Semi-Conductor Equipped Parts
- Battery
- Connecting The Battery
- Wiring Procedure
- Using The Multi Circuit Tester
- Location Of Electrical Components
- Charging System
- Troubleshooting
- Inspection
- Starter System
- Troubleshooting
- Starter Motor Removal And Disassembly
- Starter Motor Inspection
- Starter Motor Reassembly And Remounting
- Starter Relay Inspection
- Neutral Relay Inspection
- Ignition/Starter Control Relay
- Parking Brake Switch
- Ignition System
- Troubleshooting
- Inspection
- 2wd/4wd Selecting System
- Description
- Troubleshooting
- Inspection
- Speedometer
- Parts Names
- Operating Procedure
- Inspection
- Lamps
- Headlight And Auxiliary Light
- Brake Light/Taillight
- Diode
- Switches
- Battery
- Specifications
- Initial Charging
- Servicing
- Recharging Operation


09 SERVICING INFORMATION

- Troubleshooting
- Engine
- Drive Train
- Carburetor
- Chassis
- Brakes
- Radiator (Cooling System)
- Electrical
- Battery
- Wiring Diagram
- Wiring Harness, Cable, And Hose Routing
- Wiring Harness Routing
- Cable Routing
- Carburetor Hose Routing
- Cooling System Hose Routing
- Front Brake Hose Routing
- Rear Brake Hose Routing
- Special Tools
- Tightening Torque
- Engine
- Differential
- Chassis
- Tightening Torque Chart
- Service Data


10 LT-A500FK3 (’03-MODEL)

- Specifications
- Engine
- Transfer
- Gearshift Cam
- Drive Bevel Gear Bearing
- Propeller Shaft Installation
- Chassis
- Parking Interlock Cable Adjustment
- Front Wheel, Front Brake, Front Suspension And Steering Reassembling Information
- Rear Brake
- Wiring Diagram
- Rear Brake Hose Routing
- Service Data


11 LT-A500FK4 (’04-MODEL)

- Specifications
- Service Data
- Tightening Torque
- Front Wheel, Front Suspension And Steering Assembly
- Handlebar Grip Installation
- Fuel Meter Inspection
- Fuel Level Gauge Inspection
- Fuel Level Gauge Installation
- Wiring Diagram
- Wire Harness Routing
- Cable Routing


12 LT-A500FK5 (’05-MODEL)

- Specifications
- Service Data
- Tightening Torque
- Front And Rear Brake Caliper Mounting Bolts
- Wiring Harness Routing


13 LT-A500FK6 (’06-MODEL)

- Specifications
- Service Data
- Tightening Torque
- Wiring Diagram


14 LT-A500FK7 ('07-MODEL)

- Specifications
- Service Data
- Front Brake Hose Routing
- Rear Brake Hose Routing