Suzuki LT-A500FK7 ATV Service Bulletin

Below you will find brief information for ATV LT-A500FK7. This Service Bulletin provides essential information for properly servicing the ATV LT-A500FK7. It includes specifications, service data, and detailed instructions for routing the front and rear brake hoses.

PDF Download

Document

MOTORCYCLE

DATE:

PAGE:

June. 7, 2006

SUBJECT:

SERVICE INFORMATION

APPLICABLE MODEL:

LT-A500FK7

EFFECTIVE ENGINE OR FRAME NO.:

5SAAM43A 77100001 –

REFERENCE:

P-24, 28, 33

This bulletin is to inform you of the service information for the above model.

Please use the following service manual along with the information contained in this bulletin for properly servicing.

LT-A500F Service Manual: 99500-44044-01E

LT-A500F Service Manual CD-ROM: 99560-44041-01E

We hope that this information will be useful in your service activities.

PAGE

SPECIFICATIONS...................................................................................... 2

SERVICE DATA ......................................................................................... 3

FRONT BRAKE HOSE ROUTING........................................................... 11

REAR BRAKE HOSE ROUTING ............................................................. 12

NOTE:

The specifications and service data are same as K6 model.

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................................................

2 095 mm (82.5 in)

Overall width........................................................................................

1 170 mm (46.1 in)

Overall height ......................................................................................

1 235 mm (48.6 in)

Wheelbase ..........................................................................................

1 270 mm (50.0 in)

Ground clearance................................................................................

250 mm (9.8 in)

Seat height ..........................................................................................

860 mm (33.9 in)

Dry mass .............................................................................................

274 kg (604 lbs)

Front track ...........................................................................................

940 mm (37.0 in)

Rear track............................................................................................

930 mm (36.6 in)

ENGINE

Type.....................................................................................................

4-stroke, liquid-cooled, OHC

Number of cylinders ............................................................................

Bore.....................................................................................................

87.5 mm (3.445 in)

Stroke ..................................................................................................

82.0 mm (3.228 in)

Displacement ......................................................................................

493 cm

(30.1 cu. in)

Compression ratio ...............................................................................

10.2 : 1

Carburetor ...........................................................................................

KEIHIN CVK36, single

Air cleaner ...........................................................................................

Polyurethane foam element

Starter system .....................................................................................

Electric and recoil starter

Lubrication system ..............................................................................

Wet sump

Idle speed............................................................................................

1 300 ± 100 r/min

DRIVE TRAIN

Clutch ..................................................................................................

Wet shoe, automatic, centrifugal type

Transmission .......................................................................................

Automatic variable ratio (V-belt)

Transfer................................................................................................

2-speed forward with reverse

Gearshift pattern, Transmission .........................................................

Automatic

Transfer..................................................................

L-H-N-R(Hand operated)

Automatic transmission ratio ...............................................................

Variable change (2.876 – 0.703)

Secondary reduction ratio ...................................................................

2.562 (41/16)

Final reduction ratio (Front & Rear) .....................................................

3.600 (36/10)

Transfer gear ratio, Low ......................................................................

2.500 (40/16)

High...................................................................... 1.200 (30/25)

Reverse................................................................

2.000 (28/16 × 32/28)

Drive system........................................................................................

Shaft drive

CHASSIS

Front suspension.................................................................................

Independent, double wishbone, coil spring, oil damped

Rear suspension .................................................................................

Swing arm type, coil spring, oil damped

Front wheel travel ................................................................................

180 mm (7.1 in)

Rear wheel travel ................................................................................

200 mm (7.9 in)

Caster..................................................................................................

3.3°

Trail......................................................................................................

17 mm (0.67 in)

Toe-in...................................................................................................

7 mm (0.3 in)

Camber ...............................................................................................

0.45°

Steering angle .....................................................................................

45° (right & left)

Turning radius......................................................................................

3.0 m (9.8 ft)

Front brake ..........................................................................................

Disc brake, twin

Rear brake...........................................................................................

Disc brake

Front tire size.......................................................................................

AT25 × 8-12

✩✩, tubeless

Rear tire size .......................................................................................

AT25 × 10-12

✩✩, tubeless

ELECTRICAL

Ignition type .........................................................................................

Electronic ignition (CDI)

Ignition timing ......................................................................................

10° B.T.D.C. at 1 300 r/min

Spark plug ...........................................................................................

NGK CR6E or DENSO U20ESR-N

Battery.................................................................................................

12 V 64.8 kC (18 Ah)/10 HR

Generator ............................................................................................

Three-phase A.C. generator

Main fuse.............................................................................................

30 A

Fuse ....................................................................................................

10/10/10/10/10/15 A

Headlight .............................................................................................

12 V 30/30 W × 2

AUX lamp ............................................................................................

12 V 40 W

Brake light/Taillight ..............................................................................

12 V 21/5 W

Parking indicator light ..........................................................................

LED

Speedometer light ...............................................................................

LED

Coolant temperature indicator light .....................................................

LED

Neutral indicator light...........................................................................

LED

High beam indicator light.....................................................................

LED

Reverse indicator light .........................................................................

LED

CAPACITIES

Fuel tank, including reserve ...............................................................

19.0 L (5.0/4.2 US/Imp gal) reserve............................................................................... 4.2 L (1.1/0.9 US/Imp gal)

Engine oil, oil change.........................................................................

2 500 ml (2.6/2.2 US/Imp qt) with filter change ..............................................................

2 700 ml (2.9/2.4 US/Imp qt) overhaul............................................................................

3 200 ml (3.4/2.8 US/Imp qt)

Differential gear oil ..............................................................................

300 ml (10.1/10.6 US/Imp oz)

Final gear oil........................................................................................

350 ml (11.8/12.3 US/Imp oz)

Coolant ................................................................................................

2.0 L (2.1/1.8 US/lmp qt)

– 2 –

SERVICE DATA

VALVE + GUIDE

ITEM

Valve diam.

Valve clearance (when cold)

Valve guide to valve stem clearance

Valve guide I.D.

Valve stem O.D.

Valve stem deflection

Valve stem runout

Valve head thickness

Valve stem end length

Valve seat width

Valve head radial runout

Valve spring free length

Valve spring tension

EX.

IN. & EX.

IN.

EX.

IN.

EX.

IN.

EX.

IN. & EX.

IN.

IN. & EX.

STANDARD

30.6

(1.20)

27.0

(1.06)

0.05 – 0.10

(0.002 – 0.004)

0.17 – 0.22

(0.007 – 0.009)

0.010 – 0.037

(0.0004 – 0.0015)

0.030 – 0.057

(0.0012 – 0.0024)

5.000 – 5.012

(0.1969 – 0.1973)

4.975 – 4.990

(0.1959 – 0.1965)

4.955 – 4.970

(0.1951 – 0.1957)

—

0.9 – 1.1

(0.035 – 0.043)

—

182 – 210 N

(18.6 – 21.4 kgf, 41.0 – 47.2 lbs) at length 31.5 mm (1.24 in)

—

0.35

(0.014)

0.05

(0.002)

0.5

(0.02)

2.3

(0.09)

—

0.03

(0.001)

38.3

(1.53)

—

Unit: mm (in)

LIMIT

—

– 3 –

CAMSHAFT + CYLINDER HEAD

ITEM

Cam height

IN.

Camshaft journal oil clearance

Camshaft journal holder I.D.

Camshaft journal O.D.

Camshaft runout

Rocker arm I.D.

Rocker arm shaft O.D.

Cylinder head distortion

Cylinder head cover distortion

EX.

«22

«17.5

«22

«17.5

«22

«17.5

IN. & EX.

STANDARD

33.430 – 33.498

(1.3161 – 1.3188)

33.500 – 33.568

(1.3189 – 1.3216)

0.032 – 0.066

(0.0013 – 0.0026)

0.028 – 0.059

(0.0011 – 0.0023)

22.012 – 22.025

(0.8666 – 0.8671)

17.512 – 17.525

(0.6894 – 0.6900)

21.959 – 21.980

(0.8645 – 0.8654)

17.466 – 17.484

(0.6876 – 0.6883)

—

12.000 – 12.018

(0.4724 – 0.4731)

11.973 – 11.984

(0.4714 – 0.4718)

—

CYLINDER + PISTON + PISTON RING

ITEM

Compression pressure

(Automatic-decomp. actuated)

Piston to cylinder clearance

STANDARD

Approx. 1 000 kPa (10.0 kgf/cm

, 142 psi)

Cylinder bore

Piston diam.

0.030 – 0.040

(0.0012 – 0.0016)

87.500 – 87.515

(3.4449 – 3.4455)

87.465 – 87.480

(3.4435 – 3.4441)

Measure at 15 mm (0.6 in) from the skirt end.

Cylinder distortion

—

Piston ring free end gap

1st R Approx. 11.2 (0.44)

Piston ring end gap

2nd R

1st

2nd

Approx. 11.9 (0.47)

0.10 – 0.25

(0.004 – 0.009)

0.10 – 0.25

(0.004 – 0.009)

—

0.10

(0.004)

—

0.05

(0.002)

0.05

(0.002)

Unit: mm (in)

LIMIT

33.130

(1.3043)

33.200

(1.3071)

0.150

(0.0059)

0.150

(0.0059)

—

Unit: mm (in)

LIMIT

—

Nicks or

Scratches

87.380

(3.4402)

0.05

(0.002)

8.9

(0.35)

9.5

(0.37)

0.50

(0.020)

0.50

(0.020)

– 4 –

ITEM

Piston ring to groove clearance

Piston ring groove width

Piston ring thickness

Piston pin bore

Piston pin O.D.

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Conrod big end width

Crank web to web width

Crankshaft runout

2nd

Oil

1st

2nd

1st

2nd

1st

OIL PUMP

ITEM

Oil pressure (at 60 °C, 140 °F)

STANDARD

—

1.01 – 1.03

(0.0398 – 0.0406)

1.21 – 1.23

(0.0476 – 0.0484)

2.51 – 2.53

(0.0988 – 0.0996)

0.97 – 0.99

(0.038 – 0.039)

1.17 – 1.19

(0.0461 – 0.0469)

23.002 – 23.008

(0.9056 – 0.9058)

22.995 – 23.000

(0.9053 – 0.9055)

STANDARD

23.006 – 23.014

(0.9057 – 0.9061)

—

0.10 – 0.65

(0.004 – 0.026)

24.95 – 25.00

(0.982 – 0.984)

71.0 ± 0.1

(2.795 ± 0.004)

—

STANDARD

Above 130 kPa (1.3 kgf/cm

, 18 psi)

Below 170 kPa (1.7 kgf/cm

, 24 psi) at 3 000 r/min

CLUTCH

ITEM

Clutch wheel I.D.

Clutch shoe

Clutch engagement r/min

Clutch lock-up r/min

STANDARD

140.0 – 140.2

(5.512 – 5.520)

—

1 600 – 2 000 r/min

3 600 – 4 200 r/min

LIMIT

0.180

(0.0071)

0.150

(0.0059)

—

23.030

(0.9067)

22.980

(0.9047)

Unit: mm (in)

LIMIT

23.040

(0.9071)

3.0

(0.12)

1.0

(0.04)

—

0.08

(0.003)

LIMIT

—

Unit: mm (in)

LIMIT

140.5

(5.53)

No groove at any part

—

– 5 –

DRIVE TRAIN

ITEM

Automatic transmission ratio

Secondary reduction ratio

Final reduction ratio Front

Rear

Transfer gear ratio Low

High

Reverse

Drive belt width

Movable driven face spring free length

Shift fork to groove clearance

Shift fork groove width

High/Low

Shift fork thickness

Reverse

High/Low

Reverse

Front/rear output shaft bevel gear backlash

Front drive (defferential) gear backlash

Rear drive (final) gear backlash

STANDARD

Variable change (2.876 – 0.703)

2.562 (41/16)

3.600 (36/10)

2.500 (40/16)

1.200 (30/25)

2.000 (28/16 × 32/28)

34.7

(1.37)

153.0

(6.02)

0.10 – 0.30

(0.004 – 0.012)

5.50 – 5.60

(0.217 – 0.220)

5.50 – 5.60

(0.217 – 0.220)

5.30 – 5.40

(0.209 – 0.213)

5.30 – 5.40

(0.209 – 0.213)

0.03 – 0.15

(0.001 – 0.006)

0.05 – 0.10

(0.002 – 0.004)

0.08 – 0.013

(0.0031 – 0.0051)

Unit: mm (in) Except ratio

LIMIT

—

33.7

(1.33)

145.4

(5.72)

0.50

(0.020)

—

THERMOSTAT + RADIATOR + FAN + COOLANT

ITEM

Thermostat valve opening temperature

Thermostat valve lift

Radiator cap valve opening pressure

Engine coolant temp. indicator light switch operating temperature

Cooling fan thermo-switch operating temperature

Engine coolant type

Engine coolant including reserve

STANDARD/SPECIFICATION

73.5 – 76.5 °C

(164 – 170 °F)

Over 3 mm (0.12 in) at 90 °C (194 °F)

95 – 125 kPa

(0.95 – 1.25 kgf/cm 2 , 13.5 – 17.8 psi)

OFF

→ ON

→ OFF

Approx. 115 °C (239 °F)

Approx. 108 °C (226 °F)

OFF

→ ON

→ OFF

Approx. 88 °C (190 °F)

Approx. 82 °C (180 °F)

Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

2 000 ml

(2.1/1.8 US/lmp qt)

LIMIT

—

– 6 –

CARBURETOR

Carburetor type

Bore size

I.D. No.

Idle r/min

Float height

ITEM

Main jet

Jet needle

Needle jet

Slow jet

Pilot screw

Throttle cable play

Choke cable play

(M.J.)

(J.N.)

(N.J.)

(S.J.)

(P.S.)

SPECIFICATION

P-24, 28

KEIHIN CVK36

36 mm

03G2

1 300 ± 100 r/min

17.0 ± 1.0 mm

(0.67 ± 0.04 in)

#128

NBAY

#35

1 and 7/8 turns back

3 – 5 mm

(0.12 – 0.20 in)

0.5 – 1.0 mm

(0.02 – 0.04 in)

P-33

←

03G3

←

PRE-SET

←

ELECTRICAL

Spark plug

ITEM

Spark performance

Ignition coil resistance

Generator coil resistance

Generator no-load voltage

(When engine is cold)

Generator Max. output

Regulated voltage

Ignition coil primary peak voltage

Pick-up coil peak voltage

Power source coil peak voltage

Starter relay resistance

Battery Type designation

Capacity

Type

Gap

Primary

SPECIFICATION

NGK: CR6E

DENSO: U20ESR-N

0.7 – 0.8

(0.028 – 0.031)

Over 8 (0.3) at 1 atm.

0.1 – 1.5

Ω

Secondary

Pick-up

Power source

Charging

12 – 22 k

Ω

150 – 300

Ω

0.05 – 1.0

Ω

0.1 – 1.5

Ω

More than 60 V (AC) at 5 000 r/min

Approx. 325 W at 5 000 r/min

13.5 – 15.0 V at 5 000 r/min

More than 150 V

More than 4.0 V

More than 0.3 V

3 – 5

Ω

YTX20CH-BS

12 V 64.8 kC (18 Ah)/10 HR

NOTE

Terminal –

Ground

Plug cap –

Terminal

Bl – G

Y – W

B – B

+ : Ground

- : W/Bl

+ : G, - : Bl

+ : Y, - : W

– 7 –

Fuse size

ITEM

Main

Power source

Headlight (HI)

Headlight (LO)

Tail

Ignition

Fan

WATTAGE

ITEM

Headlight HI

Auxiliary light

Brake light/Taillight

Speedometer light

Reverse indicator light

Neutral indicator light

Parking indicator light

High beam indicator light

Engine coolant temp. indicator light

BRAKE + WHEEL

ITEM

Rear brake cable play

Rear brake pedal height

Brake disc thickness

Brake disc runout

Master cylinder bore

Master cylinder piston diam.

Brake caliper cylinder bore

SPECIFICATION

30 A

10 A

15 A

10 A

SPECIFICATION

30 × 2 pcs.

21/5

LED

Front

Rear

STANDARD/SPECIFICATION

3 – 5

(0.12 – 0.20)

15 – 25

(0.59 – 0.98)

3.3 – 3.7

(0.130 – 0.146)

3.8 – 4.2

(0.209 – 0.224)

Front

Rear

Front

Rear

Front

Rear

—

14.000 – 14.043

(0.5512 – 0.5529)

12.700 – 12.743

(0.5000 – 0.5017)

13.957 – 13.984

(0.5495 – 0.5506)

12.657 – 12.684

(0.4983 – 0.4994)

32.030 – 32.280

(1.2610 – 1.2630)

33.960 – 34.036

(1.3370 – 1.3400)

NOTE

Unit: W

—

Unit: mm (in)

LIMIT

—

3.0

(0.12)

3.5

(0.197)

0.30

(0.012)

—

– 8 –

ITEM

Brake caliper piston diam.

Brake fluid type

Steering angle

Turning radius

Toe-in (with 75 kg, 165 lbs)

Camber

Caster

Wheel rim size

Tire size

Tire type

Tire tread depth

Front

Rear

Right

Left

Front

Rear

Front

Rear

Front

Rear

STANDARD/SPECIFICATION

31.948 – 31.998

(1.2578 – 1.2598)

33.884 – 33.934

(1.3340 – 1.3360)

DOT 4

45°

3.0 m (9.8 ft)

7 ± 4

(0.30 ± 0.16)

0.45°

3.3°

12 × 6.0 AT

12 × 7.5 AT

AT25 8-12

✩ ✩

AT25 10-12

✩ ✩

DUNLOP: KT121D

DUNLOP: KT405D

—

TIRE PRESSURE

COLD INFLATION

TIRE PRESSURE

FRONT

REAR kPa

VEHICLE LOAD CAPACITY LIMIT: 172 kg (380 lbs) kgf/cm 2

0.35

0.30

psi

5.1

4.4

NOTE

LOAD CAPACITY

UP TO 172 kg (380 lbs)

LIMIT

—

4.0

(0.16)

4.0

(0.16)

– 9 –

FUEL + OIL

Fuel type

ITEM

Fuel tank capacity

Engine oil type

Engine oil capacity including reserve reserve

Front/Rear drive gear oil type

Front drive (differential) gear oil capacity

Rear drive gear oil capacity

SPECIFICATION

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE

(Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Overhaul

19.0 L

(5.0/4.2 US/lmp gal)

4.2 L

(1.1/0.9 US/lmp gal)

SAE 10W-40, API SF/SG or SH/SJ with JASO MA

Change

2 500 ml

(2.6/2.2 US/lmp qt)

Filter change

2 700 ml

(2.9/2.4 US/lmp qt)

3 200 ml

(3.4/2.8 US/lmp qt)

Hypoid gear oil SAE #90

API grade GL-5

300 ml

(10.1/10.6 US/lpm oz)

350 ml

(11.8/12. US/lpm oz)

NOTE

– 10 –

FRONT BRAKE HOSE ROUTING

– 11 –

REAR BRAKE HOSE ROUTING

– 12 –

Hello! I am an AI chatbot specifically trained to assist you with the Suzuki LT-A500FK7 ATV Service Bulletin. I have thoroughly reviewed the document and can help you locate the exact information you need or explain the content in clear and simple terms. Whether you’re looking for guidance on specific features, troubleshooting steps, or general usage, feel free to ask your questions. The more details you provide about your concerns or needs, the more accurately and effectively I can assist you!

Show related prompts

Assistant typing

Assistant terminated