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1987-1990 Suzuki LT 500 R (RJ /RK /RL ) Quad Zilla Service Repair Manual (FREE PREVIEW) PDF Download
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Basic Information Identification Make: Suzuki Model: LT500R Quad Zilla Model Code Range: RJ / RK / RL Codes Chassis Codes: RJ (1987), RK (1988), RL (1989), RM (1990) Generation Generation...
Typ: Autos
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Art.-Nr: 48389
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Maruti Suzuki
Suzuki
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| Basic Information | |
| Identification | |
| Make: | Suzuki |
| Model: | LT500R Quad Zilla |
| Model Code Range: | RJ / RK / RL |
| Codes | |
| Chassis Codes: | RJ (1987), RK (1988), RL (1989), RM (1990) |
| Generation | |
| Generation Identifier: | First Generation |
| Introduction | |
| Market Position | |
| Product Positioning: | Essential resource for owners and technicians seeking dealer-level repair and maintenance capabilities for the Suzuki LT500R Quad Zilla. |
| Competitive Analysis | |
| Manual Value Proposition: | Provides comprehensive, dealer-equivalent information at a fraction of the cost, empowering DIY enthusiasts and professionals alike. |
| Key Features | |
| Unique Selling Points: | Detailed illustrations, step-by-step instructions, extensive coverage of all systems, printable format. |
| Manual Details | |
| Coverage Areas | |
| Covered Models: | 1987 Suzuki LT500R, 1988 Suzuki LT500RJ, 1989 Suzuki LT500RK, 1990 Suzuki LT500RL |
| Page Count | |
| Estimated Page Count: | Comprehensive (Exact count not provided, but extensive based on listed topics) |
| Manual Type | |
| Manual Type: | Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| File Format: | |
| Manual Coverage | |
| Systems Covered | |
| Powertrain Systems: | Engine, Gearbox, Clutch, Transmission, Lubrication System, Cooling System, Fuel System, Ignition System, Electric Starter |
| Chassis Systems: | Frame, Body Panels, Fenders, Exhaust System, Front Wheel, Steering System, Rear Wheel System, Wheels & Tires |
| Electrical Systems: | Alternator, Starter Clutch, Battery/Charging System, Lights/Meters/Switches, Wiring Diagrams |
| Suspension Braking: | Suspension (Front and Rear), Braking System |
| Procedures Included | |
| Diagnostic Repair: | All diagnostic and repair procedures covered |
| Maintenance Rebuild: | Repair, Maintain, Rebuild, Refurbish, Restore |
| Technical Depth | |
| Depth Of Coverage: | Detailed illustrations, step-by-step instructions, comprehensive technical information and specifications |
| Engine Rebuild Procedures: | Includes detailed steps for engine removal/installation, disassembly, inspection, and reassembly of internal components (crankcase, piston, cylinder, crankshaft, valves). |
| Transmission Overhaul: | Covers gearbox and clutch inspection, repair, and overhaul, including transmission system components. |
| Suspension And Steering Service: | Detailed procedures for servicing the front wheel and steering system, as well as the rear suspension system. |
| Electrical System Diagnostics: | Comprehensive coverage of the electrical system including alternator, starter clutch, battery/charging system, ignition system, lighting, and detailed wiring diagrams for troubleshooting. |
| Troubleshooting Guides: | Includes a dedicated troubleshooting section to help diagnose and resolve common problems. |
| Chassis And Body Repair: | Procedures for working on the frame, body panels, fenders, and exhaust system. |
| Specifications And Data: | Provides essential technical specifications, torque values, clearances, and data required for accurate repairs and adjustments. |
| Manual Specifications | |
| File Specifications | |
| File Format: | |
| Print Quality: | Printable without restriction |
| Readability Requirements: | Adobe PDF Reader |
| Delivery | |
| Delivery Method: | Download link on checkout page after payment |
| Binding Type | |
| Binding Type: | Digital (PDF download) |
| Paper Type | |
| Paper Type: | Not Applicable (Digital Format) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | 2-stroke, Liquid-cooled, Single-cylinder |
| Displacement: | 499 cc (30.4 cu. in.) |
| Performance | |
| Bore X Stroke: | 86.0 mm x 86.0 mm (3.39 in. x 3.39 in.) |
| Compression Ratio: | 6.8:1 |
| Horsepower Estimate: | Approximately 45-50 HP (exact figures vary by tuning and year) |
| Torque Estimate: | Not explicitly stated but significant for its class. |
| Fuel System | |
| Carburetor: | Mikuni VM34SS (or similar, specification varies by year/market) |
| Fuel Type: | Unleaded gasoline (Octane rating to be specified in manual) |
| Fuel Injection System: | Not applicable ( carbureted ) |
| Lubrication System | |
| Lubrication Type: | Premix or Oil Injection (specify in manual) |
| Cooling System | |
| Cooling Method: | Liquid-cooled |
| Transmission | |
| Standard | |
| Transmission Type: | 6-speed, constant mesh, return-shift |
| Optional | |
| Optional Transmission: | Not Applicable |
| Features | |
| Clutch Type: | Wet, multi-plate |
| Final Drive: | O-ring sealed chain |
| Dimensions | |
| Exterior | |
| Overall Length: | Not specified in product info, typical for class 70-80 inches. |
| Overall Width: | Not specified in product info, typical for class 45-50 inches. |
| Overall Height: | Not specified in product info, typical for class 40-45 inches. |
| Weights | |
| Dry Weight: | Approx. 370-400 lbs (168-181 kg) depending on year and specific components. |
| Fuel Capacity: | Approx. 3.2 gallons (12 liters) |
| Safety Features | |
| Ratings | |
| Atv Safety Considerations: | High-performance ATV; requires experienced rider, protective gear, and adherence to safe riding practices. Manual covers operational safety. |
| Active Features | |
| Braking System: | Hydraulic disc brakes, front and rear |
| Passive Features | |
| Frame Construction: | Steel frame design, detailed in chassis section. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Not Applicable (Basic instrumentation only) |
| Driver Assistance | |
| Driver Assistance Features: | Not Applicable |
| Connectivity | |
| Connectivity Features: | Not Applicable |
| Electrical Components | |
| Ignition System Type: | CDI (Capacitor Discharge Ignition) system with variable timing. |
| Lighting System: | Headlights, taillights, brake lights, and instrument cluster lighting. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Refer to manual for specific intervals based on usage; typically every 20-40 hours of operation for gearbox oil. |
| Air Filter Cleaning: | Frequent cleaning and inspection recommended, especially in dusty conditions, as per manual guidelines. |
| Spark Plug Replacement: | Refer to manual for recommended service intervals and correct spark plug type (e.g., NGK BR9ES). |
| Fluid Specifications | |
| Engine Oil Type: | 2-stroke engine oil (premix or injector oil type as specified in manual, e.g., API TC grade). |
| Gearbox Oil Type: | Suzuki recommends specific gear oil for the transmission, likely a SAE 80W API GL-4 or GL-5. |
| Coolant Type: | Ethylene glycol-based antifreeze mixture (refer to manual for specific mixture ratio and type). |
| Known Issues | |
| Common Wear Points: | Clutch wear, piston ring wear, carburetor jetting issues, electrical connector corrosion, exhaust system leaks. Manual provides diagnostic procedures for these. |
| Performance Tuning: | Manual provides baseline specifications for engine tuning, carburetor settings, and ignition timing. |
| Vehicle History | |
| Brand Heritage | |
| Suzuki Atv Legacy: | Suzuki has a long-standing reputation for building powerful and capable off-road vehicles, with the Quad Zilla line being a significant part of its performance ATV history. |
| Model Evolution | |
| Lt500R Development: | The LT500R was Suzuki's flagship performance sport ATV of its era, evolving from earlier models and setting benchmarks for power and handling. |
| Production | |
| Production Years Covered: | 1987-1990 |
| Manufacturing Location: | Japan (typically) |
| Awards & Recognition | |
| Recognitions | |
| Industry Recognition: | The LT500R was widely recognized in its time as a top-tier performance sport ATV, lauded for its power and speed. |
| Ratings | |
| Performance Benchmark: | Considered a benchmark for sport ATV performance during its production run. |