The Suzuki LT500R QuadZilla, produced from 1987 to 1990, stands as a testament to Suzuki's prowess in the high-performance all-terrain vehicle market. This powerful 2-stroke ATV, featuring a liquid-cooled 499cc engine and a 6-speed manual transmission, was engineered for aggressive sport riding and off-road capability. Known for its potent power delivery and agile handling, the QuadZilla competed effectively in its segment, offering enthusiasts a thrilling and capable machine. Its robust construction and performance-oriented design made it a significant model in Suzuki's ATV history, appealing to riders seeking an adrenaline-fueled experience. This comprehensive service manual provides essential information for the maintenance, repair, and restoration of 1987-1990 Suzuki LT500R QuadZilla ATVs. Covering all major systems, including the engine, cooling, fuel, electrical, drivetrain, chassis, and brakes, it offers detailed step-by-step procedures, diagnostic guidance, and factory specifications. From routine maintenance and tune-ups to complete engine overhauls and component replacements, this manual is an invaluable resource for owners, technicians, and mechanics. It includes critical data such as torque specifications, fluid types, and troubleshooting tips for common issues, ensuring the QuadZilla can be kept in optimal working condition. 🏷️ Basic Information Identification Make: Suzuki Model: LT500R QuadZilla Vehicle Type: All-Terrain Vehicle (ATV) Generation: First Generation Production Years Covered: 1987, 1988, 1989, 1990 Codes Model Codes: LT500R (1987), LT500RJ (1988), LT500RK (1989), LT500RL (1990) 👋 Introduction Market Position Market Position: The Suzuki LT500R QuadZilla was a high-performance sport ATV in its era, known for its powerful engine and aggressive styling. This manual serves as an indispensable tool for owners and enthusiasts seeking to maintain, repair, and restore these iconic machines. Competitive Analysis Competitive Analysis: Competed against other high-performance 2-stroke ATVs of the late 1980s, offering significant power and agility. This manual provides the critical technical data needed to keep these machines running at their peak, a key differentiator for enthusiasts. Key Features Key Features: Comprehensive coverage for multiple model years, detailed step-by-step instructions, clear illustrations and diagrams, troubleshooting guide, factory-level repair information, DIY friendly. Instant download capability. 📋 Manual Details Coverage Areas Coverage: Complete service, repair, and maintenance for 1987-1990 Suzuki LT500R QuadZilla ATVs. Page Count Page Count: 239 pages Manual Type Manual Type: Service Manual / Repair Manual / Workshop Manual / Factory Manual Language Language: English Format Format: Digital Download (PDF, ZIP, RAR, EXE) 📖 Manual Coverage Systems Covered Systems: Engine (rebuild, tune-up, diagnostics), Cooling System, Fuel Systems (carburetor, fuel pump, EFI for applicable models), Electrical System (ignition, charging system, battery, wiring diagrams), Chassis, Suspension (front forks, rear shock/strut), Drivetrain (transmission, clutch, drive shaft, rear axle), Brakes (front and rear), Steering, Bodywork (fenders, plastics), Wheels and Tires. Procedures Included Procedures: Periodic maintenance, tune-up procedures, engine overhaul, troubleshooting common problems, repair and replacement of all major components, carburetor adjustment, suspension setup, electrical diagnostics, brake servicing, lubrication, fluid changes, installation procedures, preventative maintenance. Technical Depth Depth: Comprehensive from basic maintenance and adjustments to complete engine rebuilds, transmission overhauls, and advanced electrical diagnostics. Includes torque specifications, clearances, fluid types and capacities, and detailed step-by-step instructions with illustrations. 📊 Manual Specifications File Format File Format Details: PDF format, compatible with all PDF readers. May be zipped/compressed requiring extraction software (WinZip, WinRAR). Digital delivery, no physical copy. File size can be up to 5GB. Printable and savable. Print Quality Print Quality: High-resolution digital scan, suitable for printing. Zoomable illustrations and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Displacement: 499cc (499 cubic centimeters) Bore X Stroke: 85.0 mm x 87.0 mm (approximate) Compression Ratio: 7.4:1 (approximate, check manual for specific year variations) Performance Horsepower: Approx. 45-50 HP (varies slightly by year and tune) Torque: Refer to manual for specific torque figures. Fuel System Carburetor: Mikuni VM34SS (typically) Fuel Injection: Not standard on all models; early models are carbureted. Some later iterations or modifications might exist. Cooling System Cooling Type: Liquid-cooled Lubrication Oil Type: 2-stroke engine oil, specific mix ratio with gasoline or oil injection system (refer to manual for exact specifications and pre-mix ratio). 🔧 Transmission Standard Transmission Type: 6-speed manual with clutch Optional Optional Transmission: N/A Features Features: Constant mesh, foot-operated gear shifter. Fluid Specifications Transmission Oil Type: Refer to manual for specific transmission oil type and capacity (typically gear oil). 📐 Dimensions Exterior Overall Length: Refer to manual for exact dimensions. Overall Width: Refer to manual for exact dimensions. Overall Height: Refer to manual for exact dimensions. Weights Dry Weight: Approx. 350-370 lbs (159-168 kg, varies by year) Fuel Capacity: Approx. 2.6 gallons (9.8 liters, check manual for exact figure) 🛡️ Safety Features Ratings Safety Ratings: N/A (ATVs typically do not receive standardized crash ratings like cars). Active Features Active Safety Features: Disc brakes (front and rear), robust suspension system designed for off-road stability. Passive Features Passive Safety Features: Durable frame...