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Suzuki LT-F500FK7 Service Bulletin

Summary of LT-F500FK7

  • Page 1

    Motorcycle date: june. 7, 2006 page: 1 of 12 subject: service information applicable model: lt-f500fk7 effective engine or frame no.: 5saam44a 77100001 – reference: p-24, 28, 33 contents this bulletin is to inform you of the service information for the above model. Please use the following service m...

  • Page 2: Specifications

    – 2 – specifications dimensions and dry mass overall length ...................................................................................... 2 095 mm (82.5 in) overall width........................................................................................ 1 170 mm (46.1 in) overall heigh...

  • Page 3: Service Data

    – 3 – service data valve + guide unit: mm (in) item standard limit valve diam. In. 30.6 (1.20) — ex. 27.0 (1.06) — valve clearance (when cold) in. 0.05 – 0.10 (0.002 – 0.004) — ex. 0.17 – 0.22 (0.007 – 0.009) — valve guide to valve stem clearance in. 0.010 – 0.037 (0.0004 – 0.0015) — ex. 0.030 – 0.0...

  • Page 4

    – 4 – camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 33.430 – 33.498 (1.3161 – 1.3188) 33.130 (1.3043) ex. 33.500 – 33.568 (1.3189 – 1.3216) 33.200 (1.3071) camshaft journal oil clearance right & center 0.032 – 0.066 (0.0013 – ...

  • Page 5

    – 5 – conrod + crankshaft unit: mm (in) oil pump item standard limit piston ring to groove clearance 1st — 0.180 (0.0071) 2nd — 0.150 (0.0059) piston ring groove width 1st 1.30 – 1.32 (0.051 – 0.052) — 2nd 1.01 – 1.03 (0.040 – 0.041) — oil 2.51 – 2.53 (0.0988 – 0.0996) — piston ring thickness 1st 1....

  • Page 6

    – 6 – clutch unit: mm (in) drive train unit: mm (in) except ratio item standard limit clutch release screw 1/4 – 2/4 turn back — drive plate thickness 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) drive plate claw width — 12.9 (0.51) driven plate distortion — 0.10 (0.004) clutch spring free length — 33.8...

  • Page 7

    – 7 – shaft drive unit: mm (in) thermostat + radiator + fan + coolant carburetor item standard limit secondary drive bevel gear back- lash 0.05 – 0.15 (0.002 – 0.006) — final drive bevel gear backlash 0.08 – 0.13 (0.0031 – 0.0051) — front differential drive bevel gear backlash 0.05 – 0.10 (0.0020 – ...

  • Page 8

    – 8 – electrical wattage unit: w item specification note spark plug type ngk: cr6e denso: u20esr-n gap 0.7 – 0.8 (0.028 – 0.031) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.1 – 1.5 Ω terminal – ground secondary 12 – 22 k Ω plug cap – terminal generator coil resistance...

  • Page 9

    – 9 – brake + wheel unit: mm (in) item standard/specification limit rear brake pedal height 15 – 25 (0.2 – 0.6) — brake caliper cylinder bore front 32.030 – 32.080 (1.2610 – 1.2630) — rear 33.960 – 34.036 (1.3346 – 1.3400) — brake caliper piston diam. Front 31.948 – 31.998 (1.2578 – 1.2598) — rear 3...

  • Page 10

    – 10 – tire pressure vehicle load capacity limit: 172 kg (380 lbs) fuel + oil cold inflation tire pressure kpa kgf/cm 2 psi note front 35 0.35 5.1 load capacity up to 172 kg (380 lbs) rear 30 0.30 4.4 item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2)...

  • Page 11: Front Brake Hose Routing

    – 11 – front brake hose routing after touching the brake hose union to the bottom of reservoir, tighten the union bolt to the specified torque. Br ak e hose throttle cab le b star ter cab le rear br ak e cab le p ass the br ak e pipe behind the steer ing shaft. Br ak e pipe c br ak e hose br ak e ca...

  • Page 12: Rear Brake Hose Routing

    – 12 – rear brake hose routing 35˚ 77˚ clip stopper view c view f view g f view e view d view b view a after touching the br ak e hose union to the stopper , tighten the union bolt to the specified torque . When installing the br ak e hose , fix the slee v e of br ak e hose to the shape of hose clam...