I just purchased an 89 LT-500R & have a couple of questions:
1. Does anybody know where I can get a service manual? From Suzuki its like $45, a little steep for me.
2. Does anybody know of a good graphics kit, or where to get factory graphics for this year?
3. Does anybody have advice on how to more easily kick this beast? The previous owner showed me his technique which got it to start about 2-3 kicks every time, doesn't work for me.
Thanks.

 

Also does anybody know what size in cc's it would be with stage 2 port and a 88.5 piston?

 

a trick to starting it is to:

#1 kick it over 3 times with the motor turned off
#2 find top dead center: put pressure on the kick starter and it will get real hard, push a lil harder and it will roll over and become easy to push down. but dont push it all the way down, you must stop pushing once it becomes easy to push
#3 let the kick starter all the way up and the jump up and put all your weight on the kickstarter.



i couldnt figure out a better way to explain #2, you just have to go play with kickstating it and you may understand what im saying........ but i can start it 1st kick doing it that way

 

kick when in neutral only, kicking with it in gear and the clutch pulled in makes it more difficult

and to rephase what has been said, when you feel the piston starting to build compression allow the kicker to spring back to the top of its stroke and give it good hard full kick all the way through. My buddies try to start my LT250R with a half kick and they can't get it.

I think there are some flame graphics on ebay. Same for the service manual.

As far as displacement goes, CC=(PIE(R)^2 x STROKE)/1000, porting doesn't affect the displacement.

 

And I have a Service manual I will sell since I sold my Zilla. PM me if your interested. You can find most anything you want for the beasts on ebay. The graphics, there are no aftermarket kits. you can find stock graphics repros on ebay as well.

How I kicked my zilla: If cold choke, never any throttle till it was already started. Tap down on it lightly till you get it really hard to push down right at the top of the kickstarters stroke. Then hop up with your left and slam down with your right following through and staying firm on the kickstarter. Once it starts imediatly turn the choke off you wont need it. Always worked 1st to 3rd kick. I didnt winterize mine and let it sit all winter started 7th kick with just a new plug. WEAR BOOTS. once you get the hang of it you can probably do it with less of a shoe if you have the rythm down and you are one with your engine (as zen as that sounds it happens) but for now wear boots or somthing with a thick sole so you can kick without hesitation

 

I just purchased a 90 a week ago...... same problem, hard to start. Did the technicque listed and it will start first kick. I am going to work with the jetting a little though. I think mine is lean and the pilot jet too small......

 

Man my technique used to be go all the way down with the kickstart come up til you hear 3 clicks then kick. But I always found my zilla hard started before I rebuilt, I must try those new techniques might work, i've still yet to jet it properly.

 

Although I used to have a quadzilla (see avatar),I dont remember my technics on starting that thing.

I recently disovered how my KX500 likes to start, so I thought Id share.
A FULL KICK. All the way up, all the way down to peg contact.

I think they engineered it this way, because it makes the piston travel 2 full revolutions, and it makes the big KX start up almoast first kick every time.
(imagine that!)

So, zilla guys, try to kick that thing a FULL KICK. From the very top click, (piston on the compression stroke) and kick it hard, ALL the way down.

A snap kick, eh... sometimes they work, but when it does.. it was just luck. [img]i/expressions/face-icon-small-smile.gif[/img]

 

Did you ever get a kick back? Man that hurts bad. I split a boot once!

 

goto everything2stroke.com they have the full manual available for DL free.......