does any one know who makes a service manual for my 88 lt 500? will I have to call a suzuki dealer or what? also what is this bearing problem about? any help is appreciated. thanks, jon

 

I have never found an after market publisher for the 500r...I had to buy one at the dealer!

The crank bearing bosses expand at a different rate than the bearings allowing the crank bearings to become loose, thus cavitating the bosses. This leads to crank seal failure, sucking air into the motor leaning out your mixture and potentially causing your piston to seize. It can also cause primary drive gear failure.The 100% fix for this is to have your crank bearing bosses machined out and bronze bushings pressed in, the crank bearings are then pressed into the steel sleeves and voila! Your all set-forever!(The steel bushings expand faster than the steel bearing or the aluminum case, creating a tighter grip
as the temp increases.)

To determine if you need this fix, remove your flywheel side cover, grasp your flywheel and try to lift the bike/push down on the bike in a back and forth motion. If your flywheel has any perceptible movement whatsoever you gotta do it. the best spot for the repair is Tudors Performance. They guarantee the fix for a couple of years. Although I know of a couple dozen bikes they have done, besides four for for me with no reported failures. So you should be completely satisfied.
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No dont take it to Tudors .... If you want your motor back sometime in 2003 try someone else. Im sure Jeff does quality work but he takes forever and ever and ever.

 

thanks, guys. howmuch did you pay for the service manual? also what weightoil do you guys use in the crankcase?

 

I paid right around 50 bucks for my manual, and I run 20W50 in the case.

 

Ive done several of these bronze inserts, I own 100,000 in machine shop equipment, must of my work is done on power sport toys. I can have this done in a couple of days. kennedy_fab@yahoo.com

 

The manuals are like $62 here at the dealer. I just bought one not too long ago. Keep an eye on ebay sometimes you will find them on there too.

LRD makes those bronze bushings that stormnnorm was talking about.

 

try MidWest Action Cycle I paid $45 for mine there

 

Hey I found a place that has them for $52 and they have them in stock!!! Action Sport Cycle in Alliance, OH (330)821-8777 they also ship stuff if you need it sent to you...