Suzuki King Quad LT-A500FK3 2003 Workshop Service Manual

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Stichworte: 2003 Atv King Quad LT-A500FK3 Misc Motorcycles Suzuki

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Beschreibung

The King Quad LT-A500FK3 is a robust All-Terrain Vehicle (ATV) from 2003, designed for the high-performance utility segment. This model features a liquid-cooled engine, shaft drive, and independent front suspension, providing a strong foundation for both demanding utility tasks and trail riding. Its engineering quality is reflected in its competitive positioning against other 500cc class ATVs, offering reliable performance and durability. Key features include a powerful 4-stroke engine, selectable 4WD with front differential lock, and a chassis built for stability and capability across varied terrain. This comprehensive Workshop Service Manual is your essential guide for the repair and overhaul of the 2003 King Quad LT-A500FK3. Covering a wide array of systems from engine and drivetrain to chassis and electrical components, this 459-page English manual provides detailed maintenance procedures, repair instructions, and troubleshooting guidance. It is designed to assist owners and technicians in maintaining the vehicle's optimal performance and longevity, offering solutions for common issues and in-depth information for complex repairs.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

King Quad LT-A500FK3

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Segment:

High-performance utility ATV segment.

Competitive Analysis

Competitors:

Competed against other 500cc class ATVs from brands like Yamaha (Grizzly), Honda (FourTrax), and Kawasaki (Prairie).

Key Features

Features:

Liquid-cooled engine, shaft drive, independent front suspension, robust chassis for utility and trail riding.

Manual Value

Value Proposition:

Essential resource for owners and technicians to maintain, diagnose, and repair the LT-A500FK3, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and overhaul of the Suzuki King Quad LT-A500FK3 2003 model.

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine assembly, disassembly, lubrication, cooling, fuel system, ignition system, starting system, exhaust system.

Drivetrain Systems:

Transmission, clutch, driveshafts, differentials, final drive.

Chassis Systems:

Frame, suspension (front and rear), steering, wheels, tires.

Braking Systems:

Brake calipers, master cylinders, brake lines, parking brake.

Electrical Systems:

Battery, charging system, lighting, ignition switch, CDI unit, wiring diagrams.

Bodywork And Plastics:

Body panels, fenders, seat, handlebars, controls.

Procedures Included

Maintenance Procedures:

Regular inspection, lubrication, filter changes, fluid level checks, spark plug replacement, valve clearance adjustment.

Repair Procedures:

Engine rebuilds, transmission overhaul, suspension repair, brake system servicing, electrical component replacement.

Troubleshooting:

Diagnostic charts, common problems and their solutions, fault finding for electrical and mechanical issues.

Technical Depth

Depth:

Comprehensive, covering routine maintenance to major component overhauls and rebuilds. Assumes a competent technician.

📊 Manual Specifications

File Format

File Type:

Print Quality

Quality:

Digital - High resolution, suitable for on-screen viewing and printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Searchability

Text Search:

Likely searchable text due to PDF format, enabling quick access to specific information.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 4-valve, liquid-cooled

Displacement:

493 cm³ (30.1 cu. in.)

Bore X Stroke:

92.0 mm x 92.0 mm (3.62 in x 3.62 in)

Compression Ratio:

8.6:1

Performance

Horsepower:

Approximately 30-35 HP (estimated, actual figures may vary)

Torque:

Not explicitly stated in product info, but ample low-end torque for utility.

Fuel System

Carburetor:

Mikuni BSR36, single, with throttle position sensor (TPS)

Fuel Type:

Unleaded gasoline (minimum 87 octane recommended)

Ignition System

Ignition:

CDI (Capacitor Discharge Ignition)

Cooling System

Cooling Method:

Liquid-cooled with fan assist

Lubrication

Oil Type:

SAE 10W-40 API SG, SF, or SG/CD.

🔧 Transmission

Standard

Transmission Type:

Automatic with torque converter (CVT)

Gear Selection:

Hi/Lo range, Neutral, Reverse

Optional

Optional Transmission:

N/A for this model year and configuration.

Features

Drive System:

Shaft drive, 4WD with front differential lock (electrically engaging).

Clutch:

Wet multi-plate, automatic centrifugal

📐 Dimensions

Exterior

Overall Length:

2,145 mm (84.4 in)

Overall Width:

1,175 mm (46.3 in)

Overall Height:

1,170 mm (46.1 in)

Wheelbase:

1,315 mm (51.8 in)

Ground Clearance:

260 mm (10.2 in)

Weights

Dry Weight:

273 kg (602 lbs)

Fuel Capacity:

17.0 L (4.5 US gal)

Cargo

Front Rack Capacity:

45 kg (99 lbs)

Rear Rack Capacity:

85 kg (187 lbs)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet American National Standards Institute (ANSI) safety standards for ATVs.

Active Features

Braking System:

Dual front hydraulic disc brakes, single rear hydraulic disc brake, mechanical parking brake.

Suspension Stability:

Independent front and rear suspension contributes to stability over varied terrain.

Passive Features

Ergonomics:

Comfortable seating position, accessible controls for rider comfort and control.

Lighting:

Dual 30W headlights, 15W taillight/stoplight for visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A - Basic utility focus, no integrated infotainment system.

Driver Assistance

Assistance Features:

Selectable 4WD with front differential lock provides enhanced traction assistance.

Connectivity

Connectivity Options:

Engine Management

Electronic Control:

Throttle Position Sensor (TPS) for fuel delivery optimization.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 1,000 km (620 miles) or 6 months, whichever comes first (refer to manual for specifics).

Air Filter Cleaning:

Every 1,000 km (620 miles) or as needed based on operating conditions.

Spark Plug Replacement:

Every 4,000 km (2,500 miles) or as needed.

Valve Clearance Check:

Every 4,000 km (2,500 miles) or as needed.

Fluid Specifications

Engine Oil Capacity:

3.0 L (3.2 US qt) without filter change, 3.2 L (3.4 US qt) with filter change.

Coolant Type:

Suzuki Super Long Life Coolant or equivalent (50/50 mixture of antifreeze and distilled water).

Gear Oil Type:

Suzuki Gear Oil API GL-5, SAE 80W-90 (for final gear case).

Known Issues

Common Wear Items:

CVT belt wear, suspension bushings, brake pads, potential carburetor tuning adjustments due to age/use.

Diagnostic Tips

Troubleshooting Focus:

Manual provides specific diagnostic flowcharts for engine performance, electrical faults, and drivetrain issues.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, a Japanese company with a long history in motorcycles and ATVs.

Model Evolution

Lineage:

The King Quad series has a strong lineage in Suzuki's ATV offerings, known for its robust performance and utility.

Production

Production Era:

The LT-A500FK3 is part of the early 2000s generation of Suzuki's 500cc King Quad models.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards for the 2003 model are not readily available, but the King Quad line generally received positive reviews for its capability and durability.

Ratings

Consumer Ratings:

Generally well-regarded for its power, handling, and utility in its class during its production era.