Segment:
Premium utility ATV segment, known for its robust performance and comfort.
Competitors:
Yamaha Grizzly 550, Polaris Sportsman 500/550, Can-Am Outlander 500/550.
Engine Configuration:
Powerful 500cc V-twin engine offering excellent torque and smooth power delivery.
Suspension:
Independent front and rear suspension for superior ride comfort and handling over rough terrain.
Drivetrain:
Suzuki's QuadMatic CVT automatic transmission with engine braking, and reliable shaft drive with selectable 2WD/4WD and front differential lock.
Utility:
Heavy-duty racks for cargo hauling, towing capacity, and suitability for hunting, farming, and recreational trail riding.
Engine Mechanical:
Complete engine disassembly, inspection, assembly, lubrication system, cooling system, valve train.
Engine Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, injectors, sensors (MAP, TPS, IAT, ECT).
Transmission Drivetrain:
Automatic transmission (CVT), drive shafts, differentials (front and rear locking), wheel hubs, final drive.
Electrical System:
Ignition system, starting system, charging system (alternator, regulator/rectifier), battery, lighting, instrumentation, fuses, relays.
Suspension Steering:
Front and rear suspension (independent A-arms), shock absorbers, springs, steering system, tie rods, steering shaft.
Braking System:
Front and rear disc brakes, hydraulic lines, brake calipers, master cylinders, parking brake.
Chassis Frame:
Frame inspection and repair, body panels, fenders, racks, seat.
Cooling System:
Radiator, cooling fan, coolant hoses, thermostat, water pump.
Emission Control:
Emission control systems (e.g., PAIR system, catalytic converter).
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common and complex issues, symptom-based troubleshooting guides.
Repair Rebuild:
Detailed instructions for component removal, repair, and reassembly for all major systems.
Engine Overhaul:
Full engine rebuild procedures, including piston replacement, cylinder head service, crankshaft inspection.
Electrical Diagnostics:
Wiring diagrams, component testing procedures, electrical fault finding.
Transmission Service:
CVT belt inspection and replacement, gearbox lubrication, final drive service.
Suspension Alignment:
Suspension component replacement, wheel alignment specifications and procedures.
Brake Maintenance:
Brake pad replacement, caliper service, bleeding the brake system.
Depth:
Comprehensive, covering from basic maintenance to advanced diagnostics and complete rebuilds.
Detail Level:
Step-by-step instructions with torque specifications, clearances, and testing parameters.
Diagnostic Tools:
Information on necessary special tools and diagnostic equipment.
Engine Type:
4-stroke, SOHC, V-twin, liquid-cooled
Displacement:
493cc (493 cm³)
Bore X Stroke:
72.0 mm x 60.2 mm
Horsepower:
Approximately 33-35 HP (estimated, manufacturer does not always publish exact figures for ATVs)
Torque:
Approximately 41 Nm (estimated)
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle valves
Fuel Type:
Unleaded gasoline, 87 octane (or higher)
Fuel Tank Capacity:
4.6 US gallons (17.5 L)
Oil Type:
SAE 10W-40 API SE/SF or SG (check manual for specific Suzuki recommendations)
Oil Capacity:
Approx. 2.6 US qt (2.5 L) with filter change
Atv Safety Standards:
Designed to meet ANSI standards for ATVs (though specific numerical ratings are less common than for cars).
Braking System:
Front: Dual hydraulic disc. Rear: Dual hydraulic disc. Parking brake on rear drive shaft.
Engine Braking:
CVT provides effective engine braking, especially in low range.
Differential Lock:
Electrically engaged front differential lock for enhanced traction in difficult terrain.
Frame Construction:
Steel frame, designed for durability and strength.
Lighting:
Dual 30W headlights, 8W taillight/stoplight.
Tires:
AT25x8R12 front, AT25x10R12 rear (standard for XP models, designed for traction).
Engine Oil Change:
Every 1,000 km or 6 months (refer to manual for exact Suzuki recommendations)
Air Filter Cleaning:
Inspect every 500 km, clean as needed. Replace if damaged.
Spark Plug Inspection:
Every 2,000 km or 12 months.
Valve Clearance Check:
Every 2,000 km or 12 months.
Cvt Belt Inspection:
Inspect every 1,000 km or 6 months.
Engine Oil:
SAE 10W-40 API SE/SF or SG (Suzuki branded recommended)
Coolant:
Suzuki Super Long Life Coolant (SLLC) or equivalent (50/50 mix with distilled water)
Brake Fluid:
DOT 4 hydraulic brake fluid
Final Drive Oil:
Suzuki Gear Oil (99000-25110) or SAE 80 API GL-4 hypoid gear oil (front and rear)
Common Wear Items:
CVT belt, brake pads, wheel bearings, tie rod ends due to typical ATV usage.
Efi System:
Occasional cleaning of throttle body and fuel injectors may be needed depending on fuel quality and usage.
Suzuki Atv Legacy:
Suzuki has a long-standing reputation for producing reliable and capable ATVs, including the pioneering QuadRunner series and the highly acclaimed KingQuad line.
Kingquad Development:
The KingQuad line has evolved significantly, with the 'XP' designation often signifying performance enhancements, including V-twin engines and advanced suspension, building on earlier single-cylinder models.
Production Period For This Manual:
2009-2010 model years represent a specific iteration of the KingQuad 500XP platform.
