Suzuki King Quad 500 2002-2007 Workshop Service Manual

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Taper: Atv

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UGS: 81705

Mots clés: 2002 2003 2004 2005 2006 2007 ATV King Quad 500 King Quad Models Powersports Suzuki

Variantes de produits

Description

The Suzuki King Quad 500, first generation (LT-F500F), represents a robust and versatile All-Terrain Vehicle (ATV) designed for both demanding work and recreational pursuits. Produced between 2002 and 2007, this model is powered by a 493cc, 4-stroke engine, featuring independent front suspension for enhanced ride quality and handling. Known for its reliability and power, the King Quad 500 is positioned as a strong competitor in the high-performance ATV segment, offering a valuable proposition to riders seeking a capable and durable machine for various terrains and tasks. This comprehensive Workshop Service Manual provides essential guidance for the maintenance and repair of the Suzuki King Quad 500 (LT-F500F) models from 2002 to 2007. Covering a wide array of systems, including the engine, transmission, fuel, ignition, electrical, suspension, and braking systems, this 459-page manual details everything from routine maintenance procedures and tune-ups to complete component overhauls and troubleshooting for common issues. Its scope is designed to empower owners, DIY mechanics, and professional technicians with the knowledge needed to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

King Quad 500

Generation:

First Generation (LT-F500F)

Codes

Chassis Code:

LT-F500F

👋 Introduction

Market Position

Segment:

High-performance All-Terrain Vehicle (ATV)

Competitive Analysis

Competitors:

Honda Foreman/Rancher, Yamaha Kodiak/Grizzly, Polaris Sportsman

Key Features

Value Proposition:

Reliable, powerful, and versatile ATV for work and recreation, supported by comprehensive service documentation.

Target Audience:

ATV owners, DIY mechanics, professional service technicians.

📋 Manual Details

Coverage Areas

Applicable Years:

2002, 2003, 2004, 2005, 2006, 2007

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Primary Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete Engine Repair and Overhaul

Transmission:

Complete Transmission Disassembly and Repair

Fuel System:

Fuel System Diagnosis and Repair

Ignition:

Ignition System Service and Troubleshooting

Lubrication:

Lubrication System Maintenance and Repair

Exhaust:

Exhaust System Inspection and Repair

Electrical:

Complete Electrical System Diagnosis and Repair

Bodywork:

Body Panel Removal, Installation, and Repair

Suspension Steering:

Front and Rear Suspension, Steering System Diagnosis and Repair

Brakes:

Brake System Maintenance, Repair, and Bleeding Procedures

Cooling System:

Cooling System Diagnosis, Repair, and Coolant Specifications

Wheels Tires:

Wheel and Tire Specifications and Maintenance

Frame Chassis:

Frame and Chassis Inspection and Repair

Instruments Controls:

Instrument Panel and Control Component Service

Procedures Included

Maintenance:

Routine Maintenance Procedures and Schedules

Tune Ups:

Engine Tune-Up Procedures

Removal Installation:

Component Removal and Installation

Assembly Disassembly:

Detailed Assemblies and Disassemblies

Troubleshooting:

Diagnostic Procedures for Common Issues

Troubleshooting Guides:

Systematic troubleshooting flowcharts and guides for common problems.

Torque Specifications:

Detailed torque values for all critical fasteners.

Special Tools:

Identification and usage of specific Suzuki special tools required for certain procedures.

Technical Depth

Depth:

Comprehensive: from basic maintenance to complete engine and transmission rebuilds

Diagnostic Capabilities:

Advanced diagnostic procedures, including electrical system testing using multimeters and troubleshooting logic.

Coverage Areas

Component Specific:

Includes instructions for proprietary Suzuki components as well as those manufactured by third parties.

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF

Searchability:

Searchable text content within the PDF for quick information retrieval.

Print Quality

Printable:

Binding Type

Delivery Method:

Electronic Delivery via Email

Paper Type

Physical Format:

Not a Hard Copy

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Liquid-cooled, OHC, 4-valve

Displacement:

493 cc

Performance

Horsepower:

Approx. 33 hp (estimation based on typical configurations)

Torque:

Approx. 29 lb-ft (estimation based on typical configurations)

Fuel System

Fuel Delivery:

Carburetor (Mikuni BSR36)

Fuel Type:

Unleaded Gasoline (87 Octane Minimum)

🔧 Transmission

Standard

Type:

Automatic (Suzuki Automatic Transmission - SAT) with Hi/Lo range and Reverse

Features

Drive System:

Shaft Drive (4WD)

Clutch Type:

Wet, multi-plate

📐 Dimensions

Exterior

Length:

Approx. 83.3 inches (2115 mm)

Width:

Approx. 47.0 inches (1195 mm)

Height:

Approx. 47.2 inches (1200 mm)

Weights

Curb Weight:

Approx. 600 lbs (272 kg)

Towing Capacity:

Approx. 992 lbs (450 kg)

Rack Capacity Front:

Approx. 44 lbs (20 kg)

Rack Capacity Rear:

Approx. 88 lbs (40 kg)

🛡️ Safety Features

Ratings

Rollover Protection:

Not applicable for ATVs in the same way as cars; focus on stability and rider safety practices.

Active Features

Braking System:

Hydraulic Disc Brakes (Front and Rear)

Suspension:

Independent Front Suspension (IFS), Swingarm Rear Suspension

Passive Features

Lighting:

Dual Halogen Headlights, Brake Light

💡 Technology Features

Infotainment

Features:

Basic digital instrumentation: odometer, trip meter, fuel gauge, clock, 4WD indicator, gear indicator.

Driver Assistance

Features:

On-demand 4WD system with differential lock, engine braking.

Connectivity

Features:

None (typical for this era of ATV).

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 1,000 km or 6 months (refer to manual for specific guidance)

Air Filter Cleaning:

As needed, depending on operating conditions (refer to manual)

Spark Plug Replacement:

Approx. 3,000 km or 12 months (refer to manual)

Fluid Specifications

Engine Oil:

SAE 10W-40 API SG or higher (specific Suzuki recommendation should be followed)

Engine Oil Capacity:

Approx. 3.1 US qt (2.9 L) with filter change

Coolant Type:

Permanent type antifreeze (ethylene glycol base) with distilled water (50/50 mix)

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid

Known Issues

Common Concerns:

Carburetor cleaning/adjustment, occasional CDI unit issues, drive shaft spline wear (under heavy use).

Technical Specifications

Valve Clearance Intake:

0.10 - 0.20 mm (0.004 - 0.008 in) when cold

Valve Clearance Exhaust:

0.20 - 0.30 mm (0.008 - 0.012 in) when cold

Idle Speed:

1400 ± 100 rpm

Spark Plug Gap:

0.6 - 0.7 mm (0.024 - 0.028 in)

Battery Specifications:

Refer to manual for exact battery type and rating (e.g., 12V, specific Ah rating).

Tire Pressure Front:

Refer to manual for specific PSI recommendations.

Tire Pressure Rear:

Refer to manual for specific PSI recommendations.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation

Model Evolution

Predecessor:

Suzuki Quad Runner series

Significant Updates:

Introduction of Independent Front Suspension (IFS) for improved ride quality and handling compared to earlier solid front axles.

Engine Variant Covered:

Specifically covers the 493cc engine utilized across the 2002-2007 model years.

Production

Manufacturing Location:

Japan (typically)