🏷️ Basic Information

Make:

Suzuki

Model:

King Quad

Model Variant:

LT-A500FK4

Year:

2004

Chassis Code:

LT-A500FK4

👋 Introduction

Positioning:

High-performance utility ATV for serious riders and demanding work applications

Competitors:

Polaris Sportsman 500, Honda Foreman 500, Kawasaki Prairie 400, Yamaha Kodiak 400

Features:

Powerful 500cc engine, automatic transmission, independent front and rear suspension, selectable 2WD/4WD, electric power steering (on some variants, though not explicitly stated for FK4 variant, common for the generation)

📋 Manual Details

Areas Covered:

Complete repair and overhaul for Suzuki King Quad LT-A500FK4 2004 model

Page Count:

459

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Engine overhaul, lubrication, cooling system, fuel system, ignition system, exhaust system

Transmission Drivetrain:

Automatic transmission (CVT), gear shift mechanism, drive shafts, differentials, final drive

Chassis Suspension:

Frame, front suspension (double A-arm), rear suspension (swingarm), shock absorbers, steering system

Braking System:

Front and rear disc brakes, hydraulic system, brake lever and pedal operation

Electrical System:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, ignition switch, wiring diagrams, fuses, relays

Fuel System:

Fuel tank, fuel pump, fuel filter, carburetor (Mikuni BSR42), fuel lines

Lubrication System:

Oil pump, oil filter, oil passages, oil change procedures

Cooling System:

Radiator, cooling fan, coolant hoses, thermostat

Bodywork Trim:

Body panels, fenders, seats, handlebars, racks

Maintenance Procedures:

Oil change, filter replacement, spark plug replacement, air filter cleaning/replacement, valve clearance adjustment, brake fluid flush, coolant flush, lubrication points

Repair Procedures:

Engine disassembly and reassembly, transmission overhaul, carburetor tuning and rebuilding, suspension component replacement, brake caliper overhaul, electrical component testing and replacement

Troubleshooting:

Diagnostic procedures for common performance issues, electrical faults, starting problems, and operational anomalies

Assembly Disassembly:

Detailed instructions for component removal, installation, and reassembly

Depth:

Comprehensive overhaul, detailed repair, advanced diagnostics, factory specifications

Diagnostic Tools:

Information on using standard hand tools, torque wrenches, and basic electrical testing equipment

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans, clear diagrams and text

Binding Type:

Not Applicable (PDF Download)

Paper Type:

Not Applicable (PDF Download)

⚙️ Engine Specifications

Engine Type:

4-stroke, liquid-cooled, SOHC, V-twin

Displacement:

493 cc (30.1 cubic inches)

Bore X Stroke:

65.0 mm x 74.0 mm (2.56 in x 2.91 in)

Horsepower:

Approximately 30 HP (specific dyno figures may vary)

Torque:

Approximately 28 lb-ft (specific dyno figures may vary)

Fuel Delivery:

Carburetor (Mikuni BSR42)

Fuel Type:

Unleaded gasoline, 87 octane or higher

Oil Type:

SAE 10W-40 API SG or SH (check manual for exact specifications)

Oil Capacity W Filter:

2.3 L (2.4 US qt)

Coolant Type:

Permanent type antifreeze (50/50 mix with distilled water)

Ignition Timing:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK CR9E or DENSO U27FER9 (verify with manual)

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive Modes:

2WD / 4WD selectable

Gear Reduction:

High and Low range, Reverse

Transmission Fluid Type:

Suzuki Automatic Transmission Fluid (SUZUKI ATF 5D09) or equivalent (API GL-4)

Transmission Fluid Capacity:

1.5 L (1.6 US qt)

📐 Dimensions

Overall Length:

2,065 mm (81.3 in)

Overall Width:

1,165 mm (45.9 in)

Overall Height:

1,235 mm (48.6 in)

Wheelbase:

1,275 mm (50.2 in)

Ground Clearance:

265 mm (10.4 in)

Dry Weight:

280 kg (617.3 lbs)

Curb Weight:

Approximately 290 kg (639 lbs) (with all necessary fluids)

Front Rack Capacity:

45 kg (99 lbs)

Rear Rack Capacity:

85 kg (187 lbs)

Fuel Tank Capacity:

17.3 L (4.6 US gal)

🛡️ Safety Features

Safety Features:

Disc brakes front and rear, integrated parking brake, engine braking

Active Safety:

Selectable 2WD/4WD, reliable braking system

Passive Safety:

Durable frame construction, comfortable seating position, handlebar design for control

💡 Technology Features

Infotainment Systems:

Not applicable for this utility ATV model; focus is on functionality and durability.

Driver Assistance Features:

Electric Power Steering (EPS) may be present on certain LT-A500FK4 sub-models, enhancing maneuverability (confirm specific model variant).

Connectivity Features:

Not applicable for this utility ATV model.

Lighting System:

Halogen headlights, taillight/brake light combination

🔧 Maintenance

Initial Service:

First service typically recommended at 1000 km or 6 months (refer to manual for exact mileage)

Engine Oil Change:

Every 2000 km or 6 months

Air Filter Cleaning:

Every 1000 km or as needed in dusty conditions

Valve Clearance Check:

Every 4000 km or 24 months

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Coolant Capacity:

1.4 L (1.5 US qt)

Common Wear Items:

CVT belt wear, brake pad wear, suspension bushings, wheel bearings

Potential Problems:

Carburetor performance degradation over time, fuel pump issues, cooling fan motor failure

Chassis Lubrication:

Regular greasing of suspension pivot points, steering head bearings, and drive shaft U-joints

📚 Vehicle History

Heritage Overview:

Suzuki has a long history of producing reliable and capable off-road vehicles, including a strong legacy in ATV manufacturing.

King Quad Lineage:

The King Quad line has consistently offered powerful engines and advanced features, evolving from earlier models to meet the demands of utility and recreational riders.

Manufacturing Origin:

Japan (typical for Suzuki ATVs of this era)

🏆 Awards & Recognition

Awards History:

While specific awards for the 2004 LT-A500FK4 may not be widely publicized, the King Quad line generally received positive reviews for its power and capability in the utility ATV segment during its production years.