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Suzuki KingQuad 500 Service Manual Repair 2009-2014 LT-A500XP

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🏷️ Basic Information Identification Make: Suzuki Model: KingQuad 500 AXi Model Code: LT-A500XP Generation Generation: Third Generation (2009-2014) Codes Vin Code Prefix: JS1 👋 Introduction Market Position Market Position: The...
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Suzuki KingQuad 500 Service Manual Repair 2009-2014 LT-A500XPSuzuki KingQuad 500 Service Manual Repair 2009-2014 LT-A500XPSuzuki KingQuad 500 Service Manual Repair 2009-2014 LT-A500XPSuzuki KingQuad 500 Service Manual Repair 2009-2014 LT-A500XP
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
KingQuad 500 AXi
Model Code:
LT-A500XP
Generation
Generation:
Third Generation (2009-2014)
Codes
Vin Code Prefix:
JS1
👋 Introduction
Market Position
Market Position:
The Suzuki KingQuad 500 AXi is a premium, feature-rich utility ATV known for its robust performance, advanced technology (including power steering), and exceptional off-road capability. It competes in the high-performance utility ATV segment.
Competitive Analysis
Competitive Analysis:
Key competitors include Yamaha Grizzly 550/700, Polaris Sportsman 500/570, Can-Am Outlander 500/570, and Honda Foreman 500. The KingQuad 500 AXi differentiates itself with its class-leading power steering, comfortable ride, and strong engine performance.
Key Features
Key Features:
Electronic Fuel Injection (EFI), Twin Spark Plugs for enhanced combustion, advanced independent suspension, rugged chassis, durable drivetrain, and the significant advantage of power steering for reduced rider fatigue.
📋 Manual Details
Coverage Areas
Model Years Covered:
2009, 2010, 2011, 2012, 2013, 2014
Specific Models Covered:
LT-A500XP (Models with Power Steering)
Page Count
Page Count:
624
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine teardown, rebuild, diagnosis, specifications, fuel system (EFI), ignition, lubrication, cooling system.
Transmission Drivetrain:
Automatic transmission (CVT), differential, axles, driveshafts, final drive, clutch system, lubrication.
Chassis Frame:
Frame inspection, repair, mounting points, body panels, plastics, seats.
Suspension Steering:
Front and rear suspension (independent), shocks, springs, control arms, bushings, steering system (including power steering), wheel alignment, steering knuckle.
Brakes:
Hydraulic braking system (front and rear discs), brake calipers, master cylinder, brake lines, parking brake, fluid specifications.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlights, taillights, work lights), ignition system, sensors, wiring diagrams, fuses, relays.
Fuel System:
Fuel injection system (EFI), fuel pump, fuel injectors, throttle body, fuel tank, fuel lines, pressure specifications.
Cooling System:
Radiator, cooling fan, coolant hoses, thermostat, coolant specifications, flush procedures.
Wheels Tires:
Wheel specifications, tire pressure, recommended tire sizes, lug nut torque.
Procedures Included
Maintenance Schedule:
Comprehensive scheduled maintenance procedures, oil changes, filter replacements, fluid checks, lubrication points.
Troubleshooting:
Extensive troubleshooting guides, diagnostic procedures, error code interpretation, common problems and solutions.
Repair Rebuild:
Detailed step-by-step instructions for complete teardown, repair, and reassembly of all major components.
Torque Specifications:
Precise torque values for all critical fasteners and bolts.
Diagnostic Charts:
Flowcharts and charts for diagnosing electrical and mechanical issues.
Adjustment Procedures:
Procedures for adjusting components such as valve clearance, throttle linkage, and idle speed.
Part Diagrams Illustrations:
Exploded views and detailed illustrations of all parts for easy identification and assembly.
Technical Depth
Technical Depth:
Comprehensive, covering everything from basic routine maintenance to complete engine and transmission overhauls. Suitable for DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution images and text, suitable for printing.
Binding Type
Binding Type:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
Digital Features
Searchable Text:
Yes
Clickable Chapters:
Yes
Printing Rights:
Unlimited printing rights.
Saving Rights:
Unlimited saving and burning to disc rights.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, DOHC, 4-valve, single cylinder
Displacement:
493 cc
Bore X Stroke:
94.0 mm x 71.2 mm
Fuel System:
Electronic Fuel Injection (EFI), Mikuni throttle body, single injector.
Cooling System:
Liquid-cooled
Ignition:
Electronic ignition (CDI), Twin Spark Plug configuration
Performance
Horsepower Estimate:
Approx. 35-40 HP (Actual figures vary by specific model year and tuning)
Torque Estimate:
Approx. 30-35 lb-ft (Actual figures vary by specific model year and tuning)
Fuel System
Fuel Tank Capacity:
4.8 gal (18.0 L)
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher
Engine Oil Capacity:
2.7 US qt (2.5 L) with oil filter change
Coolant Type:
High-quality permanent type antifreeze coolant (50/50 mix with distilled water)
🔧 Transmission
Standard
Transmission Type:
Torque-converter automatic transmission (CVT - Continuously Variable Transmission) with engine braking
Gear Selection:
Hi/Lo range, Neutral, Reverse, Park
Features
Drive Modes:
2WD / 4WD selectable with locking front differential
Fluid Specifications
Transmission Oil Type:
Suzuki Belt Oil (Special CVT fluid) or equivalent
Transmission Oil Capacity:
1.6 US qt (1.5 L)
📐 Dimensions
Exterior
Overall Length:
84.1 in (2136 mm)
Overall Width:
48.2 in (1225 mm)
Overall Height:
47.0 in (1195 mm)
Wheelbase:
50.2 in (1275 mm)
Ground Clearance:
10.0 in (255 mm)
Weights
Dry Weight:
648 lbs (294 kg)
Curb Weight:
670 lbs (304 kg)
Towing Capacity:
1,455 lbs (660 kg)
Rack Capacity Front:
110 lbs (50 kg)
Rack Capacity Rear:
176 lbs (80 kg)
🛡️ Safety Features
Ratings
Safety Ratings:
ATVs are not subject to traditional crash test ratings like automobiles. However, the KingQuad 500 AXi is designed with rider safety in mind through its stable chassis and advanced braking.
Active Features
Active Features:
4-wheel drive with locking differential, Engine braking, Power steering, Hydraulic disc brakes.
Passive Features
Passive Features:
Ergonomic seating position, sturdy handlebars, integrated floorboards with footwells, protective body panels.
💡 Technology Features
Infotainment
Infotainment Features:
Minimalist dashboard focused on essential operational indicators (speedometer, odometer, fuel gauge, 2WD/4WD indicator, engine check light). No advanced infotainment system.
Driver Assistance
Driver Assistance Features:
Power Steering (EPS), Engine Braking System (EBS) via CVT.
Connectivity
Connectivity Features:
Not applicable for this model year.
Lighting
Lighting System:
Dual 35W headlights, 10W taillight, 3W brake light. Some models may have additional auxiliary lighting.
Electronics
Electronic Features:
Electronic Fuel Injection (EFI), digital odometer and trip meter.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 1,000 miles (1,600 km) or 6 months, whichever comes first. Also check every 25 hours of operation.
Air Filter Cleaning Interval:
Inspect every 100 miles (160 km) or 10 hours. Clean as needed, replace if damaged.
Spark Plug Replacement Interval:
Check at 600 miles (1,000 km) or 6 months, replace as needed.
Transmission Oil Change Interval:
Every 1,000 miles (1,600 km) or 6 months, whichever comes first.
Brake Fluid Change Interval:
Every 2 years or as recommended by Suzuki.
Valve Clearance Check Interval:
Every 1,000 miles (1,600 km) or 6 months.
Fluid Specifications
Front Brake Fluid:
DOT 3 or DOT 4
Rear Brake Fluid:
DOT 3 or DOT 4
Final Drive Gear Oil Type:
Hypoid gear oil SAE 80W-90 API GL-5
Final Drive Gear Oil Capacity:
0.21 US qt (0.2 L)
Known Issues
Known Issues:
Some owners have reported occasional issues with the starter motor solenoid, CV joint boots due to harsh terrain, and potential wear on the CVT belt if used excessively under heavy load or improper maintenance. The power steering system is generally reliable but requires proper fluid levels.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Suzuki has a long-standing reputation for producing reliable and capable motorcycles and ATVs. The KingQuad line, introduced in 1991, has consistently been a benchmark for utility ATVs.
Model Evolution
Model Evolution:
The LT-A500XP represents the third generation of the KingQuad 500, significantly updated from earlier models with the introduction of electronic fuel injection and, crucially, power steering for the AXi trim. This generation focused on refinement and enhanced rider comfort and control.
Production
Production Period:
2009-2014
Manufacturing Location:
Suzuki Manufacturing, USA (for many KingQuad models)
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