Suzuki King Quad LT-A500FK4 2004 Workshop Service Manual

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Type: Atv

Vendor:

Sku: 81716

Tags: 2004 Atv King Quad LT-A500FK4 Misc Motorcycles Suzuki

Product variants

Description

The 2004 Suzuki King Quad LT-A500FK4 is a robust, high-performance utility ATV engineered for demanding work applications and serious recreational riding. Building on Suzuki's esteemed heritage in off-road vehicle manufacturing, this model offers a powerful 493cc, liquid-cooled engine paired with an automatic Continuously Variable Transmission (CVT) and selectable 2WD/4WD capabilities. Its design prioritizes reliability and capability, featuring independent front and rear suspension for superior handling and ground clearance for navigating challenging terrain. With a strong emphasis on durability and functional design, the King Quad line has consistently been recognized for its power and performance in the competitive utility ATV market. This comprehensive Workshop Service Manual provides detailed instructions for the complete repair and overhaul of the 2004 Suzuki King Quad LT-A500FK4. Covering all essential systems, including engine, transmission, drivetrain, chassis, suspension, braking, and electrical components, the manual offers in-depth procedures for maintenance, repair, and troubleshooting. It equips owners, mechanics, and technicians with the necessary information, factory specifications, and diagnostic guidance to ensure the vehicle remains in optimal working condition. The manual is presented in English and offers high-resolution scans with clear diagrams and text for ease of use.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

King Quad

Model Variant:

LT-A500FK4

Year:

Codes

Chassis Code:

LT-A500FK4

👋 Introduction

Market Position

Positioning:

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

Competitive Analysis

Competitors:

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

Key Features

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

Coverage Areas

Areas Covered:

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

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

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

Procedures Included

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

Technical Depth

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

File Format:

Print Quality

Print Quality:

High-resolution scans, clear diagrams and text

Binding Type

Binding Type:

Not Applicable (PDF Download)

Paper Type

Paper Type:

Not Applicable (PDF Download)

⚙️ Engine Specifications

Primary Engine

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)

Performance

Horsepower:

Approximately 30 HP (specific dyno figures may vary)

Torque:

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

Fuel System

Fuel Delivery:

Carburetor (Mikuni BSR42)

Fuel Type:

Unleaded gasoline, 87 octane or higher

Lubrication System

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)

Cooling System

Coolant Type:

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

Ignition System

Ignition Timing:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK CR9E or DENSO U27FER9 (verify with manual)

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Features

Drive Modes:

2WD / 4WD selectable

Gear Reduction:

High and Low range, Reverse

Fluid Specifications

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

Exterior

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)

Weights

Dry Weight:

280 kg (617.3 lbs)

Curb Weight:

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

Cargo

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

Ratings

Safety Features:

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

Active Features

Active Safety:

Selectable 2WD/4WD, reliable braking system

Passive Features

Passive Safety:

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

💡 Technology Features

Infotainment

Infotainment Systems:

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

Driver Assistance

Driver Assistance Features:

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

Connectivity

Connectivity Features:

Not applicable for this utility ATV model.

Lighting

Lighting System:

Halogen headlights, taillight/brake light combination

🔧 Maintenance

Service Intervals

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

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Coolant Capacity:

1.4 L (1.5 US qt)

Known Issues

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

Lubrication Points

Chassis Lubrication:

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

📚 Vehicle History

Brand Heritage

Heritage Overview:

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

Model Evolution

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.

Production

Manufacturing Origin:

Japan (typical for Suzuki ATVs of this era)

🏆 Awards & Recognition

Recognitions

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.