This workshop service manual provides comprehensive repair, overhaul, and maintenance information for the 2002 Suzuki King Quad LT-A500FK2. This high-performance utility ATV is equipped with a robust 493cc V-twin engine, independent suspension, and an advanced automatic Continuously Variable Transmission (CVT) with a Hi/Lo range gearbox and 2WD/4WD selection with a locking differential. Known for its capable off-road performance and durability, the King Quad is designed for demanding work and recreational use. The manual covers a wide range of systems including engine mechanicals, fuel, lubrication, cooling, transmission, drivetrain, chassis, suspension, steering, braking, and electrical systems, offering detailed procedures for complete component rebuilds and advanced diagnostics. This 459-page English language manual is intended for owners, mechanics, and service departments, providing the necessary technical depth for effective maintenance and repair. It includes detailed steps for routine maintenance such as oil changes and filter replacements, as well as complex procedures like engine disassembly and reassembly, transmission repair, carburetor tuning, and electrical diagnostics. The manual also features troubleshooting guides, diagnostic flowcharts, and specific technical data, ensuring that users can accurately identify and resolve issues. With high-resolution scans and clear diagrams, this manual is an essential resource for maintaining the King Quad LT-A500FK2 in optimal condition. 🏷️ Basic Information Identification Make: Suzuki Model: King Quad LT-A500FK2 Year: 2002 Product Type: Workshop Service Manual 👋 Introduction Market Position Vehicle Segment: High-performance utility ATV (All-Terrain Vehicle) Competitive Analysis Competitors: Honda Foreman/Rancher, Yamaha Kodiak, Kawasaki Prairie, Polaris Sportsman Key Features Vehicle Highlights: Robust 500cc class engine, independent suspension, advanced automatic transmission, capable off-road performance Manual Value Target Audience: Owners, mechanics, service departments 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair, overhaul, and maintenance procedures Page Count Page Count: 459 Manual Type Manual Type: Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, inspection, assembly, and tuning Engine Fuel System: Carburetor specifications, adjustment, and overhaul Engine Lubrication: Oil pump, lubrication passages, and oil filter service Engine Cooling: Cooling system design, maintenance, and troubleshooting Transmission Drivetrain: Automatic transmission (CVT) overhaul, clutch system, and final drive Chassis Suspension: Front and rear suspension systems, shock absorbers, and bushings Steering System: Steering column, tie rods, and steering knuckle service Braking System: Hydraulic brake system, calipers, master cylinder, and fluid replacement Electrical System: Ignition system, starting system, charging system, lighting, and wiring diagrams Fuel Tank And Lines: Fuel tank removal, fuel line maintenance, and petcock service Body Panels And Trim: Bodywork removal, installation, and cosmetic component service Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, and adjustments Troubleshooting: Diagnostic procedures for common and uncommon issues Engine Rebuild: Detailed steps for complete engine disassembly and reassembly Transmission Repair: Internal transmission component replacement and adjustment Carburetor Tuning: Step-by-step guide for carburetor synchronization and jetting Electrical Diagnostics: Testing of electrical components, circuits, and fault finding using wiring diagrams Suspension Alignment: Guidance on suspension component checks and potential alignment parameters Brake Bleeding: Proper procedure for bleeding the hydraulic brake system Wheel Bearing Replacement: Service procedures for front and rear wheel bearings Drive Shaft Maintenance: Inspection and servicing of drive shafts and universal joints Technical Depth Depth Level: Comprehensive - suitable for professional technicians and advanced DIY mechanics Diagnostic Capability: Advanced diagnostic flowcharts and troubleshooting trees Rebuild Scope: Detailed specifications and procedures for complete component rebuilds 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans with clear diagrams and text Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Searchability Searchability: Likely text-searchable PDF for quick information retrieval ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, liquid-cooled V-twin Displacement: 493 cc Bore X Stroke: 65.0 mm x 75.0 mm Compression Ratio: 8.6:1 Performance Horsepower: Approx. 32 hp (specification varies by region and tuning) Torque: Approx. 3.4 kgf⋅m @ 5,000 rpm (specification varies by region and tuning) Fuel System Fuel Delivery: Mikuni BNS36 carburetor Fuel Type: Unleaded gasoline Ignition Ignition System: Electronic ignition (CDI) Engine Management Valve Lash Specifications: Intake: 0.05-0.10 mm, Exhaust: 0.10-0.15 mm (cold engine) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Drive Modes: 2WD/4WD selection with locking differential Features Gear Reduction: Hi/Lo range gearbox Fluid Specifications Transmission Fluid Type: SAE 10W-40 API SE, SF, SG, SH, SJ or Suzuki LT-Special Oil 📐 Dimensions Exterior Overall Length: 2115 mm (83.3 in) Overall Width: 1115 mm (43.9 in) Overall Height: 1200 mm (47.2 in) Wheelbase: 1290 mm (50.8 in) Ground Clearance: 260 mm (10.2 in) Weights Dry Weight: 260 kg (573 lbs) Fuel Capacity: 17.0 L (4.5 US gal) Towing Capacity: 300 kg (660 lbs) Cargo Capacity Front Rack: 20 kg (44 lbs) Cargo Capacity Rear Rack: 40 kg (88 lbs) 🛡️ Safety Features Ratings Atv Safety Standards: Complies with applicable ANSI/SVIA safety standards Active Features Braking...