🏷️ 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: 459 Manual Type Type: Workshop Service Manual Language Primary Language: English Format File Format: PDF 📖 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: Yes 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...