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: 2004 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: 459 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: PDF 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 Fuel Tank Capacity: 17.3 L (4.6 US gal) 🛡️ Safety Features...