🏷️ 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 System Type: Hydraulic disc brakes, front and rear Parking Brake: Hand-operated lever acting on rear brake Passive Features Lighting System: Dual headlights, taillight, and brake light 💡 Technology Features Infotainment Infotainment System: Not applicable (basic ATV design focused on function) Driver Assistance Driver Assistance Features: 4WD with locking differential, engine braking Connectivity Connectivity Features: Not applicable 🔧 Maintenance Service Intervals Engine Oil Change: Every 1,000 km or 6 months (whichever comes first) Air Filter Cleaning: Every 200 km or 1 month (more frequent in dusty conditions) Spark Plug Inspection: Every 1,000 km or 6 months Valve Clearance Check: Every 2,000 km or 12 months Fluid Specifications Engine Oil Specification: SAE 10W-40 API SE, SF, SG, SH, SJ Engine Oil Capacity: 2.2 L (with filter change) Coolant Type: Ethylene glycol-based antifreeze coolant with distilled water (50:50 mixture) Brake Fluid Type: DOT 3 or DOT 4 Known Issues Common Wear Items: CVT belt wear, suspension bushings, wheel bearings, brake pads Carburetor Performance: Occasional jetting or adjustment issues, particularly at altitude or with fuel changes 📚 Vehicle History Brand Heritage Manufacturer: Suzuki Motor Corporation Model Evolution King Quad Lineage: The LT-A500FK2 represents an evolution in Suzuki's King Quad line, known for its robust...