Download Suzuki King Quad 500AXi 500 AXi LT-A500 LTA500 2009-2011 2012 Service Repair Manual PDF
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🏷️ Basic Information Identification Make: Suzuki Model: KingQuad 500AXi Model Codes: LT-A500XP, LT-A500XPZ, LTA500 Model Variant: 4x4 Generation Generation Designation: Second Generation (Post-2008) Relevant Years: 2009, 2010, 2011, 2012 👋 Introduction Market Position Segment: High-performance utility ATV (All-Terrain Vehicle). Target Audience: Recreational riders, farmers, hunters, and outdoor enthusiasts requiring robust off-road capability. Competitive Analysis Key Competitors: Yamaha Grizzly 550/700, Polaris Sportsman 500/800, Can-Am Outlander 500/800. Key Features Drivetrain: Advanced 4x4 system with differential lock for superior traction. Engine Type: Fuel-injected, liquid-cooled SOHC engine known for reliability and power delivery. Transmission: Torque-sensing, variable diameter, one-way clutch with engine brake System (CVT). Suspension: Independent front and rear suspension for a comfortable and capable ride. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair for Suzuki KingQuad 500AXi (LT-A500 models) Year Coverage: 2009-2012 (primary focus on 2009, extended for similar components in 2010-2012) Page Count Estimated Page Count: Extensive (exact number not specified, but described as 'COMPLETE' and covering numerous topics) Manual Type Type: Service Repair Manual Language Language: English Format Delivery Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, inspection, diagnosis, and repair of the 493cc engine. Transmission: Automatic transmission (CVT) service, including clutch, drive belt, and gearbox. Chassis: Frame integrity, suspension components, steering system, and wheel hub assemblies. Electrical System: Wiring diagrams, lighting system, battery service, ignition system, starting system, and charging system. Fuel System: Fuel injection system, fuel pump, fuel filter, and fuel tank maintenance. Brakes: Hydraulic brake system (front and rear disc brakes), including master cylinder, calipers, and fluid replacement. Lubrication: Lubrication points, fluid capacities, and recommended lubricant types for engine, transmission, and differentials. Cooling System: Radiator, fan, coolant, and thermostat service. Bodywork And Seats: Body panel removal, seat system maintenance. Steering: Steering column, tie rods, and power steering system (if applicable to specific trims) diagnosis and repair. Suspension: Front and rear suspension components, including shock absorbers, control arms, and bushings. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, error code interpretation (if applicable). Component Overhaul: Engine rebuild, transmission service, brake caliper overhaul, carburetor/fuel injection cleaning. Electrical Diagnosis: Wiring harness testing, component electrical testing, battery charging system checks. Suspension Alignment: Wheel alignment procedures, steering geometry checks. Brake System Maintenance: Brake fluid flush and bleeding, pad and rotor replacement. Torque Specifications: Detailed torque values for critical fasteners throughout the vehicle. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to advanced diagnostics and complete component overhauls. Equivalent to factory service information used by dealerships. 📊 Manual Specifications File Format Format: Adobe Acrobat PDF Searchability: Likely searchable text (standard for professional PDF manuals). Print Quality Quality: High resolution, suitable for printing individual sections or entire manuals. Binding Type Binding Recommendation: Print and use with 3-ring binders for easy section access and replacement. Paper Type Recommended Paper: Standard printer paper (user printable). ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, DOHC, 4-valve, single-cylinder Displacement: 493 cc (Cubic Centimeters) Bore X Stroke: 94.0 mm x 89.2 mm Cooling System: Liquid-cooled Ignition: Electronic ignition (CDI) Performance Horsepower: Approximately 38 HP (Horsepower) at 6,500 RPM (Estimated, actual may vary slightly by year/tune) Torque: Approximately 31 lb-ft (Pound-feet) at 5,000 RPM (Estimated) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Tank Capacity: 4.6 US gallons (17.5 Liters) Recommended Fuel: Unleaded gasoline, Octane Rating 87 or higher 🔧 Transmission Standard Type: Automatic, CVT (Continuously Variable Transmission) Drive Modes: 2WD, 4WD, 4WD with Differential Lock Gear Selection: High, Low, Neutral, Reverse, Park Features Engine Braking: Integrated engine braking via one-way clutch in CVT system. Drive Belt: Service and replacement of the primary drive belt is a critical maintenance item. Fluid Requirements Transmission Fluid: Suzuki High-Performance Gear Oil (or equivalent GL-5 75W-90 for differential) 📐 Dimensions Exterior Overall Length: 83.7 inches (2125 mm) Overall Width: 47.0 inches (1195 mm) Overall Height: 48.0 inches (1220 mm) Wheelbase: 50.4 inches (1280 mm) Weights Dry Weight: Approximately 624 lbs (283 kg) Curb Weight: Approximately 661 lbs (300 kg) (includes all necessary operating consumables) Cargo Front Rack Capacity: 99 lbs (45 kg) Rear Rack Capacity: 176 lbs (80 kg) Towing Towing Capacity: 1,322 lbs (600 kg) Trailer Wiring: Typically 2-inch ball hitch receiver, trailer wiring may require adaptation. 🛡️ Safety Features Ratings Crash Testing: ATVs are not subject to the same rigorous crash testing as passenger vehicles; safety relies on design and rider operation. Active Features Braking System: Hydraulic disc brakes front and rear for reliable stopping power. Drivetrain Control: Selectable 2WD/4WD with differential lock enhances traction and stability. Passive Features Frame Construction: Rugged steel frame designed for off-road durability. Lighting: Dual headlights, taillight, and brake light for visibility. Throttle Limiter: Some models may feature a throttle limiter for novice riders, which can be adjusted. 💡 Technology Features Infotainment Features: Basic functionality...
Brake fluid flush and bleeding, pad and rotor replacement.
Torque Specifications:
Detailed torque values for critical fasteners throughout the vehicle.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to advanced diagnostics and complete component overhauls. Equivalent to factory service information used by dealerships.
📊 Manual Specifications
File Format
Format:
Adobe Acrobat PDF
Searchability:
Likely searchable text (standard for professional PDF manuals).
Print Quality
Quality:
High resolution, suitable for printing individual sections or entire manuals.
Binding Type
Binding Recommendation:
Print and use with 3-ring binders for easy section access and replacement.
Paper Type
Recommended Paper:
Standard printer paper (user printable).
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, DOHC, 4-valve, single-cylinder
Displacement:
493 cc (Cubic Centimeters)
Bore X Stroke:
94.0 mm x 89.2 mm
Cooling System:
Liquid-cooled
Ignition:
Electronic ignition (CDI)
Performance
Horsepower:
Approximately 38 HP (Horsepower) at 6,500 RPM (Estimated, actual may vary slightly by year/tune)
Torque:
Approximately 31 lb-ft (Pound-feet) at 5,000 RPM (Estimated)
Integrated engine braking via one-way clutch in CVT system.
Drive Belt:
Service and replacement of the primary drive belt is a critical maintenance item.
Fluid Requirements
Transmission Fluid:
Suzuki High-Performance Gear Oil (or equivalent GL-5 75W-90 for differential)
📐 Dimensions
Exterior
Overall Length:
83.7 inches (2125 mm)
Overall Width:
47.0 inches (1195 mm)
Overall Height:
48.0 inches (1220 mm)
Wheelbase:
50.4 inches (1280 mm)
Weights
Dry Weight:
Approximately 624 lbs (283 kg)
Curb Weight:
Approximately 661 lbs (300 kg) (includes all necessary operating consumables)
Cargo
Front Rack Capacity:
99 lbs (45 kg)
Rear Rack Capacity:
176 lbs (80 kg)
Towing
Towing Capacity:
1,322 lbs (600 kg)
Trailer Wiring:
Typically 2-inch ball hitch receiver, trailer wiring may require adaptation.
🛡️ Safety Features
Ratings
Crash Testing:
ATVs are not subject to the same rigorous crash testing as passenger vehicles; safety relies on design and rider operation.
Active Features
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
Drivetrain Control:
Selectable 2WD/4WD with differential lock enhances traction and stability.
Passive Features
Frame Construction:
Rugged steel frame designed for off-road durability.
Lighting:
Dual headlights, taillight, and brake light for visibility.
Throttle Limiter:
Some models may feature a throttle limiter for novice riders, which can be adjusted.
💡 Technology Features
Infotainment
Features:
Basic functionality focused on utility; no integrated infotainment system in the typical automotive sense.
Driver Assistance
Features:
Primarily relies on mechanical systems and rider input for control and stability.
Connectivity
Features:
No electronic connectivity features (Bluetooth, Wi-Fi, etc.).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1,000 miles (1600 km) or 6 months, whichever comes first. Also recommended after strenuous use.
Air Filter Cleaning:
Every 300 miles (500 km) or 3 months; replacement as needed.
Spark Plug Inspection:
Every 1,000 miles (1600 km) or 6 months.
Drive Belt Inspection:
Every 600 miles (1000 km) or 12 months; replacement recommended every 2 years or 1800 miles (3000 km).
Brake Fluid Flush:
Every 2 years or 12,000 miles (20,000 km).
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or SH, JASO MA certified (Synthetic or Mineral)
Engine Oil Capacity:
3.0 US quarts (2.8 Liters) with filter change
Coolant Type:
Suzuki Super Long Life Coolant or equivalent (50/50 mixture of ethylene glycol and distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Gear Oil Type:
Suzuki High-Performance Gear Oil or SAE 80W-90 API GL-5 for front/rear differentials.
Known Issues
Drive Belt Wear:
CVT drive belts can wear and stretch over time, leading to reduced performance or belt failure. Regular inspection is key.
Throttle Sticking:
Rarely, throttle cables can become sticky due to dirt or lubrication issues, requiring cleaning or replacement.
Efi Sensor Issues:
Like any EFI system, sensors (e.g., TPS, MAP, O2) can occasionally require cleaning or replacement if performance is erratic.
Suspension Bushings:
Bushings in control arms and suspension pivots can wear, leading to play and handling degradation. Proper lubrication and inspection are important.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, a long-standing reputation for reliable and capable motorcycles and ATVs.
Model Evolution
Kingquad Lineage:
The KingQuad line has consistently been a benchmark in the utility ATV segment, known for its robust engineering and performance.
Second Generation:
The 2009-2012 models represent a significant update or continuation of the second-generation KingQuad platform, focusing on refinement and user comfort.
Production
Manufacturing Location:
Japan (typically for Suzuki's higher-end models).
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