Suzuki LT-A500Z King Quad 2008-2010 Factory Service Manual
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This manual covers the LT-A500Z King Quad models manufactured between 2008 and 2010. Known for its robust performance and utility, the King Quad is a high-performance utility ATV designed for recreational riders, hunters, farmers, and various utility users. Key features include a powerful 493cc engine with fuel injection for enhanced throttle response and efficiency, independent rear suspension for superior ride comfort and traction, and a torque-sensing limited-slip front differential for exceptional grip. Its engineering emphasizes reliability and capability, making it a strong contender in the utility ATV market. This comprehensive factory service manual provides detailed guidance for the maintenance, repair, and troubleshooting of your LT-A500Z King Quad. It covers all major systems, including the engine, fuel system, cooling system, electrical system, drivetrain, transmission, suspension, steering, and brakes. Within its pages, you will find step-by-step repair instructions, diagnostic procedures, torque specifications, fluid requirements, and complete wiring diagrams. This manual is an essential resource for owners and technicians alike, ensuring the vehicle remains in optimal condition and performance throughout its lifespan. 🏷️ Basic Information Identification Make: Suzuki Model: LT-A500Z King Quad Model Code: LT-A500Z Model Variant: King Quad Generation Covered Years: 2008, 2009, 2010 Codes Vin Code Prefix: JS1 👋 Introduction Market Position Category: High-performance utility ATV Target Audience: Recreational riders, hunters, farmers, utility users requiring robust performance and capability Competitive Analysis Competitors: Honda Foreman, Polaris Sportsman, Yamaha Grizzly, Can-Am Outlander Key Features Of Vehicle Feature 1: Powerful 500cc class engine for strong hauling and towing Feature 2: Independent rear suspension (IRS) for improved ride comfort and traction Feature 3: Torque-sensing, limited-slip front differential for superior traction Feature 4: Fuel injection for enhanced throttle response and fuel efficiency 📋 Manual Details Coverage Areas Product Name: Suzuki LT-A500Z King Quad 2008-2010 Factory Service Manual PDF Download Description: COMPLETE official full factory service repair manual for Suzuki LT-A500Z King Quad 2008 2009 2010 Page Count Estimated Pages: Hundreds of pages (specific count not provided, but indicative of comprehensive coverage) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, inspection, repair, and assembly procedures Fuel System: Fuel injection system, fuel pump, injectors, fuel filter, fuel tank, lines Cooling System: Radiator, fan, coolant, thermostat, water pump, hoses Ignition System: Ignition coil, spark plugs, CDI unit, wiring Exhaust System: Muffler, exhaust pipe, catalytic converter (if applicable) Drivetrain: Primary drive, secondary drive (CVT), drive shafts, differentials, axles Transmission: Automatic transmission, CVT operation, maintenance, repair Suspension: Front and rear suspension, shocks, springs, control arms, bushings Steering: Handlebars, steering column, tie rods, steering knuckle Brakes: Front and rear brake systems, master cylinder, calipers, rotors, brake fluid, lines Electrical System: Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, wiring diagrams Body And Frame: Chassis, body panels, seats, racks, fenders Troubleshooting: Diagnostic charts and procedures for common problems Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication Repair: Detailed step-by-step repair instructions for all major components Diagnostics: Troubleshooting guides, diagnostic flowcharts, error code interpretations Specifications: Torque specifications, clearances, measurements, fluid capacities Wiring Diagrams: Comprehensive electrical system wiring schematics Technical Depth Depth: Comprehensive, factory-level detail covering routine maintenance to full engine rebuilds and complex electrical diagnostics 📊 Manual Specifications File Format Type: PDF Searchability: Typically searchable text within PDF for quick information retrieval Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual Binding Type Binding For Print: Not applicable for PDF download, but designed to be printed and bound (e.g., spiral-bound, three-hole punched) Paper Type Paper For Print: Not applicable for PDF download, but typical factory manuals are printed on durable, glossy paper ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, 4-valve, single-cylinder Displacement: 493 cc Bore X Stroke: 94.0 mm x 8,5 mm (approximate, confirmation needed from manual) Cooling System: Liquid-cooled Ignition System: Electronic ignition (CDI) Performance Horsepower Estimate: Approx. 33 HP (exact figure can vary, requires manual confirmation) Torque Estimate: Approx. 29 ft-lb (exact figure can vary, requires manual confirmation) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane or higher Lubrication Oil Type: SAE 10W-40 API SG or higher Oil Capacity W Filter: Approx. 2.2 L / 2.3 US qt 🔧 Transmission Standard Type: Automatic with selectable 2WD/4WD and differential lock Features Cv Belt Type: Specific belt number referenced in manual (e.g., 27601-0040-AA) Gear Reduction Ratios: High/Low range, Neutral, Reverse (specific ratios detailed in manual) Final Drive: Shaft drive (front and rear) 📐 Dimensions Exterior Overall Length: Approx. 2,195 mm (86.4 in) Overall Width: Approx. 1,205 mm (47.4 in) Overall Height: Approx. 1,215 mm (47.8 in) Wheelbase: Approx. 1,285 mm (50.6 in) Ground Clearance: Approx. 260 mm (10.2 in) Weights Dry Weight: Approx. 276 kg (608 lbs) Gross Vehicle Weight Rating Gvwr: Not explicitly specified in general specs, but load...
This manual covers the LT-A500Z King Quad models manufactured between 2008 and 2010. Known for its robust performance and utility, the King Quad is a high-performance utility ATV designed for recreational riders, hunters, farmers, and various utility users. Key features include a powerful 493cc engine with fuel injection for enhanced throttle response and efficiency, independent rear suspension for superior ride comfort and traction, and a torque-sensing limited-slip front differential for exceptional grip. Its engineering emphasizes reliability and capability, making it a strong contender in the utility ATV market.
This comprehensive factory service manual provides detailed guidance for the maintenance, repair, and troubleshooting of your LT-A500Z King Quad. It covers all major systems, including the engine, fuel system, cooling system, electrical system, drivetrain, transmission, suspension, steering, and brakes. Within its pages, you will find step-by-step repair instructions, diagnostic procedures, torque specifications, fluid requirements, and complete wiring diagrams. This manual is an essential resource for owners and technicians alike, ensuring the vehicle remains in optimal condition and performance throughout its lifespan.
Comprehensive, factory-level detail covering routine maintenance to full engine rebuilds and complex electrical diagnostics
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Typically searchable text within PDF for quick information retrieval
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding For Print:
Not applicable for PDF download, but designed to be printed and bound (e.g., spiral-bound, three-hole punched)
Paper Type
Paper For Print:
Not applicable for PDF download, but typical factory manuals are printed on durable, glossy paper
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, 4-valve, single-cylinder
Displacement:
493 cc
Bore X Stroke:
94.0 mm x 8,5 mm (approximate, confirmation needed from manual)
Cooling System:
Liquid-cooled
Ignition System:
Electronic ignition (CDI)
Performance
Horsepower Estimate:
Approx. 33 HP (exact figure can vary, requires manual confirmation)
Torque Estimate:
Approx. 29 ft-lb (exact figure can vary, requires manual confirmation)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane or higher
Lubrication
Oil Type:
SAE 10W-40 API SG or higher
Oil Capacity W Filter:
Approx. 2.2 L / 2.3 US qt
🔧 Transmission
Standard
Type:
Automatic with selectable 2WD/4WD and differential lock
Features
Cv Belt Type:
Specific belt number referenced in manual (e.g., 27601-0040-AA)
Gear Reduction Ratios:
High/Low range, Neutral, Reverse (specific ratios detailed in manual)
Final Drive:
Shaft drive (front and rear)
📐 Dimensions
Exterior
Overall Length:
Approx. 2,195 mm (86.4 in)
Overall Width:
Approx. 1,205 mm (47.4 in)
Overall Height:
Approx. 1,215 mm (47.8 in)
Wheelbase:
Approx. 1,285 mm (50.6 in)
Ground Clearance:
Approx. 260 mm (10.2 in)
Weights
Dry Weight:
Approx. 276 kg (608 lbs)
Gross Vehicle Weight Rating Gvwr:
Not explicitly specified in general specs, but load capacities are detailed in manual
Cargo
Front Rack Capacity:
Approx. 45 kg (99 lbs)
Rear Rack Capacity:
Approx. 85 kg (187 lbs)
Towing Capacity:
Approx. 600 kg (1,322 lbs)
Tongue Weight Capacity:
Approx. 60 kg (132 lbs)
🛡️ Safety Features
Ratings
Atv Safety Standards:
Complies with ANSI standards for recreational ATVs (specific rating details typically not within service manuals, but design intent is safety)
Active Features
Braking System:
Hydraulic disc brakes front and rear
Engine Braking:
Integral engine braking via CVT
4Wd System:
Torque-sensing, limited-slip front differential enhances traction and control
Passive Features
Lighting:
Dual 35W headlights, 35/35W brake/taillight
Seatbelt:
Not applicable for ATV operation; riders wear helmets and protective gear
Rollover Protection:
Not applicable; requires proper ATV riding techniques
💡 Technology Features
Infotainment
Display Features:
Digital LCD meter with speedometer, odometer, trip meter, fuel gauge, clock, 2WD/4WD indicator, 4WD-lock indicator, engine hour meter, and service reminder.
Driver Assistance
Traction Control:
No active electronic traction control, but torque-sensing limited-slip front differential provides enhanced mechanical traction management.
Connectivity
Charging Port:
12V accessory socket for charging electronics (check manual for specifics).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 1,000 km or 3 months, whichever comes first (refer to manual for precise intervals based on usage)
Air Filter Cleaning:
Inspect and clean every 200 km or monthly; replace as needed
Spark Plug Replacement:
Check and clean every 1,000 km or 6 months; replace at specified intervals
Cv Belt Inspection:
Inspect every 1,000 km or 6 months for wear and damage
Brake Fluid Flush:
Recommended every 2 years or as per manual's detailed schedule
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG or higher
Brake Fluid:
DOT 3 or DOT 4
Coolant:
Suzuki Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with demineralized water (50/50 mix)
Final Drive Oil:
Suzuki Gear Oil API GL-5 SAE 80W-90 (for front and rear differentials)
Known Issues
Common Wear Item:
CVT belt wear due to heavy use or improper engagement.
Engine Performance:
Occasional issues with fuel injectors or throttle body needing cleaning, addressed by proper EFI system maintenance.
Electrical Component:
Regulator/rectifier failures can occur in high-demand or poorly ventilated conditions, requiring specific diagnostic procedures.
Suspension Components:
Bushings and ball joints can wear over time with off-road use, requiring periodic inspection and replacement.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation
Legacy In Powersports:
Long-standing reputation for reliable and performance-oriented motorcycles and ATVs
Model Evolution
King Quad Lineage:
The King Quad line has been a flagship model for Suzuki, known for its power and utility features.
Generation Update:
The 2008 model year brought significant updates, including the introduction of fuel injection and IRS, establishing the modern King Quad platform.
Production
Manufacturing Location:
Typically manufactured in Japan or by Suzuki's global partners.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards for the 2008-2010 King Quad are not widely publicized as distinct entities, but the model line generally receives positive reviews for its performance and utility.
Ratings
Magazine Reviews:
Consistently rated highly by ATV enthusiast magazines for its power, handling, and work capability within its class.
Certifications
Emissions Compliance:
Complies with EPA and CARB emissions standards for off-road vehicles (specific standards can be found in detailed vehicle documentation).
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