The Suzuki King Quad 500, first generation (LT-F500F), represents a robust and versatile All-Terrain Vehicle (ATV) designed for both demanding work and recreational pursuits. Produced between 2002 and 2007, this model is powered by a 493cc, 4-stroke engine, featuring independent front suspension for enhanced ride quality and handling. Known for its reliability and power, the King Quad 500 is positioned as a strong competitor in the high-performance ATV segment, offering a valuable proposition to riders seeking a capable and durable machine for various terrains and tasks. This comprehensive Workshop Service Manual provides essential guidance for the maintenance and repair of the Suzuki King Quad 500 (LT-F500F) models from 2002 to 2007. Covering a wide array of systems, including the engine, transmission, fuel, ignition, electrical, suspension, and braking systems, this 459-page manual details everything from routine maintenance procedures and tune-ups to complete component overhauls and troubleshooting for common issues. Its scope is designed to empower owners, DIY mechanics, and professional technicians with the knowledge needed to ensure the optimal performance and longevity of their vehicle. 🏷️ 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....