Suzuki kq500 Manuals

Manuals and User Guides for Suzuki kq500. We have 1 Suzuki kq500 manual available for free PDF download: Service Manual

Suzuki kq500 Service Manual (624 pages)

Brand: Suzuki | Category: Offroad Vehicle | Size: 36 MB

Table of Contents

3
- Precautions
  5
- Exhaust System
  6
- Differential
  15
- Maintenance and Lubrication
  15
- Parking Brake
  15
- Service Data
  15
- General Information
  16
  - Fuel System
    24
  - Transfer
    24
  - Automatic Transmission
    24
  - Front Suspension
    25
  - Rear Suspension
    25
  - Maintenance and Lubrication
    30
    
    Scheduled Maintenance
    30
    
    Rear Brakes
    54
    
    Service Data
    57
Section 1 Engine

67
- Emission Control Devices
  67
- Engine Electrical Devices
  67
- Engine General Information and Diagnosis
  67
- Engine Cooling System
  68
- Engine Lubrication System
  68
- Engine Mechanical
  68
- Ignition System
  69
- Starting System
  69
- Charging System
  70
- Precautions
  
  71
  - Precautions for Engine
    71
- Engine General Information and Diagnosis
  
  72
- General Description
  
  72
  - Injection Timing Description
    72
- Schematic and Routing Diagram
  
  75
  - FI System Wiring Diagram
    75
  - Terminal Alignment of ECM Coupler
    76
- Component Location
  
  77
  - FI System Parts Location
    77
- Diagnostic Information and Procedures
  
  78
- Specifications
  
  141
  - Service Data
    141
- Special Tools and Equipment
  
  142
  - Special Tool
    142
- Emission Control Devices
  
  143
- Precautions
  
  143
  - Precautions for Emission Control Devices
    143
- Repair Instructions
  
  143
  - Crankcase Breather (PCV) Hose Inspection
    143
  - Crankcase Breather (PCV) Hose Removal and Installation
    143
- Repair Instructions
  
  144
  - ECM Removal and Installation
    144
  - CKP Sensor Inspection
    144
- Precautions
  
  144
  - Precautions for Engine Electrical Device
    144
- Diagnostic Information and Procedures
  
  144
  - Engine Symptom Diagnosis
    144
  - Engine Electrical Devices
    144
    
    IAP / TP / IAT Sensor Removal and
    145
    
    ECT Sensor Removal and Installation
    145
    
    ECT Sensor Inspection
    146
    
    TO Sensor Inspection
    146
    
    TO Sensor Removal and Installation
    146
    
    ISC Valve Inspection
    146
    
    ISC Valve Removal and Installation
    147
    
    GP Switch Inspection
    147
    
    GP Switch Removal and Installation
    147
- Component Location
  
  144
  - Engine Electrical Components Location
    144
- Special Tools and Equipment
  
  148
  - Special Tool
    148
- Specifications
  
  148
  - Service Data
    148
  - Tightening Torque Specifications
    148
- Engine Mechanical
  
  149
- Schematic and Routing Diagram
  
  149
  - Throttle Cable Routing Diagram
    149
- Diagnostic Information and Procedures
  
  150
  - Engine Mechanical Symptom Diagnosis
    150
  - Compression Pressure Check
    150
- Repair Instructions
  
  151
- Specifications
  
  215
  - Service Data
    215
  - Tightening Torque Specifications
    217
  - Recommended Service Material
    218
  - Special Tool
    218
- Schematic and Routing Diagram
  
  222
  - Engine Lubrication System Chart Diagram
    222
  - Engine Lubrication Circuit Diagram
    223
- Precautions
  
  222
  - Precautions for Engine Oil
    222
- Engine Lubrication System
  
  222
- Diagnostic Information and Procedures
  
  225
  - Engine Lubrication Symptom Diagnosis
    225
  - Oil Pressure Check
    225
- Repair Instructions
  
  226
  - Engine Oil and Filter Replacement
    226
  - Engine Oil Level Inspection
    226
  - Oil Sump Filter Removal and Installation
    226
  - Oil Sump Filter Inspection and Cleaning
    227
  - Oil Jet Removal and Installation
    227
  - Oil Pump Construction
    228
  - Oil Jet Inspection
    228
  - Oil Pump Removal and Installation
    228
  - Oil Pump Inspection
    230
- Specifications
  
  231
  - Service Data
    231
  - Tightening Torque Specifications
    231
- Special Tools and Equipment
  
  231
  - Recommended Service Material
    231
  - Special Tool
    232
- Engine Cooling System
  
  233
- Precautions
  
  233
  - Precautions for Engine Cooling System
    233
  - Precautions for Engine Coolant
    233
- General Description
  
  234
  - Engine Coolant Description
    234
- Schematic and Routing Diagram
  
  234
  - Cooling Circuit Diagram
    234
  - Water Hose Routing Diagram
    235
- Diagnostic Information and Procedures
  
  236
  - Engine Cooling Symptom Diagnosis
    236
- Repair Instructions
  
  236
  - Cooling Circuit Inspection
    236
  - Radiator Cap Inspection
    237
  - Radiator Inspection and Cleaning
    237
  - Radiator / Cooling Fan Assembly Removal and Installation
    237
  - Water Hose Removal and Installation
    238
  - Cooling Fan Inspection
    239
  - Radiator Reservoir Tank Removal and Installation
    239
  - Radiator Reservoir Tank Inspection
    240
  - Water Hose Inspection
    240
  - ECT Sensor Removal and Installation
    240
  - ECT Sensor Inspection
    240
  - Cooling Fan Thermo-Switch Removal and Installation
    240
  - Cooling Fan Thermo-Switch Inspection
    241
  - Thermostat Removal and Installation
    242
  - Thermostat Inspection
    243
  - Water Pump Components
    244
  - Water Pump Removal and Installation
    244
  - Water Pump Disassembly and Assembly
    245
  - Water Pump Related Parts Inspection
    249
- Specifications
  
  250
  - Service Data
    250
  - Tightening Torque Specifications
    250
- Special Tools and Equipment
  
  251
  - Recommended Service Material
    251
  - Special Tool
    251
- Fuel System
  
  252
- Precautions
  
  252
  - Precautions for Fuel System
    252
- General Description
  
  253
  - Fuel System Description
    253
- Schematic and Routing Diagram
  
  254
  - Fuel Hose Routing Diagram
    254
  - Fuel Tank Breather Hose Routing Diagram
    255
- Diagnostic Information and Procedures
  
  256
  - Fuel System Diagnosis
    256
- Repair Instructions
  
  257
- Specifications
  
  264
  - Service Data
    264
  - Tightening Torque Specifications
    264
- Special Tools and Equipment
  
  265
  - Special Tool
    265
- Ignition System
  
  266
- Schematic and Routing Diagram
  
  266
  - Ignition System Diagram
    266
  - Ignition System Components Location
    266
- General Description
  
  266
  - Override Switch Description
    266
- Diagnostic Information and Procedures
  
  267
  - Ignition System Symptom Diagnosis
    267
  - No Spark or Poor Spark
    267
- Repair Instructions
  
  268
- Specifications
  
  273
  - Service Data
    273
  - Tightening Torque Specifications
    273
- Special Tools and Equipment
  
  273
  - Special Tool
    273
- Starting System
  
  274
- Schematic and Routing Diagram
  
  274
  - Starting System Diagram
    274
- Diagnostic Information and Procedures
  
  274
- Component Location
  
  274
  - Starting System Components Location
    274
- Repair Instructions
  
  276
- Specifications
  
  286
  - Service Data
    286
  - Tightening Torque Specifications
    287
- Special Tools and Equipment
  
  287
  - Recommended Service Material
    287
  - Special Tool
    287
- Diagnostic Information and Procedures
  
  288
  - Charging System Symptom Diagnosis
    288
  - Battery Runs down Quickly
    289
- Component Location
  
  288
  - Charging System Components Location
    288
- Schematic and Routing Diagram
  
  288
  - Charging System Diagram
    288
- Charging System
  
  288
- Repair Instructions
  
  290
  - Battery Current Leakage Inspection
    290
  - Regulated Voltage Inspection
    290
  - Generator Inspection
    290
  - Generator Removal and Installation
    291
  - Regulator / Rectifier Inspection
    295
  - Battery Components
    296
  - Battery Charging
    296
  - Battery Removal and Installation
    298
  - Battery Visual Inspection
    299
- Specifications
  
  299
  - Service Data
    299
  - Tightening Torque Specifications
    300
- Special Tools and Equipment
  
  300
  - Recommended Service Material
    300
  - Special Tool
    300
- Exhaust System
  
  301
- Precautions
  
  301
  - Precautions for Exhaust System
    301
- Repair Instructions
  
  301
  - Exhaust System Construction
    301
  - Exhaust Pipe / Muffler Removal and Installation
    302
  - Exhaust System Inspection
    303
  - Spark Arrester Inspection
    303
- Specifications
  
  303
  - Tightening Torque Specifications
    303
Section 2 Suspension

305
- Suspension General Diagnosis
  305
- Wheels and Tires
  305
- Precautions
  
  306
  - Precautions for Suspension
    306
- Diagnostic Information and Procedures
  
  307
  - Suspension and Wheel Symptom Diagnosis
    307
- Suspension General Diagnosis
  
  307
- Front Suspension
  
  308
- Repair Instructions
  
  308
- Special Tools and Equipment
  
  322
  - Recommended Service Material
    322
  - Special Tool
    323
- Specifications
  
  322
  - Service Data
    322
  - Tightening Torque Specifications
    322
- Rear Suspension
  
  324
- Repair Instructions
  
  324
- Specifications
  
  340
  - Service Data
    340
  - Tightening Torque Specifications
    340
- Special Tools and Equipment
  
  340
  - Recommended Service Material
    340
  - Special Tool
    341
- Repair Instructions
  
  342
- Wheels and Tires
  
  342
- Precautions
  
  342
  - Precautions for Wheel and Tire
    342
- Specifications
  
  345
  - Service Data
    345
  - Tightening Torque Specifications
    345
Section 3 Driveline / Axle

347
- Propeller Shafts
  348
- Precautions
  
  349
  - Precautions for Driveline / Axle
    349
- Repair Instructions
  
  350
- Diagnostic Information and Procedures
  
  350
  - Drive Shaft Symptom Diagnosis
    350
- Drive Chain / Drive Train / Drive Shaft
  
  350
- Special Tools and Equipment
  
  357
  - Recommended Service Material
    357
  - Special Tool
    357
- Differential
  
  358
- Diagnostic Information and Procedures
  
  358
  - Drive Train Symptom Diagnosis
    358
  - DTC "C20" (P1752) Diff-Lock Relay Circuit Malfunction
    358
- Repair Instructions
  
  359
- Specifications
  
  394
  - Service Data
    394
  - Tightening Torque Specifications
    394
- Special Tools and Equipment
  
  395
  - Recommended Service Material
    395
  - Special Tool
    395
- Diagnostic Information and Procedures
  
  397
  - Transfer Symptom Diagnosis
    397
- Transfer
  
  397
- Repair Instructions
  
  398
- Specifications
  
  411
  - Service Data
    411
  - Tightening Torque Specifications
    412
  - Special Tool
    412
- Special Tools and Equipment
  
  412
- Propeller Shafts
  
  413
- Repair Instructions
  
  413
- Specifications
  
  435
  - Service Data
    435
  - Tightening Torque Specifications
    435
- Special Tools and Equipment
  
  436
  - Recommended Service Material
    436
  - Special Tool
    437
Section 4 Brake

439
- Brake Control System and Diagnosis
  439
- Front Brakes
  439
- Precautions
  
  441
  - Precautions for Brake System
    441
  - Brake Fluid Information
    441
- Brake Control System and Diagnosis
  
  442
- Schematic and Routing Diagram
  
  442
  - Front Brake Hose Routing Diagram
    442
  - Rear Brake Cable Routing Diagram
    443
- Repair Instructions
  
  444
- Diagnostic Information and Procedures
  
  444
  - Brake Symptom Diagnosis
    444
- Specifications
  
  456
  - Service Data
    456
- Special Tools and Equipment
  
  457
  - Special Tool
    457
- Repair Instructions
  
  458
- Precautions
  
  458
  - Precautions for Front Brakes
    458
- Front Brakes
  
  458
- Specifications
  
  465
  - Service Data
    465
- Special Tools and Equipment
  
  466
  - Special Tool
    466
- Repair Instructions
  
  467
- Rear Brakes
  
  467
- Precautions
  
  467
  - Precautions for Rear Brake
    467
- Specifications
  
  475
  - Service Data
    475
- Special Tools and Equipment
  
  476
  - Special Tool
    476
- Parking Brake
  
  477
  - Schematic and Routing Diagram
    477
  - Parking / Rear Brake Cable Routing Diagram
    477
- Repair Instructions
  
  479
Section 5 Transmission / Transaxle

483
- Precautions
  
  484
  - Precautions for Transmission / Transaxle
    484
- Automatic Transmission
  
  485
- Schematic and Routing Diagram
  
  485
  - Drive Train System
    485
- Diagnostic Information and Procedures
  
  486
  - Automatic Transmission Symptom Diagnosis
    486
- Repair Instructions
  
  487
- Specifications
  
  509
  - Service Data
    509
  - Tightening Torque Specifications
    510
- Special Tools and Equipment
  
  510
  - Recommended Service Material
    510
  - Special Tool
    511
Section 6 Steering

513
- Power Assisted Steering System
  513
- Steering General Diagnosis
  513
- Precautions
  
  514
  - Precautions for Steering
    514
- Steering General Diagnosis
  
  515
- Diagnostic Information and Procedures
  
  515
  - Steering Symptom Diagnosis
    515
- Repair Instructions
  
  516
- Steering / Handlebar
  
  516
- Specifications
  
  524
  - Service Data
    524
  - Tightening Torque Specifications
    525
- Special Tools and Equipment
  
  525
  - Recommended Service Material
    525
  - Special Tool
    526
- Power Assisted Steering System
  
  527
- Precautions
  
  527
  - Precautions for EPS
    527
  - P/S System Note
    527
  - Precautions in Diagnosing Troubles
    527
- General Description
  
  528
  - P/S System Description
    528
  - EPS Diagnosis General Description
    531
  - Self Diagnostic System Description
    531
  - Fail-Safe Function Description
    531
- Schematic and Routing Diagram
  
  532
  - EPS Wiring Diagram
    532
  - EPS Control Unit Diagram
    533
  - EPS System Wiring Harness Routing Diagram
    534
- Diagnostic Information and Procedures
  
  534
- Component Location
  
  534
  - EPS Components Location
    534
- Repair Instructions
  
  573
- Special Tools and Equipment
  
  579
  - Recommended Service Material
    579
  - Special Tool
    580
- Specifications
  
  579
  - Tightening Torque Specifications
    579
Section 9 Body and Accessories

581
- Precautions
  
  583
  - Precautions for Electrical System
    583
- Component Location
  
  583
  - Electrical Components Location
    583
- Wiring Systems
  
  584
- Schematic and Routing Diagram
  
  584
  - Wiring Diagram
    584
  - Wiring Harness Routing Diagram
    587
- Specifications
  
  590
  - Service Data
    590
  - Tightening Torque Specifications
    590
- Lighting Systems
  
  591
- Repair Instructions
  
  591
  - Headlight Components
    591
  - Headlight Removal and Installation
    591
  - Headlight Bulb Replacement
    592
  - Headlight Beam Adjustment
    592
  - Rear Combination Light Components
    592
  - Rear Combination Light Removal and Installation
    593
  - Rear Combination Light Bulb Replacement
    593
  - Reversing Light Bulb Replacement (for
    594
  - Reversing Light Relay Inspection (for
    594
  - Dimmer Switch Inspection
    594
- Specifications
  
  595
  - Service Data
    595
- Special Tools and Equipment
  
  595
  - Special Tool
    595
- Combination Meter / Fuel Meter / Horn
  
  596
- General Description
  
  596
  - Combination Meter System Description
    596
- Repair Instructions
  
  597
- Specifications
  
  603
  - Service Data
    603
  - Tightening Torque Specifications
    603
- Special Tools and Equipment
  
  603
  - Recommended Service Material
    603
  - Special Tool
    603
- Exterior Parts
  
  604
- Repair Instructions
  
  604
- Body Structure
  
  617
- Repair Instructions
  
  617
  - Body Frame Construction
    617
  - Footrest Construction
    618
  - Footrest Removal and Installation
    618
  - Carrier Construction
    619
  - Front Carrier Removal and Installation
    619
  - Rear Carrier Removal and Installation
    620
  - Front Grip Bar Construction
    621
  - Front Grip Bar Removal and Installation
    621
  - Trailer Towing Construction
    622
  - Trailer Towing Removal and Instruction
    622

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Suzuki kq500 Manuals

Suzuki kq500 Service Manual (624 pages)

Table of Contents

Table of Contents

Section 1 Engine

Precautions

Engine General Information and Diagnosis

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

Repair Instructions

Repair Instructions

Precautions

Diagnostic Information and Procedures

Component Location

Special Tools and Equipment

Specifications

Engine Mechanical

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Schematic and Routing Diagram

Precautions

Engine Lubrication System

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

General Description

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Component Location

Repair Instructions

Specifications

Special Tools and Equipment

Diagnostic Information and Procedures

Component Location

Schematic and Routing Diagram

Charging System

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions

Repair Instructions

Specifications

Section 2 Suspension

Precautions

Diagnostic Information and Procedures

Suspension General Diagnosis

Front Suspension