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Suzuki
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kq500
Suzuki kq500 User Manual
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Precautions: 3-
1
Driveline
/ Axle
Precautions
Precautions
Precautions for Driveline / Axle
B931H23000001
Refer to
“Gene
ral Precautions: in Section 00”
.
W
ARNING
!
Support the vehicle with a jack or
wooden block when servicing the driv
e shaf
t
s and drive train.
348
350
Table of Contents
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
Default Chapter
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
Engine Symptom Diagnosis
78
Self-Diagnostic Procedures
81
Use of SDS Diagnosis Reset Procedures
83
Show Data When Trouble (Displaying Data at the Time of DTC)
84
SDS Check
86
DTC Table
89
Fail-Safe Function Table
89
FI System Troubleshooting
90
Malfunction Code and Defective Condition Table
92
DTC "C12" (P0335): CKP Sensor Circuit Malfunction
94
DTC "C13" (P0105-H/L): IAP Sensor Circuit Malfunction
97
DTC "C14" (P0120-H/L): TP Sensor Circuit Malfunction
104
DTC "C15" (P0115-H/L): ECT Sensor Circuit Malfunction
111
DTC "C20" (P1752): Diff-Lock Relay Circuit Malfunction
116
DTC "C21" (P0110-H/L): IAT Sensor Circuit Malfunction
118
DTC "C23" (P1651-H/L): to Sensor Circuit Malfunction
123
DTC "C24" (P0351): Ignition Coil Circuit Malfunction
130
DTC "C32" (P0201): Fuel Injector Circuit Malfunction
130
DTC "C40" (P0505-H/L): ISC Valve Circuit Malfunction
133
DTC "C41" (P230-H/L): FP Relay Circuit Malfunction
139
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
Engine Components Removable with the Engine in Place
151
Air Cleaner Element Removal and Installation
153
Air Cleaner Element Inspection and Cleaning
153
Air Cleaner Inlet Sheet Construction
154
Air Cleaner Inlet Sheet Removal and Installation
154
Air Cleaner Box Removal and Installation
154
Throttle Cable Removal and Installation
155
Throttle Cable Inspection
156
Throttle Cable Play Inspection and Adjustment
156
Throttle Body Components
156
Throttle Body Construction
157
Throttle Body Removal and Installation
157
Throttle Body Disassembly and Assembly
159
Throttle Body Inspection and Cleaning
161
Engine Assembly Removal
161
Engine Assembly Installation
165
Engine Top Side Disassembly
166
Engine Top Side Assembly
170
Valve Clearance Inspection and Adjustment
177
Camshaft Inspection
177
Camshaft Sprocket Inspection
179
Cam Chain Tension Adjuster Inspection
179
Cam Chain Guide Inspection
179
Cam Chain Tensioner Inspection
180
Cylinder Inspection
180
Piston Ring Removal and Installation
181
Piston and Piston Ring Inspection
182
Cylinder Head Cover Disassembly and Assembly
184
Cylinder Head Cover Related Parts Inspection
185
Cylinder Head Disassembly and Assembly
186
Cylinder Head Related Parts Inspection
189
Valve Guide Replacement
192
Valve Seat Repair
194
Engine Bottom Side Disassembly
194
Engine Bottom Side Assembly
200
Conrod and Crankshaft Inspection
208
Width between Crankshaft Webs
209
Crankshaft Oil Seal and Driveshaft Spacer Oil Seal Inspection
209
Bearing (Crankcase and Generator Cover) Inspection
210
Oil Seal / Bearing (Crankcase and Generator Cover) Removal and Installation
210
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
Fuel Pressure Inspection
257
Fuel Pump Inspection
257
Fuel Discharge Amount Inspection
257
Fuel Pump Relay Inspection
258
Fuel Hose Inspection
259
Fuel Feed Hose Removal and Installation
259
Fuel Level Gauge Inspection
259
Fuel Level Indicator Inspection
259
Fuel Tank Removal and Installation
259
Fuel Pump Components
260
Fuel Pump Assembly Removal and Installation
261
Fuel Pump Disassembly and Assembly
261
Fuel Mesh Filter Inspection and Cleaning
261
Fuel Injector Inspection and Cleaning
261
Fuel Injector / Fuel Delivery Pipe Removal and Installation
261
Fuel Tank Pressure Control (FTPC) Valve Removal and Installation
263
Fuel Tank Pressure Control (FTPC) Valve Inspection
264
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
Spark Plug Cap and Spark Plug Removal and Installation
268
Spark Plug Inspection and Cleaning
268
Ignition Coil and Plug Cap Inspection
269
Ignition Coil Removal and Installation
270
CKP Sensor Inspection
270
CKP Sensor Removal and Installation
271
Engine Stop Switch Inspection
271
Ignition Switch Inspection
272
Ignition Switch Removal and Installation
272
Override Switch Inspection
272
Emergency Switch Inspection (for
273
Emergency Switch Removal and Installation (for
273
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
Starting System Symptom Diagnosis
274
Starter Motor will Not Run
275
Starter Motor Runs but Does Not Crank the Engine
275
Engine Does Not Turn Though the Starter Motor Runs
275
Component Location
274
Starting System Components Location
274
Repair Instructions
276
Starter Motor Components
276
Starter Motor Removal and Installation
276
Starter Motor Disassembly and Assembly
277
Starter Motor Related Parts Inspection
278
Starter Relay Removal and Installation
279
Starter Relay Inspection
280
Neutral Relay Removal and Installation
280
Neutral Relay Inspection
281
Neutral Relay Diode Inspection
281
Parking Brake Relay Removal and Installation
281
Parking Brake Relay Inspection
282
Parking / Rear Brake Switch Inspection
282
Gear Position Switch Inspection
282
Starter Idle Gear / Starter Clutch Removal and Installation
283
Starter Driven Gear Bearing Removal and Installation
285
Starter Related Parts Inspection
285
Starter Button Inspection
286
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
Default Chapter
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
Front Suspension Components
308
Front Suspension Assembly Construction
309
Front Shock Absorber Removal and Installation
310
Front Suspension Inspection
310
Front Shock Absorber Inspection
310
Spring Pre-Load Adjustment
311
Front Wheel Hub / Steering Knuckle Removal and Installation
311
Front Hub Bearing Inspection
314
Front Hub Bearing Removal and Installation
314
Front Suspension Upper / Lower Arm Removal and Installation
316
Steering Knuckle End Inspection
317
Steering Knuckle End Removal and Installation
318
Front Suspension Arm Related Parts Inspection
319
Front Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation
320
Front Suspension Lower Arm Bushing Removal and Installation
321
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
Rear Suspension Components
324
Rear Suspension Assembly Construction
325
Rear Shock Absorber Removal and Installation
326
Rear Suspension Inspection
327
Rear Shock Absorber Inspection
327
Spring Pre-Load Adjustment
327
Rear Wheel Hub / Suspension Knuckle Removal and Installation
328
Rear Hub Bearing Inspection
329
Rear Hub Bearing Removal and Installation
329
Rear Suspension Arm Upper / Lower Removal and Installation
331
Rear Suspension Arm Related Parts Inspection
333
Rear Suspension Upper Arm Bushing and Inner Dust Seal Removal and Installation
334
Rear Suspension Lower Arm Bushing and Inner Dust Seal Removal and Installation
335
Rear Suspension Knuckle Bushing and Inner Dust Seal Removal and Installation
337
Rear Stabilizer Removal and Installation
338
Stabilizer Parts Inspection
339
Specifications
340
Service Data
340
Tightening Torque Specifications
340
Special Tools and Equipment
340
Recommended Service Material
340
Special Tool
341
Repair Instructions
342
Front and Rear Wheel Components
342
Front / Rear Wheel Removal and Installation
343
Tire Removal and Installation
343
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
Default Chapter
348
Propeller Shafts
348
Precautions
349
Precautions for Driveline / Axle
349
Repair Instructions
350
Front Drive Shaft Components
350
Front Drive Shaft Assembly Removal and Installation
351
Front Drive Shaft Disassembly and Assembly
351
Front Drive Shaft Inspection
354
Rear Drive Shaft Components
355
Rear Drive Shaft Assembly Removal and Installation
355
Rear Drive Shaft Disassembly and Assembly
356
Rear Drive Shaft Inspection
356
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
Front Drive (Differential) Components
359
Front Drive (Differential) Construction
360
Front Drive (Differential) Gear Oil Level Inspection
361
Front Drive (Differential) Gear Oil Replacement
361
Front Drive (Differential) Assembly Removal and Installation
361
Front Drive (Differential) Assembly Disassembly and Assembly
362
Front Drive (Differential) Related Parts Inspection
370
Breather Rubber Case Inspection
372
Front Drive (Differential) Gear Shim Inspection and Adjustment
372
2WD / 4WD / Diff-Lock System Inspection
375
Rear Drive Breather Hose Routing Diagram
379
Final Gear Components
380
Final Gear Construction
381
Final Gear Oil Level Inspection
382
Final Gear Oil Replacement
382
Final Gear Assembly Removal and Installation
382
Final Gear Assembly Disassembly and Assembly
383
Final Gear Related Parts Inspection
389
Final Gear Shim Inspection and Selection
390
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
Transfer Components
398
Transfer Removal and Installation
399
Transfer Construction
402
Transfer Disassembly and Assembly
402
Transfer Related Bearing Removal and Installation
404
Transfer Related Parts Inspection
404
Gearshift Cam Components
405
Gearshift System Construction
406
Gearshift Cam Disassembly and Assembly
406
Gear Position (GP) Switch Inspection
407
Gear Position (GP) Switch Removal and Installation
407
HI / lo Position Diode Inspection
408
Gearshift Shaft No. 2 / Gearshift Cam Plate Removal and Installation
409
Gearshift Linkage Inspection
410
Gearshift Shaft Oil Seal Removal and Installation
411
Specifications
411
Service Data
411
Tightening Torque Specifications
412
Special Tool
412
Special Tools and Equipment
412
Recommended Service Material
412
Front Output Shaft Components
413
Front Output Shaft Removal and Installation
413
Propeller Shafts
413
Repair Instructions
413
Front Output Shaft Disassembly and Assembly
414
Front Output Shaft Related Parts Inspection
417
Rear Output Shaft / Drive Bevel Gear Removal and Installation
418
Rear Output Shaft Components
418
Rear Output Shaft Disassembly and Assembly
420
Rear Output Shaft Related Parts Inspection
424
Driven / Drive Bevel Gear Shim Inspection and Adjustment
424
Front Propeller Shaft Components
427
Front Propeller Shaft Removal and Installation
428
Front Propeller Shaft Related Parts Inspection
429
Rear Propeller Shaft Components
430
Rear Propeller Shaft Removal and Installation
431
Rear Propeller Shaft Related Parts Inspection
434
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
Default Chapter
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
Brake Pedal Height Inspection and Adjustment
444
Front Brake Light Switch Inspection
444
Rear Brake Light Switch Inspection
445
Rear Brake Light Switch Inspection and Adjustment
445
Parking / Rear Brake Light Switch Inspection
445
Parking / Rear Brake Lever Switch Inspection
445
Brake Fluid Level Check
445
Front Brake Hose Inspection
445
Air Bleeding from Front Brake Fluid Circuit
446
Brake Fluid Replacement
447
Front Brake Hose Removal and Installation
448
Rear Brake Cable Removal and Installation
448
Front Brake Master Cylinder Components
450
Front Brake Master Cylinder Assembly Removal and Installation
450
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly
452
Front Brake Master Cylinder Parts Inspection
453
Rear Brake Pedal Construction
454
Rear Brake Pedal Removal and Installation
454
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
Front Brake Components
458
Front Brake Pad Inspection
459
Front Brake Pad Replacement
459
Front Brake Caliper Removal and Installation
460
Front Brake Caliper Disassembly and Assembly
461
Front Brake Caliper Parts Inspection
463
Front Brake Disc Removal and Installation
464
Front Brake Disc Inspection
464
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 Brake Components
467
Rear Brake Friction Plate Inspection
468
Rear Brake Friction Plate Replacement
468
Rear Brake Assembly Removal and Installation
468
Rear Brake Disassembly and Assembly
469
Rear Brake Parts Inspection
473
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
Parking / Rear Brake Inspection and Adjustment
479
Parking / Rear Brake Cable Removal and Installation
479
Parking / Rear Brake Lever Components
480
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
Automatic Transmission Components
487
Clutch Engagement and Lock-Up Speed Inspection
489
V-Belt Type Continuously Variable Automatic Transmission Removal and Installation
489
Movable Drive Face Disassembly and Assembly
492
Movable Driven Face Disassembly and Assembly
494
Drive V-Belt Inspection
498
Movable / Fixed Drive Face Parts Inspection
498
Movable / Fixed Driven Face Parts Inspection
499
Clutch Shoe Removal and Installation
499
Clutch Cover Disassembly and Assembly
502
Clutch Related Parts Inspection
504
Movable Drive Face Cover Disassembly and Assembly
505
Movable Driven Face Cover Parts Inspection
506
Shift Lever Assembly Components
507
Gearshift Knob Removal and Installation
507
Shift Lever Assembly Removal and Installation
507
Shift Lever Disassembly and Assembly
508
Shift Rod Adjustment
509
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
Default Chapter
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 / Handlebars Components
516
Steering / Handlebars Assembly Construction
517
Handlebars Inspection
520
Steering Shaft Removal and Installation
520
Tie-Rod / Tie-Rod End Removal and Installation
523
Steering Related Parts Inspection
524
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
EPS Troubleshooting
534
Pre-Diagnosis Inspection
535
EPS System Check
537
DTC (Diagnostic Trouble Code) Output
544
DTC (Diagnostic Trouble Code) Deleting
544
SDS Check
549
DTC Table
550
DTC "C1111": Torque Sensor (Main) Circuit Malfunction
551
DTC "C1113": Torque Sensor (Main / Sub) Circuit Correlation Malfunction
554
DTC "C1114": Torque Sensor Power Supply Circuit Malfunction
558
DTC "C1115": Torque Sensor (Sub) Circuit Malfunction
560
DTC "C1121": Vehicle Speed Signal Circuit Malfunction
563
DTC "C1122": Engine Speed Signal Circuit Malfunction
566
DTC "C1141", "C1142", "C1143", "C1145" EPS Motor Circuit Malfunction
569
DTC "C1153" EPS Control Unit Supply Voltage Circuit Malfunction
571
DTC "C1152", "C1154", "C1155" EPS Control Unit Malfunction
573
Component Location
534
EPS Components Location
534
Repair Instructions
573
EPS Control Unit Construction
573
EPS Control Unit Removal and Installation
574
EPS Body Assembly Components
575
EPS Body Assembly Removal and Installation
575
EPS Motor Inspection
578
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
Combination Meter Components
597
Combination Meter Removal and Installation
597
Combination Meter Disassembly and Assembly
598
Combination Meter Inspection
598
Engine Coolant Temperature Indicator Light Inspection
598
Engine Coolant Temperature Removal and Installation
599
Fuel Level Indicator Inspection
599
Fuel Level Gauge Inspection
600
Speedometer Inspection
601
Speed Sensor Removal and Installation
601
Speed Sensor Inspection
601
Ignition Switch Inspection
602
Ignition Switch Removal and Installation
602
Horn Inspection (for
602
Horn Removal and Installation (for
603
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
Exterior Parts Construction
604
Rear Fender Heat Shield Construction
606
Fuel Tank Lower Cover Heat Shield Installation
607
Fastener Removal and Installation
608
Front Side Exterior Parts Removal and Installation
609
Rear Side Exterior Parts Removal and Installation
612
Seat Removal and Installation
614
Under Cover Components
615
Under Cover Removal and Installation
615
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
4
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Suzuki kq500 Specifications
General
Brand
Suzuki
Model
kq500
Category
Offroad Vehicle
Language
English
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