Suzuki kq500 User Manual

Table of Contents 1-iii
Thermostat Inspection ...................................... 1F-11
Water Pump Components................................. 1F-12
Water Pump Removal and Installation.............. 1F-12
Water Pump Disassembly and Assembly ......... 1F-13
Water Pump Related Parts Inspection.............. 1F-17
Specifications..................................................... 1F-18
Service Data ..................................................... 1F-18
Tightening Torque Specifications...................... 1F-18
Special Tools and Equipment........................... 1F-19
Recommended Service Material....................... 1F-19
Special Tool ......................................................1F-19
Fuel System .............................................1G-1
Precautions...........................................................1G-1
Precautions for Fuel System...............................1G-1
General Description.............................................1G-2
Fuel System Description .....................................1G-2
Schematic and Routing Diagram........................1G-3
Fuel Hose Routing Diagram................................1G-3
Fuel Tank Breather Hose Routing Diagram........1G-4
Diagnostic Information and Procedures............1G-5
Fuel System Diagnosis .......................................1G-5
Repair Instructions ..............................................1G-6
Fuel Pressure Inspection ....................................1G-6
Fuel Pump Inspection .........................................1G-6
Fuel Discharge Amount Inspection .....................1G-6
Fuel Pump Relay Inspection ...............................1G-7
Fuel Hose Inspection ..........................................1G-8
Fuel Feed Hose Removal and Installation..........1G-8
Fuel Level Gauge Inspection ..............................1G-8
Fuel Level Indicator Inspection ...........................1G-8
Fuel Tank Removal and Installation....................1G-8
Fuel Pump Components .....................................1G-9
Fuel Pump Assembly Removal and
Installation.........................................................1G-9
Fuel Pump Disassembly and Assembly............1G-10
Fuel Mesh Filter Inspection and Cleaning.........1G-10
Fuel Injector Inspection and Cleaning...............1G-10
Fuel Injector / Fuel Delivery Pipe Removal
and Installation................................................1G-10
Fuel Tank Pressure Control (FTPC) Valve
Removal and Installation.................................1G-12
Fuel Tank Pressure Control (FTPC) Valve
Inspection........................................................1G-13
Specifications.....................................................1G-13
Service Data .....................................................1G-13
Tightening Torque Specifications......................1G-13
Special Tools and Equipment...........................1G-14
Special Tool ......................................................1G-14
Ignition System........................................ 1H-1
General Description.............................................1H-1
Override Switch Description................................1H-1
Schematic and Routing Diagram........................1H-1
Ignition System Diagram.....................................1H-1
Ignition System Components Location ...............1H-1
Diagnostic Information and Procedures............1H-2
Ignition System Symptom Diagnosis...................1H-2
No Spark or Poor Spark......................................1H-2
Repair Instructions ..............................................1H-3
Spark Plug Cap and Spark Plug Removal and
Installation.........................................................1H-3
Spark Plug Inspection and Cleaning...................1H-3
Ignition Coil and Plug Cap Inspection .................1H-4
Ignition Coil Removal and Installation.................1H-5
CKP Sensor Inspection.......................................1H-5
CKP Sensor Removal and Installation................1H-6
Engine Stop Switch Inspection............................1H-6
Ignition Switch Inspection....................................1H-7
Ignition Switch Removal and Installation.............1H-7
Override Switch Inspection .................................1H-7
Emergency Switch Inspection (For P-17)............1H-8
Emergency Switch Removal and Installation
(For P-17)..........................................................1H-8
Specifications.......................................................1H-8
Service Data........................................................1H-8
Tightening Torque Specifications........................1H-8
Special Tools and Equipment.............................1H-8
Special Tool ........................................................1H-8
Starting System .........................................1I-1
Schematic and Routing Diagram......................... 1I-1
Starting System Diagram ..................................... 1I-1
Component Location ............................................ 1I-1
Starting System Components Location................ 1I-1
Diagnostic Information and Procedures............. 1I-1
Starting System Symptom Diagnosis................... 1I-1
Starter Motor will not Run..................................... 1I-2
Starter Motor Runs but Does not Crank the
Engine................................................................ 1I-2
Engine Does not Turn Though the Starter
Motor Runs......................................................... 1I-2
Repair Instructions ............................................... 1I-3
Starter Motor Components................................... 1I-3
Starter Motor Removal and Installation................ 1I-3
Starter Motor Disassembly and Assembly ........... 1I-4
Starter Motor Related Parts Inspection................ 1I-5
Starter Relay Removal and Installation................ 1I-6
Starter Relay Inspection....................................... 1I-7
Neutral Relay Removal and Installation............... 1I-7
Neutral Relay Inspection...................................... 1I-8
Neutral Relay Diode Inspection............................ 1I-8
Parking Brake Relay Removal and Installation ..... 1I-8
Parking Brake Relay Inspection........................... 1I-9
Parking / Rear Brake Switch Inspection............... 1I-9
Gear Position Switch Inspection .......................... 1I-9
Starter Idle Gear / Starter Clutch Removal
and Installation................................................. 1I-10
Starter Driven Gear Bearing Removal and
Installation........................................................ 1I-12
Starter Related Parts Inspection ........................ 1I-12
Starter Button Inspection.................................... 1I-13
Specifications...................................................... 1I-13
Service Data....................................................... 1I-13
Tightening Torque Specifications....................... 1I-14
Special Tools and Equipment............................ 1I-14
Recommended Service Material........................ 1I-14
Special Tool ....................................................... 1I-14

Suzuki kq500 Specifications

General

Brand	Suzuki
Model	kq500
Category	Offroad Vehicle
Language	English