2005 Suzuki LTA700 King Quad 700 ATV Service & Repair Manual (P/N 99500-46060-01E)

This 476-page PDF reproduces Suzuki Motor Corporation factory service information for the 2005 LT-A700XK5 KingQuad 700. Copyrighted in 2004, it applies from frame JSAAP41A 52100001 and later and covers the E-17 Sweden, E-24 Australia, E-28 Canada, and E-33 U.S. market versions. The model-application table is K5-specific rather than a multi-year LT-A700X or LT-A750 listing; country-code callouts identify differences in labels, lighting, specifications, and wiring.

• Engine service: Covers in-frame work, engine removal and installation, top- and bottom-end disassembly, component inspection, and reassembly of the camshaft and cylinder head, cylinder and piston, connecting rod and crankshaft, balancer shafts, starter torque limiter, oil pump, transfer, gearshift mechanism, and crankcase.
• CVT and drive-train repair: Details the wet-shoe centrifugal clutch, drive belt, movable drive and driven faces, transfer gearing, front differential with 2WD/4WD shifting mechanism and actuator, front and rear propeller shafts, and rear final drive. Backlash, tooth-contact, bearing-preload, and shim-selection procedures are included.
• Fuel-injection diagnosis: Provides user-mode and dealer-mode self-diagnosis, TPS adjustment, fail-safe information, ECM terminal checks, circuit inspection, diagnostic reset procedures, and Suzuki Diagnosis System coverage with stored DTC and “Show Data When Trouble” review.
• Fuel, cooling, and lubrication systems: Includes fuel-pressure testing, fuel-pump and relay checks, filter service, FTPC valve inspection, throttle-body disassembly and cleaning, injector and ISC valve checks, radiator and fan diagnosis, thermostat and water-pump service, oil-pressure testing, and lubrication-circuit references.
• Chassis repair: Covers exterior-panel removal, wheels and tire replacement, front and rear drive shafts, dual hydraulic front brakes, the sealed oil-bathed rear brake, master cylinder and caliper repair, independent suspension, steering, toe-out adjustment, rear stabilizer work, and transfer shift-rod adjustment.
• Electrical and factory reference data: Includes charging, starting, electronic ignition, transfer-selection, combination-meter, lighting, switch, relay, and battery diagnostics, plus special-tool listings, routing drawings, torque tables, inspection limits, clearances, capacities, pressure-test values, and electrical test specifications.

Engine, CVT, and Drive-Train Repair Depth

The engine chapters are built around the 695cc liquid-cooled DOHC single-cylinder EFI engine. They identify which components can be serviced in the frame, then cover complete removal, internal inspection, repair, and reassembly. Valve-clearance measurement is supported by a tappet-shim selection table, while separate procedures cover compression testing, oil-pressure testing, clutch initial-engagement inspection, and clutch lock-up inspection.

The transmission and shaft-drive sections address the wet-shoe automatic clutch, V-belt CVT, two-range transfer with reverse, and bevel-gear final drives. Exploded construction views support bearing and oil-seal service, bevel-gear tooth-contact checks, differential and final-drive backlash procedures, and shim selection for correcting gear alignment. Referenced Suzuki tools include the 09910-32812 crankshaft installer, 09920-53740 clutch sleeve hub holder, 09930-82720 mode select switch, 09940-40211 fuel-pressure gauge adaptor, and 09900-25008 multi-circuit tester set.

FI, Electrical, and Chassis Diagnostics

The FI chapter traces faults through the crankshaft-position, intake-pressure, throttle-position, coolant-temperature, intake-air-temperature, tip-over, ignition-coil, injector, ISC-valve, fuel-pump-relay, and differential-lock-relay circuits. It lists the corresponding C-codes and P-codes, explains dealer-mode display behavior, and documents SDS history clearing and snapshot-data review. The SDS references identify the 09904-41010 SDS Set and 99565-01010-005 CD-ROM Ver.5.

Useful visual references include the FI System Parts Location, FI System Wiring Diagram, Front Drive Train (Differential) Construction view, Cooling Circuit, Engine Lubrication System Chart, and the wiring-harness, cable, fuel-hose, coolant-hose, breather-hose, and brake-line routing drawings. The closing wiring-diagram pages show the ECM, actuator, combination meter, charging, starting, lighting, fuse-box, fuel-injection, and differential-lock circuits.

Factory References and Important Scope Notes

System-specific torque tables and service-data pages consolidate engine, clutch, drive-train, fuel-pressure, sensor, throttle-body, charging, brake, wheel, tire, suspension, fluid, and capacity specifications. Troubleshooting charts cover hard starting, poor performance, overheating, brake faults, charging and starter problems, and battery condition, linking common complaints to the relevant inspection sections.

The manual also calls out repair mistakes that can damage expensive parts. Its engine reassembly section warns that driving the crankshaft into the case can disturb crankshaft alignment, so the specified installer is used. The cylinder-head chapter warns that torch-heating or installing a dry valve guide can distort or damage the head and guide.

Scan-quality note: this file consists of 476 PDF pages, but several pages show gray image blocks that partially cover text, tables, or illustrations in parts of the maintenance, engine, drive-train, FI, electrical, and service-data sections. Buyers should account for these isolated defects when relying on the scan for repair work.

Working on the engine, fuel system, hydraulic brakes, and electrical circuits requires the correct tools and technical experience. Follow the manual’s warnings and equipment requirements for major repair work, and use a qualified technician when a procedure is beyond your training.