Suzuki King Quad 300 LT-F300/LT-F300F ATV Service Manual, 1998–2002 (P/N 99500-42133-01E)

This Suzuki factory service manual, P/N 99500-42133-01E, Fourth Edition (September 2001), covers inspection, service, and overhaul of the LT-F300 and LT-F300F King Quad 300. It combines the 1999 base procedures with later-model updates; 2002 coverage is LT-F300FK2 only.

Text Search, Bookmarks, and Diagram Detail

Section navigation and wiring labels: PDF text search is not available. Embedded bookmarks open the main sections and model-year updates. Small wiring labels require zooming; the sideways diagrams can be rotated for reading.

One printable, 384-page PDF contains 301 pages of base-manual sections and integrated updates for 2000 (26 pages), 2001 (13), and 2002 (38). Two covers, three introductory pages, and one publication page are already included in that total.

Engine, Driveline, Brake, and Electrical Service

These selected service topics outline the workshop coverage; further topics include air-cleaner servicing and spark-arrester cleaning.

• Model coverage: 1999 LT-F300X/LT-F300FX, 2000 LT-F300Y/LT-F300FY, 2001 LT-F300K1/LT-F300FK1, and 2002 LT-F300FK2, with separate 2WD and 4WD procedures.

• Engine repair: Engine removal and installation, cylinder-head and valve service, cam timing, piston and crankshaft work, oil-pump replacement, and recoil-starter service.

• Clutch and transmission: Centrifugal clutch, wet multi-plate clutch pack, starter clutch, gearshift mechanism, constant-mesh transmission, reverse, and sub-transmission service, including engagement and lock-up tests.

• LT-F300F driveline: Secondary bevel-gear, front-differential, propeller-shaft, front-drive-shaft, and rear-axle procedures, including bearing work, shim selection, backlash checks, tooth-contact inspection, and final adjustment.

• Chassis and brakes: Wheels, tires, steering, toe-in adjustment, front and rear suspension, hydraulic front brakes, mechanical rear brakes, master-cylinder service, fluid replacement, and bleeding.

• Fuel system: Fuel-tank, valve, pump, and carburetor work, with cleaning, needle-valve inspection, float adjustment, and hose-routing information.

• Electrical diagnosis: Charging, starter, CDI ignition, relay, switch, lighting, and battery troubleshooting, supported by model-year and market-specific wiring diagrams.

It is suited to experienced mechanics working in a properly equipped shop; Suzuki assumes prior knowledge, skills, and special tools and omits generally known repair information.

Engine and Multi-Range Drivetrain

The air-cooled OHC single is covered by step-by-step disassembly and reassembly instructions. Factory standards and wear limits address rocker arms, valves and guides, camshaft journals, cylinder and piston, piston rings, connecting rod, and crankshaft.

Exploded assembly views pair component identification with torque, lubrication, sealant, and thread-lock callouts.

Clutch and range controls: Inspection data covers the plates, shoes, wheel, release mechanism, one-way clutch, gearshift forks, and transmission shafts. Sub-transmission cross sections distinguish the LT-F300 arrangement from the LT-F300F Super Low, Low, and High system.

Selector-cable procedures cover range and reverse, plus the LT-F300F 2WD/4WD/differential-lock controls.

Special tools: The manual identifies crankshaft installer 09910-32812, valve-guide remover/installer 09916-44910, clutch-sleeve-hub holder 09920-53730, and multi-circuit tester set 09900-25008. Suzuki warns that striking the crankshaft into the crankcase can disturb its alignment.

The oil pump is replaced as a complete unit; the clutch-shoe assembly is not intended for disassembly.

LT-F300F Bevel Gears and Differential Setup

Differential construction views, shim charts, bearing-preload data, gear clearances, and tooth-contact patterns support setup after bearing or gear replacement. Backlash must be rechecked after tooth-contact correction; both drive and driven gears may need replacement if correct mesh cannot be maintained.

Differential specifications list SAE 90 GL-5 hypoid oil, with an SAE 80 cold-weather alternative.

Chassis and Front-Brake Changes

Earlier models use hydraulic front drum brakes and a mechanical rear drum. The 2002 LT-F300FK2 section adds front disc-pad, caliper, disc, and master-cylinder repair, revised front-suspension procedures, and front-brake hose routing.

The brake-fluid guidance warns that incompatible silicone- or petroleum-based fluids can damage the glycol-based hydraulic system.

Carburetor and Lubrication Updates

The base 1999 specification uses the Mikuni BST31SS; the 2000 section introduces BSR29SS procedures, carried forward in the 2001 and 2002 service data.

Lubrication coverage extends to the oil cooler, oil-temperature or cooling-fan thermo-switch, pressure testing, and the Lubrication System Chart.

Electrical Fault Isolation and Routing

Charging and ignition tests address the generator, regulator/rectifier, ignition coil, pickup coil, and CDI unit. Starter-system and CDI ignition circuits accompany fault-finding charts.

Starter-motor overhaul includes brush, commutator, and armature checks. The starter flowcharts help separate wiring, switch, and relay faults from a defective motor before replacement parts are chosen.

2002 controls: Updated regulator/rectifier and CDI checks accompany the ignition/starter control relay and parking-brake interlock diagnosis. Separate tests cover the cooling-fan diode, switches, lamps, and battery.

Harness, control-cable, fuel, oil-cooler, brake, and breather-hose routing views support correct installation. Regional data distinguishes E-03 USA, E-17 Sweden, E-24 Australia, E-27 New Zealand, E-28 Canada, and E-33 California applications where applicable.

Consolidated service data covers torque specifications, fluid capacities, adjustment data, electrical test values, and standard-versus-limit dimensions.

Because the work involves hydraulic brakes, a spring-loaded recoil starter, and loaded clutch tests, the manual’s precautions and specified equipment should be followed. Suzuki warns that improper repair can leave the vehicle unsafe.

Compression and Oil-Pressure Specification Examples

For the LT-F300/LT-F300F, compression-test data lists a standard range of 1,000–1,400 kPa and an 800 kPa service limit, with the engine warm, throttle fully open, and battery fully charged.

The lubrication check specifies oil pressure above 30 kPa and below 70 kPa at 3,000 r/min with oil at 60°C.