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10 Most Common Suzuki King Quad 500 Problems- How to Fix

The Suzuki King Quad 500 is a highly-anticipated ATV with a lot of potential for both utility and recreation. It boasts a sleek new design and advanced technology, but as with any vehicle, users may encounter a few common problems.

Suzuki King Quad 500 users face issues such as wiring harness damage, faulty relays, fuel injector problems, engine starter malfunctions, electrical issues, poor idling, malfunctioned transmission components, engine stalling, overheating, and lousy brake quality.

In this article, I’ll explore the most common issues with the Suzuki King Quad 500 and provide tips on how to fix them. Whether you’re a seasoned ATV enthusiast or a newcomer, this guide will help you get the most out of your Suzuki King Quad 500.

Specifications of Suzuki King Quad 500:

Specification

Details

Engine

493cc, 4-stroke, liquid-cooled, OHC single cylinder

Bore x Stroke

87.5 mm x 82.0 mm (3.40 in. x 3.20 in.)

Compression Ratio

9.9:1

Fuel System

Suzuki electronic fuel injection

Starter

Electric

Transmission

Automatic variable ratio (V-belt) with high/low-range and reverse

Clutch

Dry shoe, automatic, centrifugal type

Driven Wheels

2WD, 4WD, and 4WD Differential Lock

Final Drive

Shaft drive

Suspension (Front)

Independent, double wishbone, coil spring, gas charged and oil damped with 5-way preload adjustable shock absorbers

Suspension (Rear)

Independent, double wishbone, coil spring, gas charged and oil damped with 5-way preload adjustable shock absorbers

Brakes (Front)

Disc brakes, twin rotors

Brakes (Rear)

Sealed oil-bathed multi-disc

Tires (Front)

AT25 x 8-12, tubeless type x 2

Tires (Rear)

AT25 x 10-12, tubeless type x 2

Fuel Tank Capacity

17.5 L (4.6 US gal.)

Ignition

Electronic ignition (transistorized)

Headlight

12V 35/35W x 2 fender-mounted, 12V 35W x 1 handlebar-mounted

Tail Light

LED

Overall Length

2150 mm (84.6 in.)

Overall Width

1215 mm (47.8 in.)

Overall Height

1285 mm (50.6 in.)

Wheelbase

1285 mm (50.6 in.)

Ground Clearance

260 mm (10.2 in.)

Seat Height

920 mm (36.2 in.)

Curb Weight

315 kg (695 lb.), 316 kg (697 lb.) CA model

Warranty

12-month limited warranty

Extension

Longer coverage periods with other benefits are available through Suzuki Extended Protection (SEP)

Now that you are familiar with the basic specification of the Suzuki King Quad 500, let me move to the next section where I will discuss the common problems and the corresponsing fixes.

1. Wiring Harness Damage in Suzuki King Quad 500:

When it comes to the Suzuki King Quad 500, one of the potential issues you may encounter is wiring harness damage. The wiring harness is a crucial component that carries electrical signals throughout the ATV, connecting various electrical components and controls. 

If the wiring harness is damaged, it can lead to electrical malfunctions or even complete failure of certain systems. 

1.1. Causes of Wiring Harness Damage:

  • Physical Damage:

The wiring harness can be susceptible to physical damage due to impact from rocks, debris, or branches while riding off-road. Also, improper handling during maintenance or storage can damage the wiring harness.

  • Moisture and Water Infiltration:

Exposure to moisture or water can cause corrosion and short circuits within the wiring harness. Riding through deep water or heavy rain without adequate protection can damage water.

  • Rodent Infestation:

Rodents, such as mice or rats, chew on wiring harnesses, causing extensive damage to the electrical system.

1.2. Signs of Wiring Harness Damage:

  • Malfunctioning Electrical Systems:

If you notice that specific electrical systems or components, such as lights, indicators, or the ignition, are not functioning properly or intermittently, it could be a sign of wiring harness damage.

  • Burnt or Frayed Wires:

Inspect the wiring harness visually and look for any burnt or frayed wires. These can indicate damage that needs to be addressed.

  • Blown Fuses:

If you experience repeated blown fuses, it may be due to a short circuit caused by wiring harness damage.

How to Fix:

Let me explain the the steps below:

  • STEP 1- Visual Inspection:

Start by conducting a thorough visual inspection of the wiring harness. Look for any visible signs of damage, including cuts, abrasions, frayed wires, or burnt sections. Take note of the specific areas that require attention.

  • STEP 2- Repairs and Splicing:

Depending on the extent of the damage, you may need to repair or splice the wiring harness. This involves replacing damaged sections of the harness or reconnecting wires using appropriate connectors, soldering, and heat shrink tubing.

  • STEP 3- Protective Measures:

To prevent future damage:

  1. Consider implementing protective measures.
  2. Use a wire loom or conduit to shield vulnerable sections of the wiring harness from physical impact.
  3. Add dielectric grease to electrical connections to protect against moisture and corrosion.
  • STEP 4- Professional Assistance:

If you are unsure about the extent of the damage or lack the necessary skills and tools, seek professional assistance from a qualified technician or take your ATV to an authorized Suzuki dealer for repairs.

2. Faulty Relays in Suzuki King Quad 500:

Relays are essential components that control the flow of electrical power to various systems and components in your ATV.

If a relay malfunctions, it can lead to issues such as non-functioning lights, starter motor problems, or other electrical system failures.

2.1. How to Identify the Faulty Relays in Suzuki King Quad 500?

  • Non-Responsive Systems:

If you find that certain electrical systems or components, such as lights, winches, or horns, are not responding when activated, it could indicate a faulty relay.

  • Clicking Sound:

Faulty relays may produce a clicking sound when you attempt to activate the corresponding electrical system. This clicking sound indicates that the relay is not engaging properly.

  • Intermittent Functionality:

Sometimes, faulty relays may cause intermittent functionality of electrical systems, where they work sporadically or inconsistently.

3. Faulty Fuel Injector:

In certain Suzuki King Quad 500 models, users have reported issues with a clogged or damaged fuel injector.

This can lead to a range of problems that affect the performance and efficiency of the ATV. It’s essential to be aware of these issues and address them promptly. 

3.1. Symptoms of the Faulty Fuel Injector in Suzuki King Quad 500:

  • Poor Idling: 

If you notice that your ATV has difficulty maintaining a steady idle or it idles roughly, it could be a sign of a clogged or malfunctioning fuel injector. The injector may not deliver the proper amount of fuel to the engine during idle, resulting in an unstable idle.

  • Poor Starting:

A fuel injector issue can also cause difficulties when starting the vehicle’s engine. You may experience extended cranking times, or the engine may struggle to start altogether. This is due to an insufficient fuel supply reaching the engine cylinders.

  • Abnormal Fuel Consumption:

A clogged or damaged fuel injector can disrupt the fuel-air mixture, leading to abnormal fuel consumption. You may find that your ATV uses more fuel than usual, requiring more frequent refueling.

  • Emission Problems:

A faulty fuel injector can impact the emission control system of the ATV, resulting in increased emissions. This can cause your King Quad 500 to fail emissions tests or produce excessive exhaust emissions.

  • Loss of Power:

If the fuel injector is not functioning properly, it can result in a loss of power during acceleration or while riding at higher speeds. The engine may feel sluggish or lack the necessary power output.

How to Fix:

Fixing a damaged fuel injector in the Suzuki King Quad 500 requires a systematic approach and, in some cases, professional assistance. Here are the general steps to address the issue:

  • STEP 1- Diagnose the Problem:

Before attempting any repairs, it’s essential to confirm that the fuel injector is the cause of the issue. 

Conduct a thorough inspection and consult a qualified technician or an authorized Suzuki dealer. They can perform diagnostic tests to determine if the fuel injector is malfunctioning or damaged.

  • STEP 2- Clean the Fuel Injector:

In some cases, a clogged fuel injector can be restored to proper functioning by cleaning it. Use a fuel injector cleaning solution specifically designed for ATV engines. 

Follow the instructions provided by the cleaner. Soak the injector in the cleaning solution to dissolve any deposits or debris. 

Then, use compressed air to blow out any remaining contaminants. Reinstall the cleaned injector back into the engine.

  • STEP 3- Replace the Fuel Injector:

If cleaning the fuel injector doesn’t resolve the issue or it is severely damaged, it may need to be replaced. 

Consult with a qualified technician or an authorized Suzuki dealer to ensure you get the correct replacement injector for your King Quad 500 model. 

Follow the manufacturer’s instructions and recommended procedures for removing the old injector and installing the new one. It is also crucial to properly torque the fasteners to the specified values.

  • STEP 4- Test and Verify:

Once the fuel injector has been cleaned or replaced, test the ATV to ensure the issue has been resolved. 

Start the engine and observe its performance, paying attention to idling, starting, fuel consumption, emissions, and power delivery. Take the vehicle for a test ride to verify that the fuel injector is functioning correctly.

4. Faulty Engine Starter:

The Suzuki King Quad 500 owners have reported various major issues which delayed the starting of the engine. Users reported that earlier, they experienced an excellent cold start, but over time, they experienced a decline in the engine’s performance.

One of the users reported in detail that the vehicle worked excellently in cold conditions. But when it was run for a while and left for 5-10 minutes, it started showing trouble again.

The engine showed issues and did not fire up even after the attempt to drain the battery. The issue of engine starters may arise due to problems with the spark plugs, fuel pump, or clogged filters which result in engine failure.

How to Fix:

To fix a faulty engine starter on your Suzuki King Quad 500, follow these steps as I mentioned below:

  • STEP 1- Check the battery:

Start by inspecting the battery. Ensure it is fully charged and in good condition. If the battery is weak or dead, replace it with a new one that meets the manufacturer’s specifications.

  • STEP 2- Check the starter relay:

Locate the starter relay in the electrical system or fuse box. Use a multimeter to test the relay for continuity and proper functioning. If it is faulty, replace it with a compatible relay.

  • STEP 3- Check the starter motor:

The starter motor is responsible for initiating the engine’s rotation. Inspect the starter motor for any signs of damage or wear.

Test it using a multimeter to check for proper voltage and current flow. If the starter motor is defective, replace it with a new one recommended by Suzuki.
  • STEP 4- Check the starter solenoid:

The starter solenoid controls the flow of electrical current to the starter motor. Inspect the solenoid for any signs of damage or malfunction. Test it using a multimeter to ensure it receives and delivers the correct voltage. Replace the starter solenoid if it is faulty.

10 Most Common Suzuki King Quad 500 Problems- How to Fix
  • STEP 5- Check the wiring:

Examine the wiring connected to the starter system. Look for any damaged or corroded wires that may impede the flow of electricity. Repair or replace any faulty wiring to ensure a proper connection.

5. Electrical Problems with Suzuki King Quad 500:

Suzuki King Quad 500 users have reported electrical problems with the vehicle due to various reasons that can disrupt its functioning. These common causes include:

  • Presence of a damaged or uncharged battery
  • Fault in the spark plug
  • Defect in the ignition switch
  • Damage in the wiring of the vehicle
  • Malfunctioned regulator or rectifier
  • Fault in the stator of the vehicle

The electrical problems can occur in the Suzuki King Quad 500, leading to issues such as a lack of power to the screen, unresponsive electrical components, or intermittent power loss. 

How to Fix:

To address these problems, follow these instructions:

  • STEP 1: Start by checking the battery and terminals. Ensure the battery is fully charged and inspect the terminals for corrosion or looseness. Clean the terminals if necessary and ensure they are tightly secured.
  • STEP 2: Inspect the fuses and fuse boxes. Locate the fuse boxes in your ATV and replace any blown fuses with the correct rating.
  • STEP 3: Examine all electrical connections for damage, looseness, or corrosion. Pay close attention to plugs, sockets, and wiring. Clean any corroded connections using an electrical contact cleaner and tighten any loose connections.
  • STEP 4: Check the grounding connections. Loose or corroded grounds can cause electrical problems. Clean and tighten the ground connections as needed.
  • STEP 5: Assess the relays for proper contact. Identify the relays and test them to ensure they are making proper contact. Replace any faulty relays with new ones that match the specifications.
  • STEP 6: Inspect the wiring harness for any visible damage, frayed wires, or wear. Repair or replace any damaged wiring to prevent electrical malfunctions.

For battery-related problems:

  • Jump-start the ATV if the battery is weak or discharged. Use jumper cables and a secondary power source.
  • Clean corroded battery terminals using a battery terminal cleaner or a mixture of baking soda and water. Ensure the terminals are tightly secured.
10 Most Common Suzuki King Quad 500 Problems- How to Fix

If you encounter blown fuse issues:

  • Check for secondary fuse boxes and inspect them for blown fuses. Replace any blown fuses with new ones of the same rating.

Address connection issues and grounding problems by:

  • Conducting a thorough inspection of all electrical connections, including plugs, sockets, and wiring.
  • Cleaning corroded connections using an appropriate electrical contact cleaner. Tighten any loose wires or connectors to ensure proper electrical contact.

If you suspect faulty relays:

  • Test and identify faulty relays using a multimeter or consult ATV’s service manual.
  • Replace any faulty relays with new ones that match the specifications.

Following these steps, you can diagnose and fix common electrical issues in the Suzuki King Quad 500, ensuring a properly functioning electrical system for optimal ATV performance.

6. Poor Idling:

Few King Quad 500 2014 model owners reported the issue of poor idling in their vehicle, along with fuel blowing and fuses when the F1 light was kept on. Although the engine may run for several more days or weeks with a few blown fuses, it may eventually stall after idling normally.

One user mentioned that their engine ran roughly and died suddenly after idling and warming up for a few minutes, but it would start up again without any problem.

However, after driving for a while, the ATV lost all power and died instantly, even when pushed hard. This problem can occur when the fuel pressure level in an ATV is inadequate or not up to specification. A faulty TPS or a significant electrical system error could also cause it.

How to Fix:

To address the problem of poor idling in the Suzuki King Quad 500, consider the following steps:

  • STEP 1- Inspect the fuel system:

Check the fuel pump for proper operation and ensure no clogs or restrictions in the fuel lines. Clean or replace any components as necessary, such as the fuel filter or fuel pressure regulator.

  • STEP 2- Test the TPS:

Use a multimeter to measure the voltage output of the TPS at various throttle positions. If the readings are outside the specified range or inconsistent, replace the TPS.

  • STEP 3- Check the electrical system:

Inspect the ATV’s electrical system, including wiring connections, sensors, and the ECU. Look for any signs of damage, corrosion, or loose connections. Repair or replace any faulty components or wiring harnesses.

7. Malfunctioned Transmission Component:

Some consumers of the King Quad 500, particularly those with the 2014 version, have reported issues with the transmission. Despite running for a few more days or weeks with a few blown fuses, the engine eventually starts slowly and may even die after idling normally.

One user reported that his engine would run rough and suddenly die after idling and warming up for a few minutes but would start up again without issue. However, after driving around a bit, the ATV lost all power and died instantly, even when pushed hard.

This issue may occur when the ATV’s fuel pressure level is insufficient or not up to specification. It could also be due to a faulty TPS or MAP sensor or a significant electrical system error.

How to Fix:

If you are experiencing a malfunctioned transmission component on your Suzuki King Quad 500, follow the steps I mentioned below:

  • STEP 1- Check the transmission fluid level and condition:

Insufficient or dirty transmission fluid can cause transmission problems. Check the transmission fluid level using the manufacturer’s recommended procedure and inspect its condition. 

If the fluid level is low or the fluid is dirty, replace or top up the transmission fluid as necessary.

  • STEP 2- Check the transmission filter:

A clogged transmission filter can impede proper fluid flow and cause transmission issues. 

Locate the transmission filter and inspect it for any signs of clogging or damage. If the filter is dirty or damaged, replace it with a new one.
  • STEP 3- Inspect the shift linkage:

A damaged or misaligned shift linkage can result in transmission problems. 

Inspect the shift linkage for any signs of damage, looseness, or misalignment. If any issues are found, repair or replace the shift linkage accordingly.

10 Most Common Suzuki King Quad 500 Problems- How to Fix
  • STEP 4- Check the clutch:

A malfunctioning clutch can contribute to transmission difficulties. Inspect the clutch assembly for any signs of wear, damage, or slipping. If necessary, replace the clutch components to ensure proper operation.

  • STEP 5- Examine the transmission solenoids:

Malfunctioning transmission solenoids can disrupt the transmission’s hydraulic control and cause issues. 

Locate the transmission solenoids and test them for proper functionality using a suitable diagnostic tool. Replace any solenoids that are found to be faulty.

8. Problems with Engine Stalling:

The Suzuki King Quad 500 shows the stalling, resulting in a loss of power for users.

A Quad King 500 user reported facing this issue for a prolonged period, with the problem gradually worsening over time. Initially, the vehicle would start and run smoothly but suddenly stall at low idle positions.

The problem could be due to insufficient ground clearance or issues with the TPS. A lack of dielectric grease oil or a bare wire in the vehicle could cause this issue. To identify such problems, inspecting all the electrical connections carefully is necessary.

How to Fix:

If you are experiencing engine stalling on your Suzuki King Quad 500, here are some potential solutions to consider:

  • STEP 1: A clogged fuel filter or malfunctioning fuel pump can cause the engine to stall. Check the fuel filter, replace it if necessary, and replace the fuel pump if it is malfunctioning.
  • STEP 2: A dirty or malfunctioning carburetor can cause the engine to stall. Check the carburetor and clean it.
  • STEP 3: The faulty ignition coil or other ignition system component can cause the engine to stall. Check the ignition system and replace any defective components.
  • STEP 4: The weak battery can cause the engine to stall. Check the battery and replace it if necessary.
  • STEP 5: Malfunctioning sensors, such as the throttle position or oxygen sensor, can cause the engine to stall. Check the sensors and replace any that are faulty.

9. Overheating Issues:

Overheating is also a common problem seen in the Suzuki King Quad 500, which disturbs the vehicle’s performance. The overheating issue in the vehicle can be caused due to fault in the radiator, thermostat, or coolant.

A blown-out head gasket can also cause overheating in the vehicle. It is recommended to avoid riding at full throttle for extended periods, particularly in hot weather or on steep inclines.

This puts extra strain on the engine and can cause it to overheat. It’s also important to regularly inspect the cooling system hoses and connections for any signs of wear or leaks, as these can also contribute to overheating.

How to Fix:

If you are experiencing overheating issues with your Suzuki King Quad 500, let me provide you with the steps to fix the issue:

  • STEP 1- Check the coolant level:

Low coolant levels can lead to overheating. Locate the coolant reservoir or radiator cap and check the coolant level. If it is low, add the appropriate coolant according to the manufacturer’s recommendations.

  • STEP 2- Inspect the radiator:

A clogged or faulty radiator can impede proper cooling and result in overheating. Inspect the radiator for any signs of clogging, such as dirt, debris, or corrosion. Clean the radiator thoroughly or repair any damage if necessary.

10 Most Common Suzuki King Quad 500 Problems- How to Fix
  • STEP 3- Check the thermostat:

A malfunctioning thermostat can cause irregular temperature regulation and contribute to overheating. Locate the thermostat near the engine and inspect it for any signs of damage or malfunction. Replace the thermostat if necessary.

  • STEP 4- Inspect the water pump:

A malfunctioning water pump can reduce coolant circulation and lead to overheating. Check the water pump for any leaks or unusual noises. If the water pump is faulty, replace it with a new one.

  • STEP 5- Check the fan:
A malfunctioning cooling fan can result in inadequate airflow and overheating. Inspect the fan for proper operation by turning on the ATV and observing if the fan engages when the engine gets hot. If the fan is not working, replace it with a new one.
  • STEP 6- Check the head gasket:

A blown head gasket can cause coolant leakage and result in overheating. Inspect the head gasket for any signs of damage or leakage. If a blown head gasket is suspected, a qualified technician is recommended to have it replaced.

  • STEP 7- Check the engine oil:

Low or dirty engine oil can contribute to overheating. Check the engine oil level and inspect its condition. If the oil level is low or the oil appears dirty, replace or top up the oil as necessary.

10. Lousy Quality of Brakes:

It’s crucial to maintain and inspect the braking system regularly to ensure the safe operation of any vehicle, including the Suzuki King Quad 500. Neglecting brake maintenance can lead to severe accidents, injuries, or even fatalities.

If the brake system is out of adjustment, it can cause poor performance. Adjust the brake system according to the manufacturer’s specifications.

In addition to the warning signs mentioned, checking the brake fluid level and replacing it if necessary is essential. Low brake fluid levels can indicate a leak in the system, which needs to be fixed immediately. 

Furthermore, the brake pads, rotors, and calipers should be checked for wear and tear and replaced if necessary. Overall, regular brake maintenance is critical for safe and reliable vehicle operation.

How to Fix:

Let me explain the steps to fix below:

  • STEP 1- Regular maintenance:

Perform regular maintenance on your braking system as recommended by the manufacturer. This includes checking and replacing brake fluid, inspecting brake pads, rotors, and calipers, and ensuring proper adjustment of the brake system.

  • STEP 2- Check brake fluid level:

Inspect the brake fluid level regularly. Low brake fluid can indicate a leak in the system or excessive wear on the brake components. If the brake fluid level is low, adding fluid and having the system inspected for leaks may be necessary.

  • STEP 3- Inspect brake pads, rotors, and calipers:

Examine the brake pads, rotors, and calipers for signs of wear and tear. Worn brake pads may reduce braking performance and should be replaced if they have reached their minimum thickness.

Inspect the rotors for any damage, such as scoring or warping, and replace them if necessary. Also, check the calipers for proper operation and any signs of wear or corrosion.

  • STEP 4- Replace worn brake components:

If the brake pads, rotors, or calipers are significantly worn or damaged, they should be replaced with new ones.

It is essential to use high-quality OEM (Original Equipment Manufacturer) parts or recommended aftermarket replacements to ensure proper braking performance.

  • STEP 5- Bleed the brake system:

Over time, air bubbles can get trapped in the brake system, leading to a spongy brake pedal and reduced braking effectiveness.

Bleeding the brake system helps remove air from the lines and ensures optimal brake performance. Follow the manufacturer's instructions or consult a qualified technician to bleed the brake system properly.

Pros and Cons of Suzuki King Quad 500:

Pros

Cons

Powerful engine for tackling various terrains

Potential electrical issues

Smooth and comfortable ride

Fuel injector clogging or damage

Reliable and durable construction

Potential poor idling

Excellent off-road capabilities

Malfunctioned transmission component

Good fuel efficiency

Possibility of overheating issues

Versatile and suitable for multiple purposes

Lousy quality of brakes

Ample storage space for cargo

Users’ Feedback/Review of the Suzuki King Quad 500:

“I recently purchased the Suzuki King Quad 500, and I am extremely satisfied with its performance. The powerful engine allows me to conquer any terrain with ease, and the comfortable ride ensures a pleasant off-road experience. The build quality is impressive, and I appreciate the ample storage space for my gear. Overall, the King Quad 500 has exceeded my expectations.”

Source: ATV.com

“I’ve been using the Suzuki King Quad 500 for over a year now, and it has been a reliable companion on all my outdoor adventures. The fuel efficiency is impressive, allowing me to go on long rides without worrying about running out of fuel. The off-road capabilities are outstanding, and the vehicle handles rough terrains with ease. It’s a versatile ATV that meets my needs perfectly.”

Source: ATV.com

Final Thought:

Like any other vehicle, the Suzuki King Quad 500 may encounter specific issues that owners should be aware of. However, these problems can be resolved effectively with proper maintenance and timely troubleshooting.

Regular inspections, adherence to manufacturer guidelines, and prompt fixes will help riders enjoy a reliable and satisfying off-road experience with this capable ATV.

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Frequently Asked Questions (FAQs):

Is the Suzuki King Quad 500 a good buy?

Many ATV enthusiasts consider the Suzuki King Quad 500 a good buy. It offers a powerful engine, reliable performance, and versatile capabilities, making it suitable for various off-road adventures. The King Quad 500 is known for its durability and ruggedness, allowing riders to navigate challenging terrains easily.

Is the Suzuki King Quad 500 considered a reliable vehicle?

The Suzuki King Quad 500 is generally considered a reliable vehicle. Suzuki is renowned for producing durable and long-lasting ATVs, and the King Quad 500 is no exception. It is built with quality materials and designed to withstand the demands of off-road riding. Many owners have reported years of trouble-free use with regular maintenance and proper care.

What type of engine comes in a Suzuki King Quad 500?

The Suzuki King Quad 500 is equipped with a 493cc (30.1 cubic inches), 4-stroke, liquid-cooled, 4-valve, OHC (Overhead Cam) single-cylinder engine. This engine configuration provides a balance of power, efficiency, and durability for off-road riding.

How far can a Suzuki Quad 500 go on a full gas tank?

On average, you can expect the King Quad 500 to travel approximately 100 to 150 miles (160 to 240 kilometers) on a full gas tank. The vehicle’s fuel tank capacity is 17.5 liters (4.6 US gallons), which provides a decent range for off-road adventures.