Atv Segment:
Mid-size utility ATV, popular for recreational and light work applications in its era.
Key Competitors:
Competed with models from Honda (e.g., FourTrax 300), Yamaha (e.g., Bear Tracker), and Kawasaki (e.g., Bayou 300).
Durability And Reliability:
Suzuki QuadRunner models are generally known for their robust construction and reliable performance.
Ease Of Maintenance:
Designed with accessible components for straightforward maintenance and repairs, aided by this comprehensive manual.
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of engine components (cylinder head, piston, crankshaft, camshaft, valve train, etc.).
Engine Fuel And Ignition:
Carburetor tuning, fuel pump, fuel lines, ignition timing, spark plug specifications, and related components.
Transmission Drivetrain:
Clutch operation, gear shifting mechanisms, final drive, and maintenance procedures.
Electrical System Overview:
Wiring diagrams, component identification, voltage checks, and troubleshooting for the entire electrical system.
Lighting And Signals:
Headlights, taillights, brake lights, turn signals (if applicable), and related wiring.
Chassis And Frame Integrity:
Frame inspection, welding procedures (if applicable), and general chassis components.
Suspension And Steering Alignment:
Front and rear suspension component inspection, bearing service, steering linkage adjustments, and alignment procedures.
Braking System Hydraulics:
Brake caliper service, master cylinder maintenance, brake fluid specifications, bleeding procedures, and pad/shoe replacement.
Wheel And Tire Service:
Tire pressure recommendations, wheel bearing maintenance, and general wheel assembly.
Lubrication And Fluid Management:
Oil change intervals, fluid types and capacities (engine oil, transmission oil, brake fluid), and grease points.
Body And Plastic Components:
Removal, installation, and maintenance of body panels and plastic shrouds.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain lubrication, and general inspection schedules.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues, covering engine performance, electrical faults, and mechanical problems.
Component Rebuilds:
Detailed step-by-step instructions for rebuilding major components like the engine and transmission.
Adjustment Procedures:
Carburetor synchronization, clutch adjustment, brake lever travel, and steering free play.
Torque Specifications:
Critical torque values for all engine, chassis, and suspension fasteners.
Wiring Diagrams:
Comprehensive and color-coded wiring diagrams for all electrical systems.
Special Tool Requirements:
Identification of any specialized tools required for specific repair or maintenance tasks.
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission overhauls. Suitable for professional technicians and advanced DIY mechanics.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
280cc (approximate, common for this model)
Cooling System:
Air-cooled
Horsepower:
Approximately 18-20 HP (estimated, specific rating varies by year/tune)
Torque:
Specifications available in manual
Carburetor Type:
Mikuni carburetor (specific model details in manual)
Fuel Type:
Unleaded gasoline
Recommended Oil Grade:
Suzuki recommends SAE 10W-40 API SG or higher (verify in manual for exact spec)
Oil Capacity:
Specifications available in manual
Engine Oil Change:
Every 1000 km or 6 months (refer to manual for precise intervals and conditions).
Air Filter Cleaning:
Regular inspection and cleaning, especially in dusty conditions (details in manual).
Spark Plug Replacement:
Recommended interval provided in manual, typically around 3000-5000 km.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (verify in manual).
Transmission Fluid:
API GL-4 SAE 80W-90 gear oil recommended (verify in manual).
Carburetor Clogging:
Common in older ATVs due to fuel sitting; requires cleaning and proper fuel storage.
Suspension Wear:
Bushings and bearings can wear over time; periodic inspection and lubrication are key.
Electrical Connector Corrosion:
Can occur in wet environments; inspect and clean connectors as per manual.