Market Segment:
High-performance sport ATV segment, known for its power and handling.
Key Competitors:
Yamaha YFZ450, Suzuki LT-R450, Honda TRX450R.
Performance Orientation:
Designed for recreational trail riding, sport riding, and competitive off-road use.
User Benefit:
Empowers owners and technicians with the knowledge to perform maintenance, diagnostics, and repairs efficiently and correctly.
Systems Covered:
Maintenance & Servicing, Engine & Clutch, Transmissions, Cooling Systems, Fuel & Exhaust, Ignition & Electrical, Brakes & Brake Assembly, Wheels & Tires, Steering & Suspension, Frame & Bodywork, Wiring Diagrams, Fault Finding Troubleshooting
Manual Type:
Service Manual / Repair Manual
File Delivery:
Instant Download
Engine Systems:
Engine assembly, cylinder head, cylinder, piston, connecting rod, crankshaft, valve clearance adjustment, timing, lubrication system (oil pump, oil tank), cooling system (radiator, water pump, thermostat), intake system, exhaust system (muffler).
Drivetrain Transmission:
Clutch (primary, secondary), transmission gears, gearshift linkage, drive chains, sprockets, gearbox overhaul, clutch component replacement.
Fuel System:
Carburettor (kits, adjustment, overhaul), fuel tank, fuel lines, fuel filter, throttle cable operation.
Electrical Ignition:
Ignition system (CDI, stator, flywheel, spark plug), electrical components (starter motor, battery, charging system, rectifier, kill switch), wiring diagrams, lighting.
Brakes:
Brake assembly, brake pads, rotors, hydraulic systems, brake bleeding, caliper service.
Wheels Tires:
Wheel bearings, tire selection, tire pressure (PSI), wheel mounting and balancing, tire replacement.
Steering Suspension:
Steering system, tie rods, ball joints, front and rear suspension (shocks, springs, swingarm), suspension adjustment.
Frame Bodywork:
Frame inspection, body panels, plastic components, fenders, skid plates, seat, handlebars, racks, decals.
Repair Procedures:
Step-by-step instructions for disassembly, inspection, repair, and reassembly of all major vehicle systems. Includes torque specifications for critical fasteners.
Maintenance Procedures:
Routine maintenance tasks such as oil changes, filter replacements, spark plug servicing, lubrication, chain adjustment, and brake checks.
Troubleshooting:
Comprehensive fault-finding guides and diagnostic procedures to identify and resolve common problems, error codes, and performance issues.
Illustration Guides:
Detailed illustrations, exploded diagrams, drawings, and photos to visually guide users through repair procedures. Bold figured numbers link illustrations to instructions.
Technical Depth:
Covers everything from basic servicing and adjustments to complete engine and transmission overhauls. Provides detailed technical specifications and data for accurate repairs.
Searchable Text:
Assumed searchable within PDF format for efficient information retrieval.
Printable:
Printable pages for on-demand reference at the workbench.
Bookmarking:
Chapters are bookmarked for quick and easy navigation to specific repair service procedures.
Table Of Contents:
Numbered table of contents for fast information lookup.
Notes Cautions Warnings:
Prominent notes, cautions, and warnings throughout each chapter to highlight critical service information.
Instruction Format:
Numbered, step-by-step instructions for all repair procedures.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
499cc (approx.)
Bore X Stroke:
Specifics available within manual
Cooling System:
Liquid-cooled
Compression Ratio:
Specifics available within manual
Horsepower:
Estimated 40-45 HP (specific figures vary)
Torque:
Specifics available within manual
Fuel Delivery:
Carbureted
Carburetor Type:
Keihin FCR (likely, specific model in manual)
Oil Type:
Specific SAE viscosity (e.g., 10W-40, 20W-50) and API classification detailed in manual.
Oil Capacity:
Specific capacity for engine and transmission oil detailed in manual.
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
Specific NGK or equivalent plug type and gap specification in manual.
Length:
Specifics available within manual
Width:
Specifics available within manual
Height:
Specifics available within manual
Dry Weight:
Approximately 360-380 lbs (specifics in manual)
Ground Clearance:
Specifics available within manual
Front Tire Size:
e.g., AT21x7-10 (specifics in manual)
Rear Tire Size:
e.g., AT20x11-9 (specifics in manual)
Tire Pressure:
Front: XX PSI, Rear: XX PSI (specifics in manual)
Oil Change Interval:
Refer to manual for specific hours/miles for engine oil and transmission oil changes.
Air Filter Cleaning:
Recommended cleaning/replacement intervals based on riding conditions, detailed in manual.
Chain Adjustment:
Regular inspection and adjustment of the drive chain are crucial; specific procedures in manual.
Coolant Type:
Specific antifreeze/coolant mixture (e.g., ethylene glycol based) required, detailed in manual.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid typically required; specific type in manual.
Carburetor Tuning:
Carburetor jetting and tuning can be sensitive to altitude and modifications; manual provides baseline settings.
Engine Vibration:
As a powerful single-cylinder, vibration is inherent; proper mounting and balancing are key.
Clutch Wear:
Clutch wear can be accelerated with aggressive riding; manual details inspection and replacement.
