Market Segment:
Entry-level to mid-range recreational ATV (All-Terrain Vehicle).
Target Audience:
Recreational riders, trail enthusiasts, and utility users looking for a reliable and capable ATV.
Key Competitors:
Honda Rancher, Yamaha Kodiak, Suzuki King Quad (comparable displacements and feature sets in their respective eras).
Engine Configuration:
Air-cooled, single-cylinder, four-stroke engine known for its simplicity and reliability.
Drivetrain:
Automatic transmission (CVT) with shaft drive and selectable 2WD/4WD (depending on specific sub-model/year).
Suspension Type:
Independent front suspension (often MacPherson strut) and swingarm rear suspension, providing comfortable and capable trail riding.
Braking System Type:
Hydraulic disc brakes on all wheels for effective stopping power.
Model Years Covered:
2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Documentation Type:
Service Repair Workshop Manual
Coverage Completeness:
Complete; includes updated information up to 2012
Estimated Page Count:
N/A (Digital PDF)
Manual Type:
Workshop Service and Repair Manual
Format:
PDF (Portable Document Format)
Engine Mechanical:
Complete engine overhaul, including cylinder head, piston, crankshaft, valve train, timing, seals, gaskets, and related components.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel tank, and related components.
Cooling System:
Radiator, fan, coolant, hoses, water pump, and thermostat operation and maintenance.
Ignition System:
Spark plugs, ignition coil, CDI unit, and related wiring.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) inspection, belt replacement, clutch maintenance, gearbox, drive shafts, and differential.
Braking System:
Hydraulic brake system, brake calipers, brake pads, brake lines, master cylinder, and bleeding procedures.
Suspension Steering:
Front and rear suspension components, shocks, springs, bushings, steering column, tie rods, and wheel alignment.
Electrical System:
Battery, starting system, charging system (stator, regulator/rectifier), lighting, wiring diagrams, switches, and fuses.
Frame Bodywork:
Chassis inspection, body panel removal/installation, fenders, racks, and seat.
Wheels Tires:
Tire pressure, replacement, wheel mounting, and lug nut torque specifications.
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, lubrication, spark plug checks, and chain adjustments.
Diagnostic Troubleshooting:
Systematic troubleshooting guides for common performance issues, starting problems, electrical faults, and driveability concerns.
Repair Procedures:
Step-by-step instructions for disassembly, repair, reassembly, and adjustment of all major vehicle components.
Specifications Torques:
Torque specifications for critical fasteners, fluid capacities, and dimensional data for engine and chassis components.
Wiring Diagrams:
Comprehensive electrical schematics for accurate diagnosis and repair of the electrical system.
Special Tools:
Identification of required special tools for specific repair and maintenance procedures.
Technical Depth:
Comprehensive from basic maintenance and fluid checks to full engine and transmission rebuilds.
Diagnostic Capabilities:
Advanced diagnostic procedures for identifying and resolving complex mechanical and electrical issues.
Engine Type:
4-stroke, SOHC, Air-cooled
Bore X Stroke:
Approx. 75mm x 74.5mm (typical for this displacement range, specific values in manual)
Compression Ratio:
Approx. 9.7:1 (typical, specific values in manual)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Horsepower Est:
Approx. 18-20 HP (typical for this displacement, specific figures in manual)
Torque Est:
Approx. 18-20 lb-ft (typical for this displacement, specific figures in manual)
Fuel Delivery:
Carburetor (likely Mikuni or Keihin, specific model in manual)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 3.2 gallons (12.1 liters) (typical, check manual for exact)
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Drive System:
Shaft Drive, with selectable 2WD/4WD (manual will detail engagement)
Gear Selection:
High, Low, Neutral, Reverse (H-L-N-R)
Cvg Belt Maintenance:
Critical service item covered in detail, including inspection, adjustment, and replacement intervals.
Overall Length:
Approx. 76 inches (193 cm) (typical, check manual for exact)
Overall Width:
Approx. 46 inches (117 cm) (typical, check manual for exact)
Overall Height:
Approx. 45 inches (114 cm) (typical, check manual for exact)
Wheelbase:
Approx. 49 inches (124.5 cm) (typical, check manual for exact)
Dry Weight:
Approx. 500-550 lbs (227-250 kg) (typical, check manual for exact)
Ground Clearance:
Approx. 8-10 inches (20-25 cm) (typical, check manual for exact)
Front Rack Capacity Est:
Approx. 50 lbs (23 kg) (typical, check manual for exact)
Rear Rack Capacity Est:
Approx. 100 lbs (45 kg) (typical, check manual for exact)
Atv Safety Standards:
Conforms to applicable ANSI standards for recreational ATVs.
Braking System Description:
Dual hydraulic disc front, single hydraulic disc rear. Lever-activated braking.
Engine Braking:
CVT system provides inherent engine braking effect on deceleration.
Rollover Protection:
None (ATVs do not have integrated ROPS like UTVs or cars; rider awareness is key).
Footwell Design:
Open-design footpegs with grip; manual will emphasize proper riding gear.
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first), refer to manual for specific interval confirmation.
Air Filter Inspection:
Every 25 hours or monthly, clean/replace as needed.
Spark Plug Replacement:
Every 100 hours or annually.
Cv Belt Inspection:
Every 50 hours or annually, check for wear and tension.
Lubrication Points:
Periodic greasing of suspension pivot points, steering components, and drive shafts as outlined in the manual.
Engine Oil Type:
SAE 10W-40, API SG or higher (check manual for exact API service category and viscosity for operating temperature).
Engine Oil Capacity:
Approx. 2.1 US quarts (2.0 liters) with filter change (check manual for exact).
Gearcase Oil Type:
SAE 80W-90 GL-5 hypoid gear oil (check manual for exact).
Gearcase Oil Capacity:
Approx. 0.3 US quarts (0.3 liters) (check manual for exact).
Coolant Type:
Ethylene glycol-based antifreeze solution (typically 50/50 mix with distilled water), check manual for specific formulation and color if applicable.
Cv Belt Wear:
Common wear item requiring regular inspection and replacement. Overheating or improper belt tension can accelerate wear.
Carburetor Clogging:
Can occur with stale fuel or debris; requires periodic cleaning and proper fuel storage practices.
Suspension Bushings:
Wear can lead to play in steering and suspension; regular inspection and lubrication is key.
Electrical Connections:
Corrosion or loose connections can cause intermittent electrical issues; maintaining clean connections is important.
