Segment:
Entry-level to mid-range utility ATV
Target Audience:
Recreational riders, light farm work, trail riding
Key Competitors Era:
Honda FourTrax 300, Suzuki QuadRunner 250, Kawasaki Bayou 220/300
Drivetrain:
Selectable 4WD system
Transmission:
Reliable 5-speed manual transmission with reverse
Engine:
Torquey 250cc air-cooled engine
Suspension:
Independent front suspension for improved comfort and control
Braking:
Powerful front and rear disc brakes
Years Covered:
1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000
Vehicle Variant Coverage:
4WD models
Estimated Pages:
Extensive (typically 300-500+ pages for a complete workshop manual of this era)
Type:
Workshop Service Repair Manual
Format:
Downloadable Digital File (likely PDF)
Engine Mechanical:
Top-end (cylinder head, valves, camshaft), Bottom-end (crankshaft, connecting rods, pistons), Cooling System, Lubrication System
Fuel System:
Carburetor (cleaning, adjustment, jetting), Fuel Pump, Fuel Tank, Fuel Lines
Transmission Drivetrain:
5-Speed Manual Transmission, Clutch (operation, adjustment, replacement), Drive Shafts, Differential (front and rear), Gearcase
Electrical System:
Ignition System (CDI, spark plugs, coils), Starting System (starter motor, solenoid), Charging System (stator, regulator/rectifier), Lighting System (headlights, taillights, brake lights), Battery, Wiring Diagrams
Suspension Steering:
Front Independent Suspension (A-arms, shocks, springs), Rear Swingarm Suspension (shock, spring), Steering System (handlebars, tie rods, steering shaft)
Braking System:
Hydraulic Disc Brakes (front and rear calipers, master cylinders, lines, pads), Parking Brake
Wheels Tires:
Wheel Hubs, Lug Nuts, Tire Specifications
Chassis Frame:
Frame Inspection, Body Panels (removal, installation), Plastics
Cooling System:
Air Cooling System details
Routine Maintenance:
Oil Changes, Filter Replacements (oil, air), Spark Plug Service, Chain Adjustment (if applicable), Battery Maintenance, Lubrication Points
Engine Overhaul:
Top-end rebuild, piston replacement, valve adjustments, complete engine disassembly and reassembly
Transmission Repair:
Clutch replacement, gear inspection, seal replacement, transmission fluid changes
Carburetor Rebuild:
Complete carburetor cleaning, adjustment, and jetting procedures
Brake Service:
Brake pad replacement, caliper service, master cylinder rebuild, bleeding procedures
Electrical Diagnostics:
Troubleshooting starting issues, charging system faults, lighting problems using wiring diagrams
Suspension Overhaul:
Shock absorber replacement, bushings replacement, suspension alignment checks
Troubleshooting:
Diagnostic charts for common problems and their solutions
Depth:
Comprehensive: Covers basic maintenance to complete engine and component rebuilds, including detailed diagnostic procedures.
Diagnostic Tools:
Details required tools and techniques for diagnosis (e.g., compression testing, multimeter usage).
Engine Type:
4-stroke, SOHC, Air-Cooled
Displacement:
230 cc (approximately)
Bore X Stroke:
Typically around 67.0 mm x 66.0 mm (verify specific model year)
Compression Ratio:
Typically around 9.2:1 (verify specific model year)
Horsepower:
Approx. 16-18 HP @ 6500 RPM (estimate, actual may vary by year)
Torque:
Approx. 14-16 lb-ft @ 5500 RPM (estimate, actual may vary by year)
Carburetor Model:
Mikuni VM34 (or similar 34mm constant velocity carburetor)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Fuel Tank Capacity:
Approximately 3.0 US gallons (11.4 L)
Engine Oil Change:
Every 100 hours or annually (whichever comes first).
Oil Filter Change:
Recommended with every oil change.
Air Filter Cleaning:
Every 20 hours or more frequently in dusty conditions.
Spark Plug Inspection:
Every 100 hours or annually.
Clutch Adjustment:
As needed, check cable free play.
Brake Fluid Flush:
Every 2 years or as needed.
Engine Oil Type:
Yamalube 4 (or equivalent SAE 10W-30 API SG or higher)
Engine Oil Capacity:
Approx. 1.6 US quarts (1.5 L) without filter change, 1.8 US quarts (1.7 L) with filter change (verify specific capacity in manual).
Transmission Oil Type:
Yamalube 4 (or equivalent SAE 10W-30 API SG or higher) or specific gear oil if indicated.
Transmission Oil Capacity:
Approx. 0.8 US quarts (0.75 L) (verify specific capacity in manual).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Common Wear Items:
Brake pads, suspension bushings, drive shaft U-joints, carburetor jets, starter motor brushes.
Carburetor Cleaning:
Carburetors can become clogged with debris over time, requiring regular cleaning and adjustment for optimal performance.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues; cleaning and dielectric grease application is recommended.