Vehicle Segment:
High-performance sport ATV, competitive in its era.
Key Competitors:
Honda TRX450R, Suzuki LT-Z400, Bombardier DS650.
Engine Type:
Liquid-cooled, four-stroke, SOHC, 4-valve, single-cylinder.
Transmission Type:
5-speed manual with reverse.
Suspension Setup:
Long-travel independent front suspension (IFP) and a rear swingarm with a monoshock.
Braking System Type:
Hydraulic disc brakes front and rear.
Design Philosophy:
Emphasis on power, handling, and rider comfort for aggressive off-road riding.
Years Covered:
2001, 2002, 2003, 2004, 2005, 2006
Estimated Page Count:
Approximately 400-500 pages (typical for this era of comprehensive service manuals)
Manual Type:
Workshop Service Manual / Repair Manual
Language:
English (standard for most Yamaha service documentation)
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of the engine.
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel pump operation; fuel tank and lines.
Ignition System:
Ignition timing, CDI unit, spark plug specifications, stator and rotor inspection.
Cooling System:
Radiator, fan, water pump, coolant type and capacity, thermostat.
Transmission And Drivetrain:
Clutch operation, gearbox disassembly and inspection, chain drive maintenance, final drive assembly.
Suspension System:
Front and rear suspension geometry, shock absorber overhaul and adjustment, A-arm and linkage maintenance.
Braking System:
Hydraulic brake system troubleshooting, caliper rebuild, master cylinder service, brake pad replacement, rotor inspection.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, starter motor, charging system (alternator/stator), fuses, relays.
Chassis And Frame:
Frame inspection for damage, steering system maintenance, handlebar and control adjustments.
Bodywork And Trim:
Plastic panel removal and installation, fender and seat maintenance.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning, chain adjustments, pre-ride inspections.
Troubleshooting:
Diagnosis of common mechanical and electrical issues with step-by-step troubleshooting guides.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis.
Component Disassembly Reassembly:
Detailed instructions for removing, servicing, and reinstalling all major and minor components.
Torque Specifications:
Precise torque values for all critical fasteners.
Depth Of Coverage:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capabilities:
Includes diagnostic procedures, fault finding charts, and symptom-based troubleshooting.
Diagrams And Illustrations:
Richly illustrated with exploded views, schematics, and step-by-step diagrams.
Engine Type:
4-stroke, liquid-cooled, SOHC, 4-valve
Bore X Stroke:
100.0 mm x 84.0 mm
Carburetor:
Keihin FCR41 (single, flat-slide, with accelerator pump)
Horsepower Estimate:
Approximately 45-50 HP (stock, at crankshaft)
Torque Estimate:
Approximately 42-45 lb-ft (stock, at crankshaft)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Fuel Capacity:
2.6 gallons (9.8 L)
Atv Safety Standards:
Meets ANSI and/or relevant industry safety standards for ATVs.
Brakes:
Dual hydraulic disc front, single hydraulic disc rear.
Suspension:
Long-travel suspension for stability and control.
Footwells:
Integrated floorboards with heel guards for rider foot protection.
Handlebars:
Handlebar-mounted front and rear brake levers for independent control.
Display Panel:
Digital multi-function meter: speedometer, odometer, trip meter, clock, neutral indicator, reverse indicator, oil temp warning light.
Engine Features:
Accelerator pump in the carburetor provides crisp throttle response.
Charging System:
12V DC generator (stator) for battery charging and electrical systems.
Engine Oil Change:
Every 1000 miles or 6 months (whichever comes first), or more frequently with hard use.
Air Filter Cleaning:
Every 10-15 hours of operation or as needed, depending on conditions.
Spark Plug Inspection Replacement:
Inspect every 500 miles, replace as needed (typically NGK CR9E or equivalent).
Chain Lubrication Adjustment:
Lubricate every 200-300 miles, adjust tension every 500 miles.
Engine Oil Type:
Yamalube 4 10W-40 or equivalent API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
2.08 US qt (1.97 L) with oil filter replacement.
Coolant Type:
Permanent type antifreeze (ethylene glycol based), 50/50 mix with distilled water.
Coolant Capacity:
1.70 L (1.8 US qt)
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Camchain Tensioner:
Some models experienced premature wear or failure of the automatic cam chain tensioner, often replaced with a manual unit.
Carburetor Jetting:
Carburetor may require re-jetting for modifications or significant altitude changes.
Oil Leaks:
Potential for oil leaks from valve cover or crankcase seals if not properly maintained or torqued.
