Vehicle Type:
All-Terrain Vehicle (ATV), Utility Quad
Target Audience:
Farm, ranch, trail riding, recreational users.
Competitors:
Honda Foreman/Rubicon, Yamaha Kodiak/Grizzly, Kawasaki Prairie/Brute Force, Polaris Sportsman.
Durability:
Known for robust construction and reliable performance in demanding conditions.
Capability:
Designed for utility tasks, hauling, towing, and off-road exploration.
PDF Benefit:
Digital format offers easy storage, quick searching, and accessibility on multiple devices, superior to outdated paper manuals.
Engine:
Engine disassembly, assembly, inspection, lubrication, cooling system, fuel system, ignition system, starting system, charging system.
Transmission:
Automatic transmission operation, maintenance, repair, torque converter, gear inspection, lubrication.
Drivetrain:
Front and rear drive shafts, differentials, CV joints, wheel hubs, lubrication.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, steering knuckles, alignment specifications.
Brakes:
Hydraulic brake system, brake calipers, master cylinder, brake lines, brake pads, brake fluid specifications, bleeding procedures.
Electrical:
Wiring diagrams, lighting system, starting and charging systems, ignition system, battery maintenance, fuses, relays, electrical component testing.
Chassis:
Frame inspection, welding procedures, body panel removal and installation, mounting points.
Fuel System:
Fuel tank, fuel pump, fuel filter, carburetor (if applicable for specific sub-models/regions), fuel line maintenance.
Cooling System:
Radiator, coolant specifications, fan operation, thermostat, water pump.
Steering:
Steering column, tie rods, steering linkage, power steering system (if equipped), lubrication.
Maintenance:
Routine maintenance procedures, service intervals, fluid changes, filter replacements, lubrication points.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting charts, electrical diagnostic flowcharts.
Repair:
Step-by-step instructions for component removal, installation, and repair across all major vehicle systems.
Rebuild:
Detailed procedures for engine, transmission, and differential rebuilds, including specifications and tolerances.
Adjustment:
Carburetor adjustment, idle speed settings, ignition timing (if adjustable), brake adjustments.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Diagnostic Capability:
Advanced diagnostic procedures, including electrical system testing and interpretation of diagnostic codes (if applicable).
Rebuild Scope:
Full scope rebuild procedures for major mechanical components like the engine and transmission.
Specifications:
Comprehensive torque specifications, clearances, and tolerances for all critical components.
Engine Type:
4-stroke, SOHC, 4-valve, Liquid-Cooled Single-Cylinder
Displacement:
499cc (30.4 cu. in.)
Bore X Stroke:
94.0 mm x 90.0 mm (3.70 in. x 3.54 in.)
Horsepower Est:
Approximately 30-35 HP (Estimate based on typical engines of this class and era; exact figure may vary.)
Torque Est:
Approximately 28-32 lb-ft (Estimate based on typical engines of this class and era; exact figure may vary.)
Fuel Delivery:
Carburetor (Mikuni BSR36)
Fuel Type:
Unleaded gasoline, 87 octane or higher
Fuel Tank Capacity:
Approximately 4.2 US gallons (16.0 L)
Oil Type:
SAE 10W-40 API SE, SF, or SG, or higher
Oil Capacity W Filter:
Approximately 2.1 US quarts (2.0 L)
Coolant Type:
Permanent-type antifreeze coolant (50% solution of ethylene glycol and distilled water)
Ignition System:
Electronic ignition (CDI)
Starting Method:
Electric Starter, Recoil Starter (back-up)
Overall Length:
Approximately 81.5 inches (2070 mm)
Overall Width:
Approximately 45.5 inches (1155 mm)
Overall Height:
Approximately 45.7 inches (1160 mm)
Wheelbase:
Approximately 50.2 inches (1275 mm)
Ground Clearance:
Approximately 6.7 inches (170 mm)
Dry Weight:
Approximately 551 lbs (250 kg)
Curb Weight:
Approximately 584 lbs (265 kg)
Payload Capacity:
Refer to manual; typically around 450-500 lbs for rider and cargo.
Front Rack Capacity:
Approximately 45 kg (99 lbs)
Rear Rack Capacity:
Approximately 85 kg (187 lbs)
Towing Capacity:
Approximately 900 lbs (400 kg)
Front Tire Size:
AT25x8-12
Rear Tire Size:
AT25x10-12
Wheel Bolt Pattern:
Refer to manual; typically 4-bolt pattern.
Atv Safety Standards:
Designed to meet ANSI/SVIA standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear, engine braking capability.
Parking Brake:
Hand-operated parking brake.
Lighting:
Dual 30W headlights, 5W taillight/brakelight.
Operator Controls:
Handlebar controls, throttle lever, brake levers.
Protective Gear:
Emphasis on wearing helmet, eye protection, gloves, and protective clothing.
Initial Break In:
First service typically recommended at 100-200 miles or 10-20 operating hours (refer to manual for specific break-in procedure).
Engine Oil Change:
Every 1000 miles or 6 months; or every 100 operating hours (refer to manual).
Air Filter Cleaning:
Every 100 operating hours or annually; replace as needed.
Spark Plug Replacement:
Typically every 3000 miles or 300 operating hours; inspect at first service.
Transmission Fluid Change:
Every 2000 miles or 12 months.
Engine Oil Grade:
SAE 10W-40
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Coolant Specification:
50/50 mixture of ethylene glycol antifreeze and distilled water
Carburetor Clogging:
Common issue with ATVs stored with fuel; fuel stabilizer recommended. Manual covers cleaning and rebuilding.
Drive Belt Wear:
CVT drive belt can wear over time; manual covers inspection and replacement procedures.
Suspension Bushings:
Bushings can wear, leading to play in suspension; manual details replacement.
