Segment:
High-performance utility ATV
Target User:
Enthusiasts seeking robust off-road capability for work and recreation
Key Competitors Era:
Yamaha Grizzly 660, Polaris Sportsman 700/800, Arctic Cat 700 EFI
Vehicle Highlights:
Powerful 700cc engine, independent rear suspension (IRS), torque-sensing front differential, robust chassis for demanding terrain
Completeness:
Complete service manual package covering all servicing aspects, including a separate parts manual.
Engine:
Complete engine overhaul, disassembly, assembly, lubrication, cooling system, fuel system, ignition system, starting system, exhaust system
Transmission:
Automatic transmission (CVT) overhaul, maintenance, fluid specifications, drive clutch and driven clutch service
Drivetrain:
Front and rear drive shafts, differentials, CV joints, propeller shafts, drive axles, wheel hubs
Chassis And Frame:
Frame inspection, body panel removal/installation, seat, handlebars, footrests
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, bushings, wheel alignment
Brakes:
Front and rear hydraulic disc brakes, brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures
Electrical System:
Battery, charging system (stator, regulator/rectifier), starting motor, lighting (headlights, taillights, brake lights), instrumentation, ignition coil, CDI unit
Fuel System:
Fuel tank, fuel pump, fuel filter, carburetor overhaul (if applicable, though this model is fuel-injected), fuel injection system components (injectors, throttle body)
Cooling System:
Radiator, cooling fan, coolant specifications, thermostat, water pump
Steering:
Steering column, tie rods, steering knuckles, linkage
Wheels And Tires:
Tire pressure recommendations, wheel nut torque specifications
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, lubrication points, valve clearance adjustment
Troubleshooting:
Diagnostic charts, common problems and solutions, electrical troubleshooting guides, engine performance issues
Repair:
Step-by-step repair instructions for all major components and systems, including complete teardown and reassembly
Diagnostics:
Detailed procedures for diagnosing faults in various systems, including electrical and mechanical diagnostics
Wiring Diagrams:
Comprehensive wiring diagram schematic for electrical systems, aiding in fault finding and component identification
Depth Level:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system troubleshooting.
Illustrations:
Detailed pictures and diagrams throughout the manual
Exploded Views:
Included in the separate parts manual for all assemblies and components
Engine Type:
Four-stroke, SOHC, V-twin, liquid-cooled
Bore X Stroke:
72.0 mm x 85.2 mm
Horsepower Approximate:
Approximately 45-50 HP (specification can vary slightly by source)
Torque Approximate:
Approximately 40-45 lb-ft (specification can vary slightly by source)
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle valves
Fuel Type:
Unleaded gasoline
Ignition System:
Electronic ignition (CDI)
Oil Type Recommendation:
API SE, SF, SG or SH classification, SAE 10W-40 or 20W-50 (refer to manual for exact Suzuki recommendation)
Cooling Method:
Liquid-cooled
Exhaust System:
Equipped with catalytic converter for emissions control
Engine Oil Change:
Refer to manual; typically every 1,000-1,500 miles or 6-12 months.
Air Filter Cleaning:
Refer to manual; inspect frequently, clean/replace as needed based on operating conditions.
Spark Plug Replacement:
Refer to manual; typically at intervals like 3,000-5,000 miles or as recommended.
Valve Adjustment:
Refer to manual; initial adjustment at lower mileage, then periodic checks.
Engine Oil Capacity:
Refer to manual; typically around 2.5 - 3.0 Quarts (with filter change)
Coolant Capacity:
Refer to manual; approximately 2.0 Liters (50/50 coolant/water mix)
Brake Fluid Type:
DOT 3 or DOT 4 (confirm with manual)
Common Wear Items:
CV boots, suspension bushings, wheel bearings, drive belts (CVT).
Potential Electrical Issues:
Regulator/rectifier failure, stator issues (as with many ATVs of this era).
Pre Ride Checks:
Tire pressure, fluid levels, lights, controls, suspension, visual inspection for damage.
