Vehicle Segment:
High-performance utility ATV (All-Terrain Vehicle).
Target Audience:
Owners seeking to perform their own maintenance and repairs, enthusiasts, and professional repair shops.
Competitors:
Honda Foreman/Rubicon, Yamaha Grizzly, Kawasaki Brute Force, Polaris Sportsman.
Key Selling Points Atv:
Powerful V-twin engine, advanced independent suspension, selectable 4WD with differential lock, electronic fuel injection.
Comprehensiveness:
Aims to replicate the depth and detail of original factory service manuals.
Accessibility:
Instant PDF download eliminates shipping delays and provides immediate access.
User Friendliness:
Designed to be easy to understand with clear language, diagrams, and pictures.
Cost Effectiveness:
Empowers owners to perform repairs themselves, saving on labor costs.
Engine Mechanical:
Detailed disassembly, inspection, and reassembly procedures for all internal engine components.
Fuel And Ignition Systems:
Comprehensive diagnostics and repair procedures for the fuel injection system (FI), throttle body, fuel pump, injectors, and ignition system.
Cooling And Lubrication:
Service procedures for the radiator, cooling fan, water pump, oil pump, oil filter, and lubrication passages.
Drivetrain Transmission:
Information on the CVT transmission, including removal, inspection, adjustment, and repair of internal components and drive belts.
Drivetrain Differential Axles:
Procedures for servicing front and rear differentials, driveshafts, CV joints, and hubs.
Chassis Suspension:
Repair and adjustment of front and rear suspension systems, including shocks, springs, A-arms, and bushings.
Chassis Steering:
Service and adjustment of the steering system, including handlebars, steering column, and tie rods.
Chassis Brakes:
Procedures for brake system maintenance, including bleeding, pad replacement, caliper servicing, and hydraulic system checks.
Electrical System Lighting Indicators:
Maintenance and troubleshooting of headlights, taillights, brake lights, turn signals, and indicator lights.
Electrical System Starting Charging:
Service for the starter motor, battery, charging system (stator, regulator/rectifier).
Electrical System Instrumentation:
Troubleshooting and repair of the digital instrument cluster and associated sensors.
Wiring Diagrams:
Detailed and color-coded wiring diagrams for all electrical systems.
Routine Maintenance:
Detailed steps for oil changes, filter replacements, spark plug servicing, and general inspections.
Troubleshooting Diagnostics:
Step-by-step diagnostic guides and flowcharts for identifying and resolving common and uncommon issues.
Component Disassembly Reassembly:
Comprehensive instructions for the complete disassembly and reassembly of all major mechanical and electrical components.
Rebuilding Overhaul:
Guidance for engine and transmission rebuilds, including specifications for wear limits and tolerances.
Adjustments Calibrations:
Procedures for adjusting clutch engagement, throttle cables, brakes, and suspension settings.
Diagnostic Capabilities:
Advanced diagnostics for FI system, including fault codes, sensor readings, and actuator testing.
Performance Tuning:
While not strictly a tuning manual, the detailed specifications allow for understanding of performance parameters.
Repair Scope:
Covers everything from basic fluid changes to complete engine and transmission overhauls, including chassis and electrical repairs.
Documentation Quality:
High-quality diagrams, illustrations, and clear, concise instructions.
Engine Type:
Liquid-cooled, 4-stroke, V-twin, DOHC, 8-valve
Displacement:
695 cc (42.4 cu. in.)
Bore X Stroke:
81.0 mm x 68.0 mm (3.19 in. x 2.68 in.)
Compression Ratio:
9.3 : 1
Carburetion:
Electronic Fuel Injection (EFI) with 32mm throttle body
Horsepower:
Approx. 50 HP (estimation, official figures not readily available for specific model year)
Torque:
Approx. 44 lb-ft (estimation, official figures not readily available for specific model year)
Fuel Delivery:
Suzuki Fuel Injection (SFI)
Fuel Type:
Unleaded gasoline, Octane rating 87 or higher
Instrument Cluster:
Multi-function digital LCD meter including speedometer, odometer, trip meter, clock, fuel gauge, 4WD indicator, reverse indicator, high beam indicator, neutral indicator, oil pressure indicator, and coolant temperature indicator.
Traction Control:
No electronic traction control; relies on mechanical systems like differential lock.
Diagnostic Ports:
Diagnostic connector for EFI system access.
Engine Oil Change:
Every 1000 km (600 miles) or 6 months, whichever comes first (refer to manual for exact details and severe duty intervals).
Air Filter Inspection:
Inspect every 500 km (300 miles) or monthly, clean/replace as needed.
Spark Plug Replacement:
Replace every 3000 km (2000 miles) or 12 months.
Gear Oil Change:
Every 2000 km (1200 miles) or 12 months (for transmission and front/rear differentials).
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
2.7 L (2.9 US qt) with oil filter change.
Cooling System Coolant:
High-quality ethylene glycol-based coolant, 50% mixture with distilled water.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Transmission Oil:
SAE 80W API GL-4 gear oil.
Front Differential Oil:
SAE 80W API GL-5 gear oil.
Rear Differential Oil:
SAE 80W API GL-5 gear oil.
Common Wear Items:
CVT belt, suspension bushings, wheel bearings, brake pads.
Potential Fi Issues:
While generally reliable, EFI systems can be sensitive to fuel quality and require proper maintenance of sensors and injectors. The manual's FI diagnosis section is crucial here.
