Systems Covered:
Engine, Transmission, Chassis, Electrical System, Fuel System, Cooling System, Braking System, Suspension, Steering, Bodywork, Drive Train, Ignition System, Lubrication, Exhaust System, Troubleshooting, Maintenance, Diagnostics, Repair Procedures.
Manual Type:
Workshop Repair Service Manual
Engine Mechanical:
Engine disassembly, assembly, inspection, rebuild, piston, cylinder, crankshaft, connecting rod, valves, camshaft, timing, compression ratio, bore, stroke, lubrication, cooling system.
Fuel System:
Carburetor (including pilot jet, main jet, mixture screw adjustment), fuel pump, fuel tank, fuel lines, fuel injection (EFI) components where applicable (though 200cc models often are carbureted), fuel filter.
Electrical System:
Ignition system, stator, magneto, battery, charging system, rectifier, regulator, starter motor, starter solenoid, lighting (headlights, taillights), wiring diagrams, fuses, switches.
Transmission Drivetrain:
Clutch (primary reduction gear), gearshift mechanism, drive shaft, drive train components, swingarm, axles, wheel hubs, reverse gear.
Suspension Steering:
Front and rear suspension, struts, shocks, springs, steering linkage, handlebars, steering column.
Braking System:
Brake calipers, brake pads, brake lines, master cylinder, brake fluid specifications, brake levers, hydraulic brakes.
Bodywork Plastics:
Fenders, seat, panels, plastic components, bodywork removal and installation.
Preventative Maintenance:
Regular service schedule, fluid checks and changes (engine oil, coolant, brake fluid), filter replacement, lubrication points, tire pressure, battery maintenance.
Troubleshooting:
Identification of common problems, error codes, diagnostic procedures, no spark issues, starting problems, performance issues, charging system faults.
Repair Rebuild:
Detailed step-by-step instructions for disassembly, inspection, repair, and reassembly of all major vehicle components and systems. Includes engine rebuilds, transmission overhauls, suspension repairs, brake system service, etc.
Diagnostics:
Procedures for diagnosing malfunctions in various systems, including electrical, fuel, ignition, and mechanical components. May include specific diagnostic charts or flowcharts.
Electrical Troubleshooting:
Includes diagnosing ignition system faults, charging issues, lighting problems, and using wiring diagrams to trace circuits.
Carburetor Adjustment:
Detailed procedures for cleaning, adjusting, and rebuilding the carburetor, including setting idle speed and mixture.
Drive Train Maintenance:
Information on inspecting and maintaining the drive shaft, CV joints (if applicable), rear axle, and swingarm lubrication.
Technical Depth:
Comprehensive, covering from basic maintenance and adjustments to complete engine and transmission overhauls. Suitable for both DIY enthusiasts and professional technicians.
Engine Type:
Single-cylinder, 4-stroke (typical for this class, confirm via manual diagrams)
Engine Displacement:
Approximately 196cc (Phoenix 200 / Sawtooth 200)
Horsepower:
Typically in the range of 13-15 HP (estimated, actual spec in manual)
Torque:
Not specified, but expected for a 200cc class engine.
Carburetor Model:
Likely a Keihin or Mikuni carb (specific model in manual, e.g., CV-type carb)
Fuel Type:
Unleaded gasoline
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Air-cooled (typical for this size and class)
Dry Weight:
Approximately 320 lbs (145 kg) - actual spec in manual
Weight Capacity:
Not specified, refer to manual for load limits.
Length:
Approx. 69.9 in (177.5 cm) - actual spec in manual
Width:
Approx. 42.4 in (107.7 cm) - actual spec in manual
Height:
Approx. 41.3 in (104.9 cm) - actual spec in manual
Front Tire Size:
e.g., AT22x7-10 or similar (specific size in manual)
Rear Tire Size:
e.g., AT20x10-9 or similar (specific size in manual)
Wheel Bolt Pattern:
Not specified, consult manual for hub details.
Initial Service:
Typically around 10-20 operating hours or first month of use for break-in service (refer to manual for exact intervals).
Regular Oil Change:
Every 100 operating hours or annually, whichever comes first (specific interval in manual).
Air Filter Service:
Inspect every 25 operating hours, clean or replace as needed. More frequent service in dusty conditions.
Spark Plug Replacement:
Inspect at regular intervals, replace as needed based on condition (specific plug type and gap in manual).
Engine Oil Type:
API SG, SF, or SH service category, SAE 10W-40 or 20W-50 (confirm viscosity based on climate from manual).
Engine Oil Capacity:
Approximately 1.5 - 1.8 quarts (1.4 - 1.7 liters) (specific capacity in manual).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (confirm from manual).
Coolant Type:
If liquid-cooled (less common for this engine size), typically a 50/50 mixture of antifreeze and distilled water. Manual will specify if applicable.
Common Issues:
Typical issues for ATVs of this age and class can include carburetor tuning problems, worn drive belts in the CVT, suspension component wear, and battery or charging system issues. Detailed troubleshooting in the manual.
Valve Clearance:
Specific intake and exhaust valve clearance values (e.g., 0.05-0.10 mm) will be detailed in the manual.
Idle Speed:
Specific idle RPM specification for the engine will be provided in the manual.
Torque Specs:
Crucial torque specifications for critical fasteners (e.g., cylinder head bolts, lug nuts, suspension components) are detailed in the manual.
