Engine Mechanical:
Complete engine overhaul, including cylinder head, piston, crankshaft, valve train, timing, lubrication system, cooling system, and seals.
Fuel System:
Fuel injection system (EFI) diagnosis, cleaning, and repair; fuel pump, injectors, throttle body, sensors (TPS, MAP, IAT), ECU.
Drivetrain:
Ultramatic® automatic transmission (CVT), drive clutch, driven clutch, belt replacement, gearbox, differential, drive shafts, CV joints.
Suspension:
Front and rear suspension components, shocks, springs, control arms, bushings, alignment procedures.
Brakes:
Hydraulic brake system, master cylinders, brake calipers, brake pads, brake discs, brake lines, bleeding procedures, parking brake.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, battery), ignition system, lighting, switches, fuses, relays.
Steering:
Steering system, handlebars, steering shaft, tie rods, steering knuckles, wheel alignment.
Chassis Frame:
Frame inspection, welds, reinforcement points, mounting hardware.
Bodywork Plastics:
Fender removal and installation, body panel repair and replacement, seat, rack systems.
Cooling System:
Radiator, coolant hoses, coolant types, thermostat, water pump.
Exhaust System:
Muffler, exhaust pipe, heat shields, gaskets.
Wheels Tires:
Tire specifications, pressure, wheel removal and installation, lug nut torque.
Maintenance:
Routine inspections, oil changes, filter replacements (air, oil, fuel), spark plug replacement, lubrication points, brake fluid checks, coolant checks.
Troubleshooting:
Diagnostic flowcharts for common problems, engine performance issues, starting problems, electrical faults, braking issues, suspension noises.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and adjustment.
Overhaul:
Complete engine rebuild, transmission overhaul, differential rebuild instructions.
Diagnostics:
EFI system diagnostics, reading diagnostic trouble codes (DTCs), sensor testing, electrical component testing.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Depth:
Comprehensive, covering basic maintenance to full engine and drivetrain rebuilds, including advanced diagnostics.
Type:
4-stroke, liquid-cooled, DOHC, 4-valve, fuel-injected
Bore X Stroke:
102 mm x 84 mm
Compression Ratio:
9.2 : 1
Horsepower:
Approx. 45-50 HP (Varies by source and measurement)
Torque:
Approx. 40-45 lb-ft (Varies by source and measurement)
Fuel Delivery:
Mikuni 44mm throttle body, EFI with YCC-T (Yamaha Chip Controlled Throttle)
Oil Type:
Yamalube 4 (10W-40) or equivalent API SG, SAE 10W-40, Type SE or higher quality motorcycle oil.
Coolant Type:
Yamaha's recommended coolant or equivalent antifreeze/coolant (50/50 mix of ethylene glycol and distilled water).
Spark Plug:
NGK CR7E or DENSO U20EPR-U
Oil Change Interval:
Every 1,000 km or 100 hours of operation; or annually, whichever comes first.
Air Filter Cleaning:
Every 500 km or 50 hours; clean more frequently in dusty conditions.
Spark Plug Replacement:
Every 1,000 km or 100 hours.
Drive Belt Inspection:
Inspect every 500 km or 50 hours; replace as needed based on wear.
Engine Oil Capacity:
1.70 US qt (1.6 L) with filter replacement.
Coolant Capacity:
1.70 US qt (1.6 L)
Common Wear Items:
Drive belt wear, CV joint boots, suspension bushings, and wheel bearings are common wear items in utility ATVs under heavy use.
Efi System Maintenance:
Regular cleaning of the throttle body and air filter is crucial for optimal EFI performance.