Engine Mechanical:
Complete engine overhaul, including disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, cylinders, crankshaft, camshaft, valves, etc.).
Engine Fuel System:
Detailed coverage of the diesel fuel injection system, including fuel pump, injectors, filters, lines, and troubleshooting of fuel delivery issues.
Cooling System:
Radiator, fan, thermostat, water pump, coolant types, bleeding procedures, and leak diagnosis.
Lubrication System:
Oil pump, oil filter, oil passages, oil change procedures, and lubrication requirements for all components.
Exhaust System:
Muffler, exhaust pipe, heat shields, and emissions control components.
Transmission Drivetrain:
Repair and maintenance of the automatic transmission, drive shafts, CV joints, differentials (front and rear), and 4WD engagement system.
Suspension System:
Front and rear suspension components, including shocks, springs, control arms, bushings, wheel bearings, and alignment specifications.
Braking System:
Hydraulic brake system, including master cylinder, brake lines, calipers, brake pads, rotors, bleeding procedures, and parking brake adjustment.
Steering System:
Handlebar, steering column, tie rods, ball joints, and power steering system (if applicable).
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, and accessory wiring.
Fuel Tank And Lines:
Fuel tank removal, installation, and fuel line routing and inspection.
Frame And Bodywork:
Frame inspection, repair, plastics, body panels, fenders, racks, and seat removal/installation.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks (if applicable for diesel glow plugs), lubrication points, and general inspections.
Troubleshooting Guides:
Diagnostic charts and step-by-step troubleshooting procedures for common and uncommon issues across all major systems.
Repair Procedures:
Detailed, illustrated instructions for component disassembly, repair, replacement, and reassembly.
Diagnostic Procedures:
Methods for diagnosing electrical faults, engine performance issues, and mechanical problems.
Torque Specifications:
Precise torque values for all critical fasteners and bolts across the ATV.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle circuits.
Special Tool Requirements:
Identification of specific tools needed for certain repair or maintenance tasks.
Diagnostic Capability:
Advanced diagnostic procedures for identifying root causes of mechanical and electrical failures.
Rebuild Procedures:
Complete engine and transmission rebuild instructions, suitable for full overhauls.
Specification Reference:
Includes all necessary technical specifications, tolerances, and clearances for accurate repairs.
Engine Type:
Diesel, typically 3-cylinder inline
Displacement:
Approximately 695cc (specifics may vary based on exact diesel engine supplier, e.g., Yanmar, Kubota).
Bore X Stroke:
Varies based on specific engine manufacturer, detailed in manual.
Compression Ratio:
Typical diesel compression ratios, around 18:1 to 22:1.
Cooling System:
Liquid-cooled
Starting System:
Electric start with glow plugs for cold weather starting.
Horsepower:
Estimated 15-20 HP (diesel engines are torque-focused).
Torque:
Significantly higher torque output than comparable gasoline engines, crucial for towing and off-road performance.
Injection System:
Indirect injection or direct injection with high-pressure fuel pump and injectors.
Fuel Filter:
Requires specific diesel fuel filter, replacement interval detailed in manual.
Length:
Approx. 83 inches (210.8 cm)
Width:
Approx. 47 inches (119.4 cm)
Height:
Approx. 48 inches (121.9 cm)
Dry Weight:
Approx. 650-700 lbs (295-318 kg) - Diesel models are typically heavier.
Ground Clearance:
Approx. 11 inches (27.9 cm)
Rack Capacity Front:
Typically around 100 lbs (45 kg)
Rack Capacity Rear:
Typically around 200 lbs (90 kg)
Towing Capacity:
Usually rated at 1,050 lbs (476 kg) or higher.
Payload Capacity:
Typically around 300-400 lbs (136-181 kg).
Engine Oil Change:
Typically every 100 hours or annually, refer to manual for exact interval and diesel-specific oil type.
Air Filter Cleaning Replacement:
Check every 50 hours, clean or replace as needed based on operating conditions.
Fuel Filter Replacement:
Critical for diesel. Typically replaced every 100-200 hours or annually. Manual will specify.
Transmission Fluid Change:
Typically every 200 hours or annually.
Coolant Flush Replacement:
Every 2 years or as recommended by coolant manufacturer.
Brake Fluid Flush:
Every 1-2 years, depending on climate and usage.
Engine Oil Type:
Diesel-specific engine oil, e.g., API CJ-4 or newer, with appropriate viscosity (e.g., 15W-40). Manual is authoritative.
Engine Oil Capacity:
Approx. 1.7 - 2.0 liters (refer to manual for exact capacity).
Coolant Type:
Ethylene glycol-based antifreeze/coolant with corrosion inhibitors. Manual specifies type and mix ratio.
Transmission Fluid Type:
Consult manual for specific CVT or ATF designation.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
CV joints, wheel bearings, brake pads, control arm bushings are typical wear items on utility ATVs.
Diesel Specific Considerations:
Glow plug system health, fuel system cleanliness (water in fuel is critical), and potential for carbon buildup in diesel engines.
