Target User:
DIY persons, professional technicians, mechanics, and workshops.
Comparative Value:
Offers significant cost savings for owners by enabling DIY repairs and maintenance, saving on labor costs.
Accessibility:
Instant download available after payment, accessible on multiple devices.
Quality:
High-quality, detailed, and illustrated manual produced by the manufacturer.
Applicable Years:
2002, 2003, 2004, 2005, 2006, 2007
Vehicle Type:
All-Terrain Vehicle (ATV)
Estimated Page Count:
Detailed, specific page count not provided but indicated as comprehensive and potentially large (up to 4000 MB).
Type:
Service Repair Manual
Alternative Types:
Workshop Manual, Factory Manual, Repair Guide
Language:
English (Implied by description and target market)
Digital Format:
PDF Download
Delivery Method:
Instant Download, E-Book, .zip, .rar, or .exe files
Engine:
Complete engine disassembly, inspection, repair, and reassembly for all components.
Fuel System:
Carburetor (likely Mikuni BSR) inspection, cleaning, adjustment, jetting, fuel pump, fuel lines, fuel tank. Troubleshooting fuel delivery issues.
Transmission:
Automatic transmission (CVT), clutch operation, gearbox, differential, driveshafts, front and rear axle maintenance and repair.
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), battery, starter motor, lighting, wiring diagrams, fuses, relays, sensors, troubleshooting electrical faults.
Braking System:
Front and rear brake caliper service, brake pad replacement, brake fluid bleeding, master cylinder inspection, brake line maintenance.
Suspension:
Front and rear suspension components, shock absorbers, control arms, bushings, steering system, wheel alignment.
Cooling System:
Radiator, fan, coolant, thermostat, hoses, troubleshooting overheating.
Chassis And Frame:
Frame inspection, welds, body panels, plastics, seat, handlebars, footrests.
Lubrication:
Oil change procedures, oil filter replacement, grease points, lubrication schedules.
Routine Maintenance:
Oil and filter changes, spark plug inspection/replacement, air filter cleaning/replacement, drive belt inspection/replacement, chain adjustment/lubrication (if applicable), brake checks.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon problems, fault codes (if applicable), symptom-based troubleshooting.
Repair Procedures:
Detailed instructions for component removal, installation, rebuilding, and adjustment for all major systems.
Diagnostics:
Guidance on identifying the root cause of issues, including electrical system diagnostics and mechanical testing.
Rebuilds:
Comprehensive instructions for engine rebuilds, transmission overhauls, and other major component restorations.
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed specifications and troubleshooting.
Illustrations:
Illustrated with clear step-by-step instructions, zoomable illustrations, detailed component explosions, and exploded views.
Factory Specifications:
Provides factory specifications for all repair and maintenance procedures, ensuring accuracy and adherence to manufacturer standards.
Compatibility:
Compatible with all operating systems (Windows, Linux, Mac) and can be read on computers, iPads, and other devices with a PDF reader.
Compression:
Some manuals may be zipped and require WinZip or WinRAR for unzipping.
Printability:
Printable from any computer and printer. No restrictions on printing.
Binding:
Not Applicable (Digital Download)
Paper:
Not Applicable (Digital Download)
User Storage:
User is responsible for saving the downloaded manual; no lifetime storage provided by the seller.
Engine Type:
4-stroke, SOHC, 2-valve
Engine Displacement:
376 cc (23.0 cu in)
Bore X Stroke:
81.0 mm x 72.8 mm (3.19 in x 2.87 in)
Cooling System:
Liquid-cooled
Ignition System:
Electronic ignition (CDI)
Horsepower:
Approx. 25-28 HP (exact figures vary by source and model year, manual will contain precise data)
Torque:
Refer to manual for specific torque figures.
Fuel Delivery:
Carburetor (likely Mikuni BSR32, single)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
3.6 US gal (13.5 L; 3.0 Imp gal)
Overall Length:
Approx. 79.7 in (2025 mm)
Overall Width:
Approx. 45.3 in (1150 mm)
Overall Height:
Approx. 45.1 in (1145 mm)
Wheelbase:
Approx. 48.0 in (1220 mm)
Ground Clearance:
Approx. 7.1 in (180 mm)
Dry Weight:
Approx. 595 lbs (270 kg)
Curb Weight:
Refer to manual for exact curb weight.
Front Rack Capacity:
Approx. 44 lbs (20 kg)
Rear Rack Capacity:
Approx. 176 lbs (80 kg)
Towing Capacity:
N/A (ATVs are generally not designed for towing in the traditional sense, but may have some limited hitch capabilities for light trailers - check specific model documentation).
Crash Safety:
N/A (ATVs are not subjected to traditional automotive crash testing. Safety is primarily rider-dependent and through protective gear.)
Braking System:
Hydraulic disc brakes front and rear.
4Wd System:
Selectable 2WD/4WD system with torque-sensing front differential for improved traction.
Lighting:
Headlights, taillight, brakelight.
Ergonomics:
Designed for rider control and comfort, with handlebars and footpegs.
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first. Also after every 20 hours of operation.
Oil Filter Replacement:
Every 1,000 km (600 miles) or 6 months.
Air Filter Cleaning:
Every 20 hours of operation or monthly, depending on usage conditions. Replacement as needed.
Spark Plug Inspection:
Every 1,000 km (600 miles) or 6 months.
Brake Fluid Change:
Every 1 year or 2,000 km (1,200 miles).
Engine Oil Type:
Suzuki recommends API SE, SF or SG grade SAE 10W-40 or SAE 20W-50 engine oil. Refer to manual for specific viscosity based on temperature. Capacity: 2.0 L (2.1 US qt) without filter change, 2.2 L (2.3 US qt) with filter change.
Gear Oil Type:
SAE 80 API GL-4 hypoid gear oil for the final gear case. Capacity: 0.35 L (0.37 US qt).
Brake Fluid Type:
DOT 4 or DOT 3 brake fluid.
Coolant Type:
Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based coolant with appropriate antifreeze/antiboil properties). A 50/50 mixture with distilled water is typically recommended. Capacity: Refer to manual, approx. 1.5-2.0 L.
Common Problems:
Potential issues can include carburetor adjustments, CVT belt wear over time, starter solenoid failures, and occasional electrical connection issues. The manual will provide specific diagnostic steps for these.
