Segment:
High-performance, utility-focused ATV segment.
Target Audience:
Recreational riders, hunters, farmers, utility users requiring robust performance and reliability.
Competitors:
Yamaha Grizzly 550/700, Polaris Sportsman 500/550/850, Can-Am Outlander 500/650/800.
Vehicle Highlights:
Independent Rear Suspension (IRS), fuel injection, selectable 2WD/4WD, engine braking, torque-sensing limited-slip front differential, high ground clearance, robust chassis.
Cost Savings:
Save significantly on service and repair costs by performing maintenance and repairs yourself.
Authenticity:
Genuine item from a trusted seller, mirroring professional technician information.
Convenience:
Instant download and printable format for easy use in any workshop environment.
Engine:
Complete engine disassembly, assembly, inspection, repair, troubleshooting, tuning, timing, lubrication, cooling system, fuel system, ignition system, exhaust system, emission control systems.
Transmission:
Automatic transmission (CVT) operation, disassembly, assembly, maintenance, repair, troubleshooting, drive belts, torque converter, planetary gears, clutches.
Drivetrain:
Four-wheel drive (4WD) system, front and rear differentials, drive shafts, U-joints, axles, hubs, operation, maintenance, repair, troubleshooting.
Chassis:
Frame, subframes, suspension components (A-arms, shocks, springs, bushings), steering system (rack and pinion, tie rods, steering column), wheel bearings, alignment specifications.
Brakes:
Hydraulic brake system, front and rear brake calipers, master cylinder, brake lines, brake pads, brake discs, bleeding procedures, maintenance, repair, troubleshooting.
Electrical:
Starter system, charging system (stator, regulator/rectifier, battery), ignition system, lighting (headlights, taillights, turn signals), instrumentation, wiring harnesses, fuses, relays, troubleshooting using diagrams.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel injection system (EFI), injectors, throttle body, idle air control (IAC) valve, troubleshooting, cleaning, and replacement procedures.
Cooling System:
Radiator, cooling fan, water pump, thermostat, coolant hoses, coolant specifications, flush and refill procedures, troubleshooting overheating issues.
Body And Frame:
Body panels, fenders, racks, seat, handlebars, controls, lighting installation, removal, and repair.
Diagnostic Procedures:
Troubleshooting charts, common problems and their solutions, diagnostic codes (if applicable), electrical system diagnosis, mechanical component testing.
Maintenance:
Oil changes, filter replacements, spark plug inspection and replacement, air filter cleaning and replacement, brake fluid checks and replacement, coolant checks, chain adjustment (if applicable), lubrication points.
Repair:
Component replacement, engine rebuilds, transmission service, suspension repair, steering system repair, brake system repair, electrical component repair, fuel system repair.
Rebuild:
Complete engine and transmission rebuild procedures with detailed steps and specifications.
Installation:
Procedures for installing common aftermarket accessories or replacement parts may be implied by the repair sections.
Depth:
Comprehensive - from basic preventative maintenance to complete engine and transmission rebuilds, including advanced diagnostics.
User Level:
Suitable for professional technicians, mechanics, and advanced DIY enthusiasts.
Engine Type:
Four-stroke, SOHC, 4-valve, single-cylinder, liquid-cooled
Displacement:
493 cc (29.9 cu. in.)
Bore X Stroke:
94.0 mm x 89.0 mm (3.70 in. x 3.50 in.)
Compression Ratio:
9.3 : 1
Cooling Method:
Liquid-cooled
Horsepower:
Approx. 33 HP (specific rating may vary slightly by region/testing)
Torque:
Approx. 28 lb-ft (specific rating may vary slightly by region/testing)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Oil Type:
SAE 10W-40 API SG or higher, JASO T903 MA standard recommended.
Oil Capacity:
Approx. 3.2 L (3.4 US qt.) with filter change.
Ignition System:
Electronic ignition (CDI)
Spark Plug:
NGK CR7E or Champion RA8HC.
Engine Oil Change:
Every 1,000 km (600 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Inspect every 500 km (300 miles) or 3 months; clean or replace as needed.
Spark Plug Inspection:
Inspect every 1,000 km (600 miles) or 6 months; replace if necessary.
Cvt Belt Inspection:
Inspect every 2,000 km (1,200 miles) or 12 months; replace as per wear indicators.
Brake Fluid Change:
Recommended every 2 years or as per manual guidelines for best performance.
Coolant Type:
Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based coolant with an anti-corrosive additive).
Common Wear Items:
CVT belt wear, front differential seals, wheel bearings, ball joints, tie rod ends (typical for ATVs of this era with high mileage).
Potential Efi Issues:
Infrequent: clogged fuel injectors, idle control valve issues, sensor malfunctions.