Vehicle Segment:
ATV (All-Terrain Vehicle) / Utility Vehicle
Target User:
Recreational riders, utility users for farming, hunting, and property management.
Key Competitors:
Arctic Cat, Honda, Yamaha, Kawasaki ATVs of similar displacement and era.
Powertrain Configuration:
Known for reliable 4-stroke, single-cylinder engines.
Drive System:
Typically shaft-driven with selectable 2WD/4WD.
Suspension Type:
Independent front suspension, often solid rear axle or independent rear suspension depending on specific sub-model.
Systems Covered:
Engine, Fuel System, Electrical System, Ignition System, Cooling System, Lubrication System, Transmission (Primary/Final Drive), Suspension, Steering, Brakes, Chassis, Bodywork, Accessories, Troubleshooting
Estimated Page Count:
300-500
Manual Type:
Service Manual / Repair Manual
Engine Mechanical:
Complete overhaul procedures, component identification, specifications, disassembly, inspection, assembly for 400cc and 500cc engines.
Fuel System:
Carburetor service, fuel pump operation, fuel lines, fuel tank maintenance, specifications.
Electrical System:
Wiring diagrams, component testing, battery maintenance, charging system diagnostics (stator, regulator/rectifier), starter motor, lighting, instrumentation.
Ignition System:
CDI unit, ignition coil, spark plug specifications and testing.
Cooling System:
Radiator, fan operation, coolant specifications, thermostat, hoses, pump maintenance.
Lubrication System:
Oil pump, oil filter, oil cooler (if equipped), lubrication points, oil specifications.
Transmission Drivetrain:
Primary drive clutch, secondary clutch, belt inspection and replacement, final drive maintenance, gear oil specifications.
Suspension:
Front and rear suspension component inspection, adjustment procedures, bearing maintenance, shock absorber service.
Steering:
Handlebar assembly, tie rod ends, steering linkage inspection and adjustment, wheel alignment.
Brakes:
Hydraulic brake system, caliper service, master cylinder, brake fluid specifications, bleeding procedures, brake pad replacement.
Chassis Frame:
Frame inspection for damage, weld integrity, component mounting points.
Bodywork:
Plastic body panel removal and installation, mounting hardware.
Preventative Maintenance:
Scheduled maintenance intervals, fluid checks, filter replacements, belt inspections.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common and uncommon issues, fault code interpretation (if applicable).
Component Repair:
Detailed instructions for repairing or replacing individual components across all systems.
Rebuilds Overhauls:
Comprehensive guides for complete engine and transmission rebuilds.
Adjustments Calibrations:
Carburetor jetting, ignition timing (if adjustable), steering alignment, brake lever free play.
Depth Level:
Comprehensive: covers everything from basic owner maintenance to complete engine teardowns and diagnostics.
Engine Type 400:
4-stroke, Liquid-Cooled, SOHC, Single Cylinder
Engine Type 500:
4-stroke, Liquid-Cooled, SOHC, Single Cylinder
Displacement 400:
Approx. 375-400cc
Displacement 500:
Approx. 499cc
Horsepower Approx:
30-35 HP (estimated range for 500cc)
Torque Approx:
30-35 lb-ft (estimated range for 500cc)
Fuel Delivery:
Carburetor (likely Mikuni or Keihin)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Approximately 3.5-4.0 Gallons
Oil Change Interval:
Typically every 20-40 operating hours or annually.
Air Filter Cleaning:
Check every 10-20 operating hours, clean or replace as needed.
Spark Plug Replacement:
Recommended every 100-200 operating hours or annually.
Cv Belt Inspection:
Inspect every 20-40 operating hours for wear and damage.
Engine Oil Type Grade:
API SG/SH or higher, SAE 0W-40 or 10W-40 (confirm with manual for exact spec).
Engine Oil Capacity:
Approximately 1.5-2.0 Liters (confirm with manual).
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid (confirm with manual).
Final Drive Gear Oil Type:
SAE 80W-90 Hypoid Gear Oil.
Final Drive Gear Oil Capacity:
Approximately 150-200 ml (confirm with manual).
Common Wear Items:
CVT belt, tie rod ends, wheel bearings, brake pads.
Potential Engine Issues:
Carburetor gumming if fuel sits, occasional stator or regulator/rectifier failure.
