Target Audience:
Recreational riders, utility users, farm work, trail riding.
Competitors 2003:
Honda TRX350 Rancher, Kawasaki Bayou 300, Suzuki LT-F400 Eiger, Arctic Cat 400.
Engine Type:
Reliable air-cooled, 4-stroke engine.
Drivetrain:
Shaft-driven 4WD (on some variants, check specific model).
Suspension:
Independent front suspension, swingarm rear suspension.
Engine:
Complete engine overhaul, top-end and bottom-end components, cooling system, lubrication system, ignition system.
Transmission:
Clutch operation, gear shifting mechanisms, final drive, lubrication, troubleshooting transmission issues.
Chassis And Suspension:
Front and rear suspension systems, shock absorbers, steering components, wheel bearings, chassis frame inspection and repair.
Brakes:
Front and rear brake system maintenance, hydraulic lines, brake pads, calipers, master cylinder, bleeding procedures.
Electrical System:
Wiring diagrams, battery, starter motor, charging system, lighting, fuses, switches, troubleshooting electrical faults.
Fuel System:
Carburetor inspection, adjustment, and overhaul; fuel pump, fuel lines, fuel tank maintenance.
Body And Frame:
Body panel removal and installation, fenders, racks, seat, handlebars, cosmetic repairs.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustments, lubrication points, spark plug replacement.
Troubleshooting:
Diagnostic charts, common problems and solutions, error code interpretation (if applicable).
Repair:
Step-by-step repair instructions for all major components and systems.
Overhaul:
Complete engine and transmission overhaul procedures.
Disassembly And Assembly:
Detailed procedures for disassembling and reassembling various components.
Diagnostic Capabilities:
Advanced diagnostic procedures for engine performance, electrical systems, and drivability issues.
Rebuild Instructions:
Comprehensive instructions for rebuilding the engine, transmission, and carburetor.
Specifications:
Torque specifications, tolerances, clearances, fluid capacities, and other critical technical data.
Engine Type:
4-stroke, SOHC, 2-valve
Bore X Stroke:
83.0 mm x 64.5 mm
Cooling System:
Air-cooled
Horsepower Estimate:
Approx. 20-22 hp @ 6000 rpm (unverified manufacturer spec)
Torque Estimate:
Approx. 20-22 lb-ft @ 4500 rpm (unverified manufacturer spec)
Carburetor Type:
Mikuni VM Series (likely VM32) or Keihin equivalent.
Fuel Capacity:
3.6 US gal (13.7 L)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Oil Type Recommendation:
Yamaha recommends Yamalube 4 (or equivalent SAE 20W-40 or 10W-30, depending on climate).
Transmission Type:
5-speed manual with automatic clutch and reverse.
Clutch Type:
Wet, multi-disc, automatic centrifugal clutch.
Final Drive:
Shaft drive.
Transmission Oil Type:
Yamalube Gear Oil (or equivalent SAE 80 hypoid gear oil).
Gear Ratios:
Specific ratios detailed within the manual.
Length:
Approx. 77.2 inches (1960 mm)
Width:
Approx. 42.7 inches (1085 mm)
Height:
Approx. 43.9 inches (1115 mm)
Wheelbase:
Approx. 49.2 inches (1250 mm)
Dry Weight:
Approx. 463 lbs (210 kg)
Ground Clearance:
Approx. 7.2 inches (183 mm)
Front Rack Capacity:
Approx. 88 lbs (40 kg)
Rear Rack Capacity:
Approx. 176 lbs (80 kg)
Front Tire Size:
AT22x7-10
Rear Tire Size:
AT22x10-10
Tire Pressure Front:
Check manual for specific PSI, typically 3-5 PSI
Tire Pressure Rear:
Check manual for specific PSI, typically 3-5 PSI
Atv Safety Standards:
Manufactured to meet ANSI standards for All-Terrain Vehicles.
Braking System:
Hydraulic disc brakes front and rear.
Lighting:
Dual 30W headlights, 8W taillight/brake light.
Parking Brake:
Mechanical parking brake, typically on rear brake caliper or drum.
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first).
Gear Oil Change:
Every 300 hours or 12 months.
Air Filter Cleaning:
Every 20 hours or as needed based on conditions.
Spark Plug Replacement:
Every 100 hours or 6 months.
Valve Clearance Check:
Every 100 hours or 6 months.
Engine Oil Capacity:
1.90 US qt (1.8 L) with filter replacement.
Transmission Oil Capacity:
0.65 US qt (0.62 L).
Common Wear Items:
Carburetor jets clogging, brake pad wear, wheel bearings, suspension bushings, starter motor solenoid.
Carburetor Tuning:
Proper carburetor jetting and cleaning is crucial for optimal performance, especially with fuel variability.
Clutch Adjustment:
Occasional adjustment of the automatic clutch may be required for smooth engagement.
