Market Segment:
Mid-size utility ATV, popular for trail riding and light work
Competitors:
Honda FourTrax, Suzuki QuadRunner, Kawasaki Bayou, Polaris Sportsman (in their respective displacement classes)
Value Proposition:
Cost savings on repairs and maintenance, empowerment of owner to perform their own servicing
Ease Of Use:
Designed for users without specialized technical knowledge, with clear instructions and diagrams
Primary Coverage:
Service, Repair, and Maintenance
Secondary Coverage:
Rebuilding, Refurbishing, Restoration
Estimated Page Count:
Extensive (A-Z coverage implies comprehensive detail, likely exceeding 300 pages)
Manual Type:
Service Manual / Workshop Manual
Digital Format:
PDF (Portable Document Format)
Engine Systems:
Engine assembly, disassembly, troubleshooting, tuning, lubrication, cooling system
Fuel System:
Carburetor, fuel tank, fuel lines, fuel filter, fuel pump
Ignition System:
Ignition coil, CDI unit, spark plugs, wiring
Transmission System:
Clutch, gearbox, final drive, drive shafts, differential
Brakes System:
Hydraulic brake system, brake calipers, brake discs, brake pads, master cylinder, parking brake
Suspension System:
Front and rear suspension components, shock absorbers, A-arms, bushings
Steering System:
Handlebar assembly, steering column, tie rods, steering knuckles
Electrical System:
Wiring diagrams, lighting system, starting system, charging system, battery, fuses, switches
Frame And Body:
Frame inspection, body panels, seat, fenders, racks
Cooling System:
Radiator, fan, hoses, coolant
Exhaust System:
Exhaust pipe, muffler, heat shields
Diagnostic Procedures:
Comprehensive troubleshooting guides for all systems
Repair Procedures:
Step-by-step instructions for all mechanical and electrical repairs
Maintenance Procedures:
Regular service tasks, fluid changes, filter replacements, adjustments
Rebuild Procedures:
Complete engine and transmission rebuild instructions
Installation Procedures:
Instructions for component replacement and accessory installation
Technical Depth:
Professional technician level, covering detailed diagnostics and complex repairs
Detail Level:
All repairs A-Z, providing complete information for mechanics and enthusiasts
Searchability:
Searchable text within the PDF
Print Quality:
High resolution, suitable for printing
Printable Pages:
User can print individual pages or entire sections as needed
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Operating Systems:
PC & MAC computers; Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7 & 8
Software Required:
Adobe Acrobat Reader or compatible PDF viewer
Engine Type:
Four-stroke, SOHC, Air-cooled
Displacement:
230 cc (approximate)
Bore X Stroke:
68.5 mm x 64.0 mm (typical for this engine)
Compression Ratio:
9.3:1 (typical)
Horsepower:
Approximately 16-18 HP (varies slightly by year/tuning)
Torque:
Approximately 13-15 lb-ft (varies slightly by year/tuning)
Carburetor Type:
Mikuni VM Series (e.g., VM24) or similar
Fuel Type:
Unleaded Gasoline (Octane rating typically 87)
Oil Type:
Yamalube 4 (or equivalent API SG, JASO MA, SAE 10W-40 or 20W-50)
Oil Capacity:
Approximately 1.8 L (1.9 US qt) with filter change
Transmission Type:
5-speed manual with automatic clutch and reverse
Optional Transmission:
N/A (This model typically came with the 5-speed manual)
Clutch Type:
Wet, multi-plate, automatic engagement
Final Drive:
O-ring sealed chain (primary drive), Gears (final drive)
Length:
Approx. 71.7 in (1820 mm)
Width:
Approx. 41.3 in (1050 mm)
Height:
Approx. 42.5 in (1080 mm)
Wheelbase:
Approx. 47.2 in (1200 mm)
Dry Weight:
Approx. 470 lbs (213 kg)
Fuel Capacity:
Approx. 3.0 US gal (11.5 L)
Towing Capacity:
Typically not specified for this model due to ATV regulations and design
Atv Safety Standards:
Adheres to ANSI standards for ATVs
Braking System:
Hydraulic disc brakes front and rear, Parking brake
Drive System:
On-Command 2WD/4WD system for adaptable traction
Design Considerations:
Low center of gravity for stability, durable construction
Engine Oil Change:
Every 1000 km or 12 months, whichever comes first
Air Filter Cleaning:
Every 500 km or 6 months (more frequently in dusty conditions)
Spark Plug Replacement:
Inspect every 1000 km, replace as needed
Valve Clearance Adjustment:
Every 2000 km or 24 months
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Transmission Oil:
Yamalube 4 (or equivalent API SG, JASO MA, SAE 10W-40 or 20W-50)
Common Wear Items:
Wheel bearings, ball joints, tie rod ends, brake pads, swingarm bushings
Carburetor Performance:
Can be prone to clogging from debris; regular cleaning recommended. Pilot jet circuit can be sensitive to fuel quality.
Electrical Connections:
Corrosion can occur on connectors, especially in wet environments; dielectric grease is recommended.
