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Introduction
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Market Position
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Vehicle Segment:
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Entry-level to Mid-range Sport/Utility ATV
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Target Audience:
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Recreational riders, entry-level off-road enthusiasts, agricultural users
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Competitive Analysis
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Key Competitors:
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Honda FourTrax 250, Yamaha Warrior 350 (pre-2004), Kawasaki Bayou 250, Polaris Sportsman 300/330
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Key Features
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Powertrain Highlights:
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Reliable single-cylinder engine, practical torque delivery, selectable 2WD
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Handling Attributes:
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Comfortable ride, predictable handling, suitable for various terrains
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Manual Value Proposition
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Core Benefit:
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Empowers owners and technicians with comprehensive repair and maintenance knowledge for extended vehicle life and optimal performance.
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Manual Details
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Coverage Areas
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Coverage Years:
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2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
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Regions Covered:
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North America, Europe, Asia, Australia (global applicability expected)
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Page Count
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Estimated Page Count:
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400-600 pages (typical for comprehensive workshop manuals)
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Manual Type
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Manual Classification:
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Workshop Manual / Service Manual / Repair Manual
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Language
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Language:
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English
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Format
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Format:
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PDF Download
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Manual Coverage
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Systems Covered
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Powertrain:
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Engine mechanical, fuel system, lubrication, cooling, exhaust, ignition, starting system, charging system, transmission (gearbox, clutch, drive shafts)
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Chassis:
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Frame, suspension (front and rear), steering, brakes (front and rear), wheels, tires
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Electrical:
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Wiring diagrams, lighting system, instrumentation, battery, starter, alternator, ignition system, switches, relays, fuses
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Bodywork:
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Body panels, fenders, seat, handlebars, controls, storage compartments
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Procedures Included
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Maintenance:
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Routine checks, fluid changes, filter replacements, lubrication, valve adjustments, spark plug replacement, brake pad replacement
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Troubleshooting:
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Diagnostic charts, common problems and solutions, symptom-based troubleshooting, electrical diagnostics
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Repair:
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Engine overhaul, transmission repair, suspension component replacement, brake system repair, electrical component repair, carburetor overhaul
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Disassembly Assembly:
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Step-by-step instructions for removing and installing major components and sub-assemblies
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Specifications Data:
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Torque specifications, clearances, tolerances, fluid capacities, electrical values
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Technical Depth
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Diagnostic Capability:
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Advanced diagnostic procedures, electrical system tracing, component testing
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Rebuild Level:
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Complete engine rebuild, transmission overhaul, carburetor rebuilding
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Information Type:
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Detailed diagrams, exploded views, step-by-step instructions, service bulletins (potentially)
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Engine Specifications
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Primary Engine
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Engine Type:
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Four-stroke, SOHC, single-cylinder
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Displacement:
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246 cc (15.0 cu. in.)
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Bore X Stroke:
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66.0 mm x 72.0 mm (2.60 in x 2.83 in)
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Compression Ratio:
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9.3:1
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Cooling System:
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Air-cooled
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Performance
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Horsepower Estimated:
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16-18 HP (at approximately 6500 RPM)
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Torque Estimated:
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14-16 lb-ft (at approximately 5000 RPM)
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Fuel System
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Fuel Delivery:
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Mikuni VM Series Carburetor
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Carburetor Model:
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Mikuni VM26SS (or similar variant)
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Fuel Type:
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Unleaded gasoline
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Ignition
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Ignition System:
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CDI (Capacitor Discharge Ignition)
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Spark Plug Type:
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NGK CR9E or similar (refer to manual for exact spec)
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Lubrication
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Oil Type:
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SAE 10W-40 API SF or SG (refer to manual for exact specification)
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Oil Capacity:
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Approx. 1.7 L (1.8 US qt.) with filter change (refer to manual for exact specification)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 100 hours or 6 months, whichever comes first (refer to manual for precise intervals)
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Air Filter Cleaning:
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Every 20 hours or as needed based on conditions (refer to manual)
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Spark Plug Inspection:
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Every 100 hours or 6 months (refer to manual)
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Valve Clearance Check:
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Every 200 hours or 12 months (refer to manual)
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Fluid Specifications
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Engine Oil Specification:
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SAE 10W-40 API SF/SG
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Gearbox Oil Specification:
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Suzuki Gear Oil SAE 80W API GL-5
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Brake Fluid Specification:
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DOT 3 or DOT 4 hydraulic brake fluid
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Known Issues
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Common Wear Items:
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Brake pads, tires, drive chain, spark plug, air filter, carburetor jets (clogging)
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Potential Problems:
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Carburetor adjustments needed due to altitude/fuel variations, occasional starter motor issues, suspension wear over time
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