Positioning:
Performance-oriented ATV for motocross and competitive off-road riding.
Competitors:
Yamaha YFZ450, Suzuki LT-R450, Honda TRX450R.
Vehicle Attributes:
Powerful single-cylinder engine, aggressive chassis design, high-quality suspension components, lightweight construction.
Primary Coverage:
Comprehensive mechanical and electrical service, repair, and maintenance procedures.
Target Audience:
Professional mechanical technicians, experienced DIY enthusiasts.
Estimated Pages:
300-500 (typical for this class of manual, exact count not provided in product info)
Type:
Workshop Service Manual / Repair Manual
Engine:
Complete engine overhaul, internal component diagnosis and repair, piston, rings, cylinder head, valves, camshaft, crankshaft, oil pump, cooling system.
Fuel System:
Carburetor (Keihin FCR-MX likely), fuel lines, fuel pump (if applicable), fuel tank maintenance and repair.
Transmission Drivetrain:
Clutch system, gearbox inspection and repair, shifting mechanism, final drive (chain and sprockets).
Electrical System:
Ignition system, starter motor, battery, charging system (stator, regulator/rectifier), lighting, wiring diagrams, troubleshooting.
Suspension:
Front fork (WP Suspension likely) disassembly, assembly, seal replacement, oil changes, adjustment; rear shock absorber service and adjustment.
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders), brake pad replacement, fluid bleeding, rotor inspection and service.
Chassis Frame:
Frame inspection, subframe, steering head bearings, wheel bearings, swingarm, linkage system.
Bodywork Trim:
Removal and installation of plastics, seat, handlebars, footpegs.
Maintenance:
Scheduled maintenance tasks, oil and filter changes, air filter cleaning/replacement, spark plug service, chain adjustment, valve clearance checks.
Troubleshooting:
Diagnostic charts, common problems and solutions, fault finding procedures.
Repair:
Detailed step-by-step instructions for component disassembly, inspection, repair, and reassembly.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical specifications, diagnostic parameters.
Depth:
In-depth technical coverage, suitable for complete engine rebuilds, complex electrical diagnostics, and suspension overhauls.
Type:
Single-cylinder, 4-stroke, Liquid-cooled (LC4)
Bore X Stroke:
95 mm x 63.4 mm
Compression Ratio:
12.3:1
Valve Train:
SOHC, 4 valves
Horsepower Est:
Approx. 45-50 HP (varies by tuning and specific model year)
Torque Est:
Approx. 40-45 Nm (varies)
Carburetor:
Keihin FCR-MX 39mm
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Oil Type Recommended:
JASO MA certified 10W-40 or 10W-50 Synthetic Motorcycle Oil
Oil Capacity Est:
Approx. 1.6 - 1.8 Liters (with filter change)
Safety Certification:
N/A (ATV specific safety standards apply, not typical automotive crash ratings).
Braking System:
Hydraulic disc brakes front and rear, performance-oriented.
Suspension Design:
Independent front suspension, swingarm rear suspension for stability and control.
Handlebars:
Fat bar handlebars for improved control and impact absorption.
Oil Change:
Every 15-20 operating hours or annually, per manual recommendations.
Air Filter Cleaning:
After every few rides or as conditions dictate, critical for performance.
Valve Clearance Check:
Typically every 50-100 operating hours, crucial for engine health.
Coolant Type:
Ethylene glycol based antifreeze coolant, 50% mixture with distilled water.
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
Chain and sprockets, wheel bearings, steering head bearings, brake pads, tires.
Engine Considerations:
Regular valve adjustments and proper carburetor tuning are key to maintaining optimal performance and preventing issues.
Filter Part Numbers:
Refer to manual for specific OEM or aftermarket filter part numbers (e.g., oil filter, air filter).
