Engine:
Complete engine disassembly, assembly, inspection, and repair. Includes details on valve adjustment, piston and cylinder service, crankshaft and connecting rod inspection, timing chain, and more.
Gearbox And Clutch:
Transmission service, clutch inspection and replacement, gear shift mechanism, and final drive unit.
Cooling System:
Radiator, cooling fan, coolant flow, thermostat operation, and water pump service.
Fuel System:
Fuel pump, fuel injectors, fuel filter, carburetor (if applicable to specific sub-models within the range), fuel tank, and related lines.
Braking System:
Hydraulic brake system, brake calipers, brake pads, brake discs, brake lines, bleeding procedures, and parking brake.
Suspension:
Front and rear suspension components, shock absorbers, A-arms, ball joints, steering knuckles, and bushings. Includes adjustment and replacement procedures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, sensors, and fuses.
Body And Fixtures:
Body panel removal and installation, seat service, luggage racks, fenders, and handle bar assembly.
Exhaust System:
Exhaust pipe, muffler, and heat shields inspection and replacement.
Wheels And Tyres:
Tire pressure, tire wear inspection, wheel removal and installation, and lug nut torque specifications.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for accurate troubleshooting and component identification.
Steering System:
Handlebar assembly, steering shaft, tie rods, and steering knuckle geometry.
Frame And Bodywork:
Frame inspection, front and rear body panel removal/installation, seat mounting, and storage compartments.
Maintenance:
Scheduled maintenance tasks, lubrication points, fluid changes (oil, coolant, brake fluid), filter replacements, and pre-ride inspections.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides, and solutions for electrical and mechanical issues.
Repair:
Step-by-step repair instructions for all major and minor components, including detailed disassembly and reassembly sequences.
Technical Specifications:
Key technical data, torque specifications, engine clearances, fluid capacities, and electrical component resistances.
Engine Rebuild:
Complete engine overhaul procedures, including piston ring replacement, cylinder honing, crankshaft bearing inspection, and gasket replacement.
Fuel System Diagnostics:
Troubleshooting EFI system faults, checking fuel pressure, injector pulse width, and sensor readings.
Depth:
Professional Quality, highly detailed, step-by-step instructions with exploded pictures and diagrams. Equivalent to factory service manuals used by professional mechanics.
Engine Type:
Liquid-cooled, 4-stroke, SOHC, V-twin
Displacement:
695 cc (approx. 42.4 cu. in.)
Bore X Stroke:
72.0 mm x 85.0 mm (approx. 2.83 in. x 3.35 in.)
Compression Ratio:
9.3 : 1 (typical for this era V-twin)
Horsepower:
Estimated 50-55 HP (may vary slightly by model year/tuning)
Torque:
Estimated 40-45 lb-ft (may vary slightly by model year/tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Type:
API SG or SH, SAE 10W-40 motorcycle oil recommended. Check manual for specific viscosity based on temperature.
Oil Capacity:
Approximately 2.7 L (2.8 US qt) with filter change. Consult manual for exact capacity.
Length:
Approx. 2,155 mm (84.8 in.)
Width:
Approx. 1,165 mm (45.9 in.)
Height:
Approx. 1,210 mm (47.6 in.)
Dry Weight:
Approx. 276 kg (608.5 lbs)
Curb Weight:
Not explicitly stated, but would include fluids and battery, typically around 300kg.
Fuel Capacity:
Approximately 17.5 L (4.6 US gal)
Towing Capacity:
Typically rated around 1,000 lbs (450 kg) for unbraked trailers, consult specific model documentation for exact rating.
Front Rack Capacity:
Approx. 45 kg (99 lbs)
Rear Rack Capacity:
Approx. 85 kg (187 lbs)
Engine Oil Change:
Typically every 1,000 km (600 miles) or 6 months, whichever comes first. Refer to manual for exact interval.
Air Filter Cleaning Or Replacement:
Recommended every 1,000 km (600 miles), or more frequently in dusty conditions.
Spark Plug Replacement:
Typically around 6,000 km (3,700 miles) or as per manual recommendation.
Valve Adjustment:
Recommended every 6,000 km (3,700 miles) or as indicated by performance changes.
Coolant:
Permanent type antifreeze coolant (ethylene glycol base) with a 50/50 mixture with distilled water. Suzuki recommends specific coolant or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Always use fresh, sealed brake fluid.
Gear Oil Front And Rear Differential:
Suzuki recommends specific hypoid gear oil or equivalent. Consult manual for viscosity and API classification (e.g., GL-5).
Common Wear Items:
Brake pads, tires, drive belts (CVT), suspension bushings, and wheel bearings are common wear items on ATVs used in demanding conditions.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent faults; regular inspection is advised.
