Rubicon Service Manual - Crossfire Motorcycles
Contents
1. n READ THIS MANUAL CAREFULLY UE CROSSFIRE MOTORCYCLES 500ATV OWNER S MANUAL ur zur i i TO CET apr tr AA a P rawea INTRODUCTION Congratulations on your purchase of the 500ATV With the purchase of this ATV you can now appreciate the high degree of craftsmanship This manual will provide you with a good basic understanding of the features and operation of this ATV This manual includes important safety information It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult you dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION FREE TRAINING IS AVAILABLE TO ANYONE WHO BUYS A NEW ATV THIS ATV AND ANY OTHER ATV OVER 90cc SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SE RIOUS INJURY OR DEATH Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT A YOUR SAFETY IS INVOLVED A NETTER Failure to fo2. Idle speed adjustment NOTE A diagnostic tachometer must be used for this procedure 1 Start the engine and warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Remove the seat 3 Then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direction b to decrease the engine speed 4 Install the seat Specified idle speed GOOD 150 mir Ree ED SI 3 CAUTION The carburetor was set at the factory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine performance and damage may result 64 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional service technician Throttle lever adjustment NOTE Adjust the engine idling speed before check the throttle lever free play Specified idle speed 3 0 5 0 mm 0 12 0 20 in 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle lever free play to the Specified valve clearance 3 Tighten the locknut 1 Adjusting bolt 2 Locknut a Throttle lever free
3. Replace Warm engine before Engine oil filter Replace cartridge Engine oil 3 strainer A Final gear oil Check for oil A Differential 3 Replace every 12 months Front brake Check operation fluid leakage e Correct if necessary Check operation fluid leakage e Adjust if necessary Whichever 6 6 12 5L 310 620 1240 ene Select lever Check operation safety system e Adjust if necessary cable A Check operation e Check for cracks or damage Wheels e Check balance damage runout Repair if necessary Check bearing assemblies for Replace if damaged Front and Check operation ma e Correct if necessar suspension Y e Check operation Replace if damaged system Check toe in Adjust if necessary Rear upper and lower Lubricate with lithium soap based knuckle grease pivots Drive shaft universal joint 45 _ rA EVERY Whichever 6 6 2 ITEM ROUTINE comes first ERA 1000 2000 3000 155 310 620 1240 Nene Check for cracks or damage Front and Check operation ii axle Replace if damaged Stabilizer i bushes Check for cracks or damage Pf pui e Check all chassis fittings and Fittings and fasteners fasteners e Correct if necessary Lights and Check operation switches e Adjust headlight beams Since these items require special tools data and technical skills have your dealer perform the
4. hills and rough terrain and in turns eavoid paved surfaces pavement may seriously affect handling and control ereduce speed and use extra caution at all times when carrying a passenger dismount passenger when conditions require emake sure passenger reads and understands this label and passenger safety label LOCATE AND READ OPERATOR S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Ah SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and riding on hills or over obstacles if you fail to take proper precautions SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Contact an authorized ATV dealer Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry more than 1 passenger on an ATV Always avoid operating an ATV on any
5. at all times when carrying a passenger dismount passenger when conditions require emake sure passenger reads and understands this label and passenger safety label LOCATE AND READ OPERATOR S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS A WARNING POTENTIAL HAZARD Carrying more than 1 passenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passengers HOW TO AVOID THE HAZARD Never carry more than 1 passenger The long seat is to allow the operator and 1 passenger to shift position as needed during operation It is not for carrying more than 1 passenger RA WA 47 gt vV hh a N Jt a nu A AL IB a S _ SJ S was i gt ce TREVI EH OSE AAA SO i i TLE M A A j pi Eiig v SAL Y 28 During operation Always keep your feet on the footboards during operation Otherwise your feet may contact the rear wheels ela espe ae ay a VA x 4 LA o A EOS IC A x i AMB A eye F Is arti thee gt EP Pa k N A x 29 A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation WHAT CAN HAPPEN Removing even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con
6. caps are properly installed Il Ifthe engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the wheel axles Ill Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job 80 IV Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places V Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth VI Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy VII Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes STORAGE Long term storage 60 days or more of atmosphere coat all exposed metal your machine will require some surfaces with a light film of oil Do not preventive procedures to guard against apply oil to any rubber parts or the seat deterioration After thoroughly cleaning cover the machine prepare for storage as 7 Remove the battery and charge it follows Store it in a dry place and recharge it 1 Drain the fuel system once a month Do not store the battery in 2 Remove the spark plug pour about an excessively warm or cold
7. into the forward neutral and reverse Remove the fuel tank cap by Insert key and turning it counterclockwise Fuel tank cap 1 Drive select lever Fuel tank cap 20 Starter choke NOTE Use the starter choke in reference to the figure Starting a cold engine requires a rener Position Cold engine start ambient temperature below air fuel mixture A separate starter circuit 5 C 40 F supplies this mixture Position Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position Cold engine start ambient temperature above 25 C 80 F and warm engine start position ll 7 Im Wy N il 1 Starter choke a Starter choke 1 Fully open 2 Half open 3 Closed 21 Seat 1 To remove the passenger seat unscrew the seat lock bolts 2 b To remove the driver seat pull the seat lock lever upward and pull up the seat at the rear NOTE Make sure that the seat is securely fitted 22 Front and rear shock absorber adjustment The spring preload can be adjusted to suit the rider s weight and riding conditions Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction 1 Special wrench NOTE A special wrench can be obtained at your dealer to make this adjustment 1 Spring preload adjusti
8. or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY Please contact with your dealer 4 WARNING POTENTIAL HAZARD Improper handling of gasoline WHAT CAN HAPPEN Gasoline can catch fire and you could be burned HOW TO AVOID THE HAZARD Always turn off the engine when refueling Do not refuel immediately after the engine has been running and is still very hot Do not spill gasoline on the engine or exhaust pipe muffler when refueling Never refuel while smoking or in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your clothing change your clothes 4h WARNING POTENTIAL HAZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation 10 DESCRIPTION AND MACHINE IDENTIFICATION 100909000 TIRE UE Sheen 1 Coolant reservoir
9. paved surfaces including sidewalks driveways parking lots and streets Never operate an ATV on any public street road or highway even dirt or gravel one Never operate an ATV without wearing an approved motorcycle helmet that fits properly for you and passenger You should also wear eye protection goggles or face shield gloves boots a long sleeved shirt or a jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility operating conditions and your experience 5 Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to tu
10. place less one tablespoon of SAE 10W30 or than 0 C 30 F or more than 30 C 20W40 motor oil in the spark plug hole 90 F and rein stall the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt air cover 81 SPECIFICATIONS oe EEE Overalllengi__ 206mm 20m 1 180 mm_ 64 in 1 175mm_ 62m Seatheght B66mm 840m 1300 mm 611m Basic weight Basowe ooo 355 Kg 78256 ene 82 MODEL Lubrication system Engine oil Recommended engine oil classification 110 130 F SAE SW30 20 0 API Service SE SF SG type or higher MODEL XY500 ATV Front gear case oil Lai T ri ICI T__ ooo ui T_T about 4L_ 1 Gal Samo T_ o Transen EN Primary reduction system V belt 84 SETI CO AN CI EN Te Size fe se o ee TT Front brake Single dsc brake 85 SETI Toreros ightfootoperatonTLefthand parking O E _ Shockabsomber T__ Wheel tave T__ O Bewa T_ aey ____ SSS medy O Bub voltage wattage rany ooo 86 MODEL findcatorfaht G__ Neutral indicator ight 1 1 1 x Foes Reverse gear indicato Toh 87
11. play 65 Front brake pad check Rear brake pad check Check the brake pads for damage and Check the brake pads for damage and wear If a brake pad thickness is less wear If a brake pad thickness is less than 1 0 mm 0 04 in have your dealer than 2 mm 0 08 in have your dealer replace the pads as a set replace the pads as a set Vet EW E LEE a Brake pad thickness NOTE The wheels need to be removed to check the brake pads 66 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish when necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage 1 Minimum level mark Observe these precautions e When checking the fluid level make sure the top of the master cylinder reservoirs are level e Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance Recommended brake fluid DOT3 or DOT 4 67 1 Minimum level mark Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance Be careful that water does not enter the m
12. ssssssssssssssssssssesscsssesssecssscesscsssesssesssecesscsssessscsssecssscesscsssesssecssecssecessesaseessecssecsseees 16 Throttle LeverSpeed lMiter nis anne 17 Speed limiter oia a ari 18 brake leverand Drake pedaliera 19 Drive select lever san ie 20 FUEL tank cassia N RR IRA RT RTRT RI reer cere 20 Starterichoke un lella 21 Se ON RER 22 Front and rear shock absorber adjustMent ccsccsccsccsccsccsccscccceccecceccncceccsccnccnccsccscescescescescecceccesceccssoces 23 RIDINGYOUR AIV Asse ae einen 24 GETTING TO KNOW YOUR ADV Galilei 25 RIDE WITH CARE AND GOOD JUDGEMENT s 0400 00000000 000000 nannten neh nennen nen nahen naeh en 25 AU rna a a aA 29 BE CAREFUL WHERE YOU RIDE 4 aaa aa eaa a a a E a a E aa EE aaas 32 TURNING YOURATV sanieren 35 RIDING DOWNHILL ita a 37 CLIMBING UPHILL cia nel 38 PARKING ON A SLOPE spiciali RE NONE RENEE RETI RE a 41 PERIODIC MAINTENANCE AND ADJUSTMENT iii 42 Owners manual ANG toolkit 2 2 side cal alia 42 PERIODIC MAINTENANCE LUBRICATION abe ee 43 Engine oiland oilfilter cartridge 48 To check tne engine ol levels sn 48 Changing the final gear Old aretino 52 Front gear ollreplacement an 53 Cooling Syste Mi AA A ihn 54 Changing the cool business 55 A ill le SES SA LOLA ARIA E RI SOI E 57 Spark plus Inspection anar daa iii idas 58 Air filter element CLEANING sis dice E A eae eaet conkers tee anaes 60 Valve ciearance adjUstmMmentiscra rad a id 65 Throttl
13. 2 Drive select lever 3 Rearview mirror 4 Front storage compartment 5 V belt cooling duct check hose IN 6 V belt cooling duct check hose OUT 7 Vacuum pump 8 Spark arrester 9 Passenger seat 10 Tail brake light 11 Radiator cap 12 Auxiliary DC jack 12V 120W 10A 13 Main switch 14 Front brake lever 15 Throttle lever NOTE The machine you have purchased may differ 16 Right handiebarswitch slightly from those shown in the figures of this manual 11 1 OTRA AT 77 4 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Speedometer Starter choke Left handlebar switches Parking brake lever Rear shock absorber assembly Spring preload adjusting ring Front shock absorber assembly Spring preload adjusting ring Rear brake fluid reservoir Brake pedal Spark plug Engine oil dipstick Air filter case V belt case Fuel tank cap Storage compartment and tool kit Oil filter cartridge Identification number records Record the vehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen un ADE N lt A JNS en gt i NN Ni ES A tz NOTE The vehicle identification number is used to identify your machine 12 CONTROL FUNCTIONS Main switch Functions of the respective switch positions are as follows COL The engine can be started only a
14. 8 Troubleshooting Although the machines receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your machine requires any repair take it to your dealer The skilled technicians at your dealer dealership have the tools experience and know how to properly service your machine Use only genuine parts on your machine Imitation parts may look like parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills 79 WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces CLEANING AND STORAGE CLEANING Keep cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components Before cleaning the machine a Block off the endof the exhaust pipe to prevent water entry A plastic bag and strong rubber band may be used b Make sure the spark plug and all filler
15. AE 10W30 motor oil 71 7 72 Battery This machine is equipped with a CAUTION sealed type battery Therefore it is not Do not try to remove the sealing caps of necessary to check the electrolyte or add the battery cells You may damage the distilled water in the battery If the battery battery seems to have discharged consult your dealer 4h WARNING POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN Fez i WS i gt ei N PL You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases 1 Negative battery terminal HOW TO AVOID THE HAZARD pa x E i N SE Y 87 m Te a SFORNA Dane ng Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children 73 Fuse replacement Antidote 1 The main fuse and the fan fuse are l under the battery panel the front driver EXTERNAL Flush with water controller fuse and the auxiliary DC jack INTERNAL Drink large quantities of fuse are inside the right panel water or milk Follow with milk of 2 If a fuse is blown turn off the main magnesia beaten egg or vegetable oil switch and the switch of the circuit in Get prompt medical attention EYES question then install a new fuse of the Flush with water for 15 minutes and get lea aria un u nd
16. HAZARD After servicing Make sure the brakes operate smoothly and that the free play is correct O Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by your dealer dA WARNING POTENTIAL HAZARD NOTE When adjusting the rear brake lever free play O Be sure not to step on the brake pedal O Make sure the brake pedal does not move Adjusting the brake pedal The top of the brake pedal should be positioned 72 mm 2 83 in above the top of the footrest If not ask your dealer to adjust it a Brake pedal position 70 Cable inspection and lubrication Lubricating the brake lever and A WARNING brake pedal and parking lever POTENTIAL HAZARD De Damaged control cable conrolcables Lubricate the pivoting parts WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes Recommended lubricant Lithium soap based grease all purpose grease damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask your dealer to replace them Recommended lubricant S
17. ING plug with the specified plug K6RTC 58 Installation 1 Measure the electrode gap with a wire SPark plug gap thickness gauge and if necessary adjust 0 6 0 7mm 0 024 0 028 in the gap to specification 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque 17 5 Nm 1 75 m kgf 12 5 ft Ibf 4 Install the spark plug cap 5 Install the panel NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible a Spark plug gap 59 Air filter element cleaning NOTE There is a check the air filter case If dust collects filter frame A Remove these bolts and remove the air in the air filter clean the air filter element and air filter case If have water in the air filter exchange the air filter element A i 1 Remove passenger seat and driver seat 2 Remove the right panel 3 Remove the clip bolt j ui x HE JI eb gt i ee i An y y 4 l 1 Bolts 2 Air filter frame 5 Pull off the lock plate remove the air filter case cover 6 Take out the air filter element N 7 Inspect the air filter element and replace 1 clip bolt it if damaged 60 1 Compressed air gun 2 Filter element 1 Air filter case
18. Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger NEVER operate this vehicle if you are under age 16 This ATV is designed to carry operator and cargo and 1 passenger 26 PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY NEVER RIDE MORE THAN AFTER USING 1 PASSENGER ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS euse an approved helmet and protective gear esecurely grasp hand holds and plant feet amy on footrests while seated in the passenger sea etell operator to slow down or stop if uncomfortable get off and walk if conditions require 27 Improper use can result in SEVERE INJURY or DEATH DOA ALWAYS USE NEVERUSE NEVER CARRY NEVER USE AN APPROVED ONPUBLIC MORE THAN WITH DRUGS HELMETAND ROADS 1PASSENGER OR ALCOHOL PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER operate ewithout proper ATV training or instruction eat speeds too fast for you skills or the conditions eon public roads a collision can occur with another vehicle ewith a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS euse proper riding techniques to avoid overturns on hills and rough terrain and in turns eavoid paved surfaces pavement may seriously affect handling and control ereduce speed and use extra caution
19. RY or DEATH NEVER CARRY NEVER RIDE MORE THAN AFTER USING DRUGS OR 1 PASSENGER ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS euse an approved helmet and protective gear esecurely grasp hand holds and plant feet amy on footrests while seated in the passenger sea etell operator to slow down or stop if uncomfortable get off and walk if conditions require Overloading this ATV or carrying cargo improprly can change handling stability and braking performance and can lead to an accident Never exceed the maximum Rear cargo limit of 40Kg 88 ibs NEVER sit on the carrier Refer to instructions in the Owner s manual Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger NEVER operate this vehicle if you are under age 16 Improper use can result in SEVERE INJURY or DEATH DOG ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC MORE THAN WITH DRUGS HELMET AND ROADS 1PASSENGER OR ALCOHOL PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER operate ewithout proper ATV training or instruction eat speeds too fast for you skills or the conditions eon public roads a collision can occur with another vehicle ewith a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS euse proper riding techniques to avoid overturns on
20. aster cylinder reservoirs when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately Have your dealer check the cause if the brake fluid level goes down Brake fluid replacement Complete fluid replacement should be done only by trained service personnel Have your dealer replace the following components during periodic maintenance or when they are damaged or leaking O Replace the oil seals every two years O Replace the brake hoses everv four vears Front brake lever free play The front brake lever should have a free play of zero mm Zero in at the lever end If not have your dealer check the brake system a Front brake lever free play 68 Adjusting the parking brake lever and brake pedal Adjusting the parking brake lever The parking brake lever free play should be 5 7 mm 0 19 0 27 in 1 Loosen the locknut 2 Turn the adjusting bolt in direction to increase free play and in direction b to decrease free play 3 Tighten the locknut 2 Locknut 1 Adjusting bolt 3 Lockup bar PERI WES Br MESI be obtained ask your dealer to make that adjustment 4h WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE
21. cover 7 Use the compressed air gun blow the filter element according to the photo if you have not compressed air gun you should be tap it lightly until it cleanly 8 Install the air filter element assembly 9 Install the air filter case cover by hooking the lock plate onto the air filter case 10 Install the air filter clip bolt and the air filter frame 11 Install the right panel 12 Install passenger seat and driver seat gt ESA IN N N di WARNING POTENTIAL HAZARD Usina solvents or gasoline to clean the NOTE The air filter element should be cleaned every 61 SN_AN hnire It chrn l he claanad and liihricatarl CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating 62 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to your dealer who has the professional knowledge and experience to do so However the idling speed may be performed by the owner as a part of the usual maintenance routine NOTE Adjust the engine idling speed before check the throttle lever free play Specified idle speed 3 0 5 0 mm 0 12 0 20 in
22. e lever adjustment id 65 Inspecting the brake fluid level ii eis 67 Cable Inspection and lubrication iii aaa 71 Batterv nee O 73 Replacine a headlight DUI seri nee ehe te Tees 76 Troubleshooting ass iii 79 CLEANING AND STORAGE 22 22 elio abet 80 SPECIFICAUON S ee ee een 82 Circuit Diagram Wiring Diagram and troubleshooting chart LOCATION OF THE WARNING AND SPECIFICATION LABELS APTT LENSES LAA ge A _ gt AB LI 7 gt 5 AS INA E ANI ES CH a Mi y Y cen Il BA A gt x 9 I j A f HR DI JA Z 4 7 nf 4 Af a WA AA MA ADD Read and understand all of the labels on your machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your dealer o Overloading this ATV or carrying cargo improprly can change handling stability and braking performance and can lead to an accident Never exceed the maximum front cargo limit of 30Kg 66 ibs NEVER sit on the carrier Refer to instructions in the Owner s manual Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death eCold tire pressure Front 7 0 2psi 47 1 5kPa Rear 7 0 2psi 47 1 5kPa e Maximum weight capacity 485lbs 220Kg PASSENGER SAFETY To reduce the risk of SEVERE INJU
23. f the ATV is 10 Right turn overloaded If this happens reduce the load to 11 Fuel meter specification Restart after making sure that the light is out Continuous use while the light is on may cause damage to the engine NOTE When the fuel meter has only one mark should be refilled as soon as possible Temporality tank remaining has only about AL 14 Handlebar switches CAUTION Do not use the headlights with the engine turned off for more than twenty minutes The battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it Engine stop switch R Make sure that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is set to 1 Start switch 2 Make sure that you must clutch at Front brake lever or 3 Low beams High beams turn 20 m trample Brake pedal before starting motor cranks the engine 4 Turning switch lt e gt when this switch is pushed 5 Horn switch Pe 6 Start switch 7 Engine stop switch R 0 8 Starter choke 15 Driver model turn switch 1 4WD 4WD Loc 2 4WD 2WD When change from 2WD 4WD 4WD Lock model should be stop the ATV and set
24. g technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be learned first at low speed As you approach a curve slow down and begin to turn the handlebars in the desired direction As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before at tempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions If the ATV begins to tip over to the outside while negotiating a turn lean more to the side It may also be necessary to cradiallv lat aff an tha thrattla and ctaar ta This procedure should be practiced at slow speed many times in a large off road area with no obstacles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the procedure again If the riding surface is slippery or loose it may help to position more of your
25. h the front and rear brakes gradually Whenever possible ride your ATV straight downhill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear 37 CLIMBING UPHILL 4h WARNING Never go over the top of any hill POTENTIAL HAZARD at high speed Climbing hills improperly An obstacle a sharp drop or WHAT CAN HAPPEN another vehicle or person could Could cause loss of control or be on the other side of the hill cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never operate the ATV on hills steeper than 25 38 CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shallow water of up to a maximum recommended depth equal to the bottom of the footrests Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks and obstacles if possible 3 Proceed slowly avoiding rocks and obstacles if possible 4 Test your brakes after leaving the water Do not continue to ride your ATV
26. hills or other inclines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily x Py wr grrr A OS N b r VD nn Ol F 7S fx Nn Ca A 2 or g 4 t Wk BEE gt y IE l ay SUR aye RO e x 1 etn U d 7 uF a nt oe u di he fal DITA MARNA x IM H h gt eg f wat gt rd A TA i TRON ur m td 4 i I 5 4 y Fr pe PR A 7 y k i m4 41 PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient condition possible Safety is an obligation of the machine owner The most important points of machine inspection adjustment and lubrication are explained on the following pages A WARNING Owner s manual and tool kit You are recommended to put this owner s manual in the vinyl bag and always carry it under the seat Put the owner s tool kit and low pressure tire gauge under the seat POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can we cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing mai
27. ighten the oil filler cap 9 Install the panel and bolt Change the engine oil with or without and then tighten the oil filler cap oil filter cartridge 48 replacement The engine oil should be between the minimum and inNay fever marks Skip steps 5 9 if the oil filter cartridge is not being replaced 1 Remove bolt and panel 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase NS TTT 1 Engine oil drain bolt NOTE Make sure the O ring is seated properly 5 Remove left side panel 6 Remove the oil filter cartridge with an oil filter wrench 7 Apply a light coat of engine oil to the O ring of the new oil filter cartridge 8 Install the new oil filter cartridge Tightening torque 17Nm or 1 7m kgf or 12 ft ibf IL o a minutes Pnsieenir iiah ptri geck for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 3 Turn the engine off and then check the oil level and correct it if necessary e SER 70 90 lie SAE 20W40 SAE 10W30 1 O ring 20 10 0 10 20 30 40 API Service SE SF SG type or higher 9 Install the left side panel Engine oil classification of the ATV 10 Install the engine oil drain bolt and then tighten it t
28. ling it off 4 Remove the headlight bulb holder by turning it counterclockwise 5 Remove the defective bulb by unhooking the headlight bulb holder tabs 6 Insert a new headlight bulb into the bulb holder and then secure the bulb by hooking the tabs onto the bulb 7 Install the headlight bulb holder by turning it clockwise 8 Install the headlight bulb holder cover at the rear of the headlight 9 Install the headlight panel 10 Install the bolts and the fender 1 Headlight panel 2 bolts 1 Headlight bulb holder CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 77 Headlight beam adjustment Tail brake light bulb replacement CAUTION 1 Remove the tail brake light bulb holder by turning it counterclockwise 2 Remove the defective bulb by It is advisable to have your dealer make Selen unhooking the tail brake light bulb holder tabs 3 Insert a new tail brake light bulb into To raise the beam turn the adjusting the bulb holder and install the screw indirection tail brake light bulb holder by turning it To lower the beam turn the adjusting clockwise screw indirection Ni 122 va 1 Head beam adjusting screw 7
29. llow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine Avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer IMPORTANT NOTICE This ATV is designed and manufactured for OFF ROAD use only It is illegal and unsafe to operate this ATV on any public street road or highway This ATV complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV A WARNING Indicates a potential hazard that could result in serious injury or death CONTENS LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 SAFERCINFORMAFION Lun 5 DESCRIPTION AND MACHINE IDENTIFICATION ooccoccncnccncnoconccccccconononoococonoco0o0000000010 11 Identification number records ssssssssssssssssssesssesssesssecesscsssesssessnecesscessesssesssecesscesscsssecasesssecssecessesaseessecsseesseeess 12 CONTROL FUNCTIONS ee 13 Vasi 13 Indicator and warning lights ss sssssssssssssssssssesssecssscsssesssesssecsnecssscsssecssecssecesscessccssesssecssecssecsssceaseessecssecessees 14 Handlebar SWAB Eee en nee te 15 Driver model turn SWitch
30. moothly check for the cause Correct the problem before riding the ATV Consult your dealer if you can t find or solve the Problem Yourself Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV UH Le 1 Locknut 2 Adjusting screw a No more than 18 mm 0 70 in A WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 18 mm 0 70 in Always make sure the throttle lever free play is adjusted to 3 0 5 0 mm 0 12 0 20 in 18 brake lever and brake pedal Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 Front brake lever Brake pedal The brake pedal is located on the right side of the ATV Push down on the pedal To apply the rear brake 1 Brake pedal Parking brake lever The brake lever is located on the left handlebar pull the lever toward and push the handlebar to apply the rear brake 19 Drive select lever The drive select lever is used to shift your machine
31. ng ring 2 Position indicator Standard position 2 1 Minimum soft 5 Maximum hard 23 RIDING YOUR ATV Riding Your ATV Indicates a potential hazard that could result in serious injury or death GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use This section riding your ATV provides general ATV riding instructions for recreational riding The skills and techniques described in this section however are appropriate for all types of riding Riding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the operation of the controls Please also read REDET EA RENO SODDJ DGEMENT 25 Get training if you are inexperienced Beginners should get training from a certified instructor Become familiar with this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics Not recommended for children under 16 years of age
32. ntenance unless otherwise specified Have your dealer perform service if you are not familiar with machine service 1 Owner s manual 2 Owner s tool kit and Low pressure tire gauge Il BAU mi A 42 PERIODIC MAINTENANCE LUBRICATION NOTE eFor ATVs not equipped with an odometer or an hour meter follow the month maintenance intervals eFor ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals How ever keep in mind that ifthe ATV isn t used for a long period of time the month maintenance intervals should be followed EVERY Whichever 6 6 12 ROUTINE comes first REA 1000 2000 3000 155 Po e u o e Check valve clearance e Adjust if necessary e Check coolant leakage Repair if necessary e Replace coolant every 24 months Check condition Spark plug e Adjust gap and clean e Replace if necessary Air filter Every 20 40 hours element More often in wet or dusty areas Check starter choke ju engine ling spend lelelelo 43 Valves Cooling system MER EVERY Whichever o 6 6 12 ITEM ROUTINE comes first o 1000 2000 3000 ISS 310 620 1240 11860 Crankcase e Check breather hose for gl or breather damage system e Replace if necessary e Check for leakage e Tighten if necessary e Replace gasket s if necessary Exhaust system va a e Check fuel hose for cracks or damage Ep if necessary
33. nual Dismount on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low 7s and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply those several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo
34. o e Li I is gt S al N E gt BF tud gt ce glk Wi Q ee vbw A RN qe AA SANS n an V SEN EN Sp 2 E x SSL NET ro Vol e ZIA A Amon R OE o j gt D S a S x Rx o y e SY BUS 4 ET ye 2 um 5 ay tn 1 E ella ke SRS SS Soe Mey E Mus U u 2 77 72235 ZI hy 4 pen aH All N I i TH fa Het X2 each side 1 Rear axle boot pats X2 each side 1 Front axle boot 57 Spark plug inspection REMOVA Inspection 1 Remove panel The spark plug is an important engine 2 Remove the spark plug cap component and is easy to inspect The 3 Use the spark plug wrench in the tool kit condition of the spark plug can indicate to remove the spark plug as shown the condition of the engine The ideal color on the white insulator around the center electrode is a medium to light tan color for a ATV that is being ridden Sa normally Do not attempt to diagnose ies IS iS im Sy such problems yourself A VI Instead take the ATV to your dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If Spark plug wrench a electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark SPESSO Spark P
35. o the specified torque Tightening torque 23Nm P i asin sile Oil quantity or 2 3m kgf or 16ft ibf a l e Without oil filter cartridge replacement 11 Add the specified amount of recommended 2 5L 0 64 US at engine oil and then install the engine oil filler cap P nn at With oil filter cartridge replacement and tighten it 12 Start the engine and warm it up for several 2 6L 2 US al Final gear oil Checking the final gear oil level 130 F 1 Place the ATV on a level surface 2 Remove the panel and the oil filler bolt and then check the oil level in the final gear case 3 If the oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten it 1 y NOTE The oil level should be at the brim of the filler hole TS Be sure no foreign material enters the final gear case 2 Correct level 1 Final gear oil filler bolt 3 Final gear oil 51 Changing the final gear oil 1 Place the ATV on a level surface 2 Place a container under the final gear case to collect the used oil 3 Remove the oil filler bolt and the drain bolt to drain the oil 4 Install the drain bolt and then tighten it to the specified torque 23 Nm or 2 3m kgf or 16 ft ibf 5 Add the recommended final gear oil to the brim of the filler hole 6 Install the oil filler bolt and then tighten it 7 Check f
36. ollant re 54 NOTE The coolant should be between the minimum and maximum level marks CAUTION Hard water or salt water is harmful to the engine you may use soft water if you can t get distilled water 4 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before re moving the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Changing the coolant 1 Place the ATV on a level surface 2 Place a container under the engine and then remove the coolant drain bolt Use a trough or a similar object as shown to prevent coolant from spilling on the footrest 3 Remove the battery panel and bolt A Remove the radiator cap ANRICHTEN TI N ZUR 7 Disconnect the hose on the coolant reservoir side and then drain the coolant from the coolant reservoir 5 8 After draining the coolant thoroughly 56 CAUTION Hard water or salt water is harmful to the engine you may use soft water if you can t get distilled water Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by your dealer N P WE N 2 2 EI DT PEC f PART ES Dare py 798 Y PON 7 EAS 2 N
37. only Paved surfaces may seriously affect en 6 E null I ES Na Sa handling and control of the ATV and may Do nat ride on any public road street or high cause the vehicle to go out of control way HOW TO AVOID THE HAZARD Riding on public roads can result in collisions With other vehicles Always avoid paved surfaces including sidewalks driveways parking lots and streets SI Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and oth32 ar hiddan hasarde inhicrh mai narica tha 4h WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 4h WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose 34 TURNING YOUR ATV To achieve maximum traction while riding off road the two rear wheels are mounted solidiy on one axle and turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special turnin
38. or oil leakage if oil leakage is found check for the cause Recommended oil SAE 80W 90 API GL 4 Hypoid gear oil Oil quantity 0 33L0 35 US qt UE Final gear oil drain bolt Be sure no foreign material enters the final gear case 52 Front gear oil replacement 1 Place the ATV on a level surface 2 Place a container under the differential gear case to collect the used oll 3 Remove the oil filler bolt and oil drain bolt to drain the oil 4 Install the oil drain bolt and then tighten it to the specified torque 23 Nm or 2 3m kgf or 16 ft ibf 5 Fill the differential gear case with the specified amount of the recommended oil 6 Install the oil filler bolt and then tighten it to the specified torques 10 Nm or 1 0 m kgf or 7 2ft Ibf 7 Check for oil leakage If oil leakage is found check for the cause Recommended oil SAE 80W 90 API GL 4 Hypoid gear oil Oil quantity 0 33L0 35 US qt CAUTION Be sure no foreign material enters the final gear case 53 1 Front gear oil filler bolt Cooling system 1 Place the ATV on a level surface 2 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature 3 If the coolant is at or below the minimum level mark remove the reservoir cap add coolant to the maximum level mark install the reservoir cap servoir and cap 2 Miximum level mark 3 Maximum level mark 1 Co
39. prompt medical attention Keep batteries again consult your dealer away from sparks flames cigarettes or other sources of ignition Ventilate when charging or using in a closed space Specified fuses CAUTION Battery fuse 30A Power output fuse 10A A special battery charger constant Fan fuse 10A voltage ampere or constant voltage is Main switch fuse 10A required for recharging a sealed type Light fuse 20A battery using a conventional battery charger may shorten the battery life 74 Battery maintenance 1 When th hine i t d f in When the machine is not used for a month or longer remove the battery and POTENTIAL HAZARD store it in a cool dark place Completely Using an improper fuse recharge the battery before WHAT CAN HAPPEN reinstallation An improper fuse can cause damage 2 Always make sure the connections are to the electrical system which could correct when putting the battery back in the machine lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse CAUTION To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 fuse box 2 Battery fuse 75 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the bolts and the fender 2 Remove the headlight panel 3 Remove the bulb holder cover at the rear of the headlight by pul
40. rn at faster speeds Do not turn at excessive speed Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible 6 Always use proper procedures if you stall or roll backwards when climbing a hill Maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this ma
41. service 46 NOTE eRecommended brake fluid DOT 3 or DOT 4 eBrake fluid replacement eWhen disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required eOn the inner parts of the master cylinder and caliper replace the oil seals every two years e Replace the brake hoses every four years or if Indicates a potential hazard that could cracked or damaged Indicates a potential hazard that could result in serious injury or death 47 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart Check the engine oil level 1 Remove the bolt and panel 2 Place the ATV on a level surface 3 Start the engine warm it up for several minutes and then turn it off 4 Wait a few minutes until the oil settles 5 Remove the engine oil filler cap and wipe off the dipstick with a clean rag 6 Insert the dipstick in the oil filler hole screwing it in and then remove it again to check the oil level 7 If the engine oil is at or below the minimum level mark add sufficient oil of the lt recommended type to raise it to the correct level gt NL 8 Insert the dipstick into the oil filler hole and then 1 Maximum level mark 2 Minimum level mark t
42. t this position and the headlights taillight and meter lighting come on when the light switch is on Pe All electrical circuits are switched off without clock at meter The key can be removed in this position 13 12 4WD indicator light olo 13 Position light tell tale indicator light PE 14 Clock si it 8 9 Go 15 High beams indicator ED 16 Accumulating mileage and subtotal mileage Coolant temperature warning light_ E When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes The electrical circuit of the warning light can be checked according to the following procedures 1 Set the engine stop switch to and turn the Indicator and warning lights 1 Speed meter key to ON Sn o 2 Shift the drive select lever into the neutral position 3 Coolant temperature warning light des i f 4 Low indicator light L 3 Push the start switch If the warning light does not 5 High indicator light H come on while the start switch is pushed please call 6 Neutral indicator light N your dealer check the electrical circuit 7 Reverse indicator light R CAUTION 8 4WD LOCK indicator light DIFF LOCK i i ff The engine may overheat i
43. tact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control of the ATV or overturn A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off yr iy x 7 pith Ah a AA NI ov Ad u f y F J i 30 Modifications 4 WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer 31 BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of control A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use
44. the switch to correspond position WARNING To achieve maximum traction while riding in 2WD or 4WD the two rear wheels are mounted solidly on one axle and turn together at the same speed Furthermore when riding in 4WD LOCK DIFF LOCK the front wheels also turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special turning technique must be use to allow the ATV to make turns quickly and easily It is essential that this skills be learned first at low speed 16 Throttle Lever Once the engine is running movement of the throttle lever will increase the engine speed Regulate the speed of the machine by varying the throttle position Because the throttle is spring loaded the machine will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released 1 Throttle lever 17 A WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle cable could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work s
45. weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip 36 Lean towards inside oftum om i Support your weight on the outer footboard RIDING DOWNHILL When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as possible Move back on the seat and sit with your arms straight Engine compression will do most of the braking for you For maximum engine compression braking effect change to AWD before beginning to descend the hill Improper braking may cause a loss of traction Use caution while descending a hill with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground Apply bot
46. without verifying that you have regained proper braking ability 39 A WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings After riding your ATV in water be sure to check th trapped water at the air filter V belt cooling duct th storage compartment If necessary drain any water th may have accumulated Also if it has been operated i salt water or muddy conditions 40 PARKING ON A SLOPE 44 WARNING 1 Bring the machine to a Stop by applying the POTENTIAL HAZARD pal a ill Sa ee enge Stop the engine Parking on a hill or other incline 3 pull the lever toward and push lockup bar lock WHAT CAN HAPPEN the handlebar to apply the rear brake The ATV could roll out of control increasing 4 Always block the front wheels and rear wheels the chance of an accident on the downhill side as illustrated HOW TO AVOID THE HAZARD j i WA hai Pg AL i WN AAT Mi 7 wi TA FN Oe Le A iy Kr big W a A Ah AAN Y N IN MEST ae en wy KIA a AL A A Avoid parking on
Download Pdf Manuals
Related Search