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1. 37 Safety decals and locations 38 rearrack load warning Never carry passenger on rear rack refer to warning on ATV for loading Safety Warning Never carry more than 2 passengers driver included tire pressure and loading warning Refer to specific warning on ATV Warning check engine oil refer to warning on ATV Safety decals and locations Gear shifting warning Driving warning Gear shifting have to be operated Improper ATV use may cause severe injury when ATV is stopped or death refer to warning on ATV Front rack load warning 4WD LOCK operating warning Never carry passenger on front rack refer to specific warning on ATV Refer to warning on ATV for load 39 Safety decals and locations Passenger warning Never carry passenger under age 12 Passenger should sit on passenger seat and hold handrail A0 Driver age warning never operate this ATV if you are under age 16 Q Loading trailer towing warning Loading or trailer towing refer to warning on ATV Safety decals and locations Safe riding gear Always wear clothing suited to the type of riding ATV riding requires special protectiv
2. 23 Operator Safety HOW TO AVOID THE HAZARD Always follow proper procedures or turning as described in the owner s manual Practise turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed AWARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 22 Practice on smaller hills before attempting large hills 24 Operator Safety AWARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn A HOW TO AVOIDL THE HAZARD Always follow proper procedures for climbing hills as ee described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 22 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed And obstacle a sharp drop or another vehicle or person could be on the other side of the hill 25 Operator Safety AWARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAP
3. This indicator light comes on when moving the head light switch to EO oon z007 V PO OST OOOO S00000H8E ae 18 88 rag a CEmMmOTO ADJ e 59 Features amp Controls Lo Gear Indicator L This indicator light comes on when the gear selector is in the L position Hi Gear Indicator H This indicator light comes on when the gear selector is in the H position Neutral Indicator N D This indicator light comes on when the gear selector is in the N position Reverse Gear Indicator R This indicator light comes on when the gear selector is in the R position Park Indicator P This indicator light comes on when the gear selector is in the P position EPS Indicator This indicator light will be on when EPS Electric Power Steering is equipped to the vehicle Refer to Page 150 for detailed information Override Indicator 4 This indicator light comes on when pressing the override switch Always exercise caution to use override button Refer to page 37 for detailed information Right turning signal Indicator 42 This indicator light comes on when moving the turning switch to gt 60 Features amp Controls Digital Clock 43 Time setting Press and release ADJ 44 once to advance the setting by one hour press and hold the button
4. 53 Features amp Controls This ATV is equipped with an on command four wheel drive switch 2WD 4WD anda front diff lock switch LOCK 4WD Select the appropriate drive according to terrain and the conditions e Two wheel drive 2WD Power is supplied to the rear wheels only e Four wheel drive 4WD Power is supplied to the rear and front wheels e Four wheel drive with the front diff locked 4WD LOCK Power is supplied to the rear and front wheels when the front diff is locked Unlike the 4WD mode all wheels turn at the same speed e on command four wheel drive switch 2WD 4WD To change from 2WD to 4WD stop the ATV and then set the switch to 4WD When the ATV is in 4WD the 4WD indicator will come on in the dashboard display To change from 4WD to 2WD stop the ATV be sure the lever Wis moved to the front diff lock switch and then set the switch to 2WD When the ATV is in 2WD the 2WD indicator will come on in the dashboard display 54 Features amp Controls Front Diff lock Switch LOCK 4WD To lock the front diff in 4WD make sure the on command four wheel drive switch is set to 4WD stop the ATV move the lever to 2WD 4WD switch then set the switch to LOCK when the front diff is locked the 4WD in lock es indicator light x willcomeon ANOTE eWhen the s
5. 3 5 mm a 3 Fasten nut IL rore e Q e Front brake pad check L SSS Check the brake pads for damage and wear If your dealer replace the pads as a set ANOTE he wheels need to be removed to check brake pads D Maintenance amp Lubrication e Rear brake pad inspection Inspect the brake pads for damage and wear If the thickness is less than 1 5 mm have your dealer replace the pads e Inspect 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 lower level and replenish when necessary The front brake fluid master cylinder reservoir is located the right of the handlebar The rear brake fluid master cylinder reservoir is near the rear brake pedal e a 116 Maintenance amp Lubrication e Inspect brake fluid level Observe these precautions 1 When checking the fluid level make sure the top of the master cylinder reservoir is level by turning the handlebars 2 Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance ANOTE Recommended brake fluid DOT3 or DOT 4 3 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction a
6. Drain the fuel system and refuel Fuel valve is out of use Replace Old or non recommended fuel Fouled or defective spark plug s Replace with new fuel Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel injector Clean or replace new fuel injector Low battery voltage Recharge battery to 12 5 VDC Mechanical failure See your dealer 14t Troubleshooting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery
7. s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury 21 Operator Safety HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation AWARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 22 Operator Safety AWARNING POTENTIAL HAZARD oe Failure to use extra caution when operating on excessively v We y rough slippery or loose terrain es s WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could aes is result in an accident or overturn e HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain AWARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn
8. Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range Shift transmission to low range during loading of the ATV to prevent belt burning Starting out going up asteep incline When starting out on an incline use low range or dismount the ATV after first applying the park brake and perform the K turn as described on page 81 Driving at low RPM or low ground speed at approximately 5 10 km h Drive at a higher speed or use low range more frequently The use of low range is highly recommended for cooler CVT operating temperatures and longer component life Insufficient warm up of ATVs exposed to low ambient temperatures Warm the engine before driving the belt will become more flexible and prevent belt burning Slow and easy clutch engagement Use the throttle quickly and effectively for efficient engagement Towing pushing at lowRPM low ground speed Use low range only Utility use plowing snow dirt etc Use low range only 137 Troubleshooting Possible Cause Solution Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARRNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects froma stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle ap
9. amp Lubrication e Front and rear suspension adjustment The spring preload can be adjusted to suit the rider s weight and riding conditions Standard shock absorbers ANOTE When adjusting the rear shock absorbers the rear wheels need to be removed adjust the spring preload as follows To increase the spring preload turn the adjusting ring in Direction To decrease the spring preload turn the adjusting ring in Direction ANOTE A special wrench can be obtained at a dealer to make this adjustment Standard position B A Minimum soft E Maximum hard A DANGER Always adjust the shock absorbers on the left and right side to the same setting 128 Maintenance amp Lubrication Vehicle immersion AWARNING If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine For example if engine is not properly handled after immersion starting will damage the engine Optional shock absorber adjustment Front adjustment procedures Spring adjustment Loosen lock nut Turn adjust nut to proper hardness then tighten lock nut 129 Damping restore adjustment Turn adjuster to SLOW side until to end and counter shifts then turn to FAST side until suitable to your comfort Damping press adjustment Turn adjuster to HARD side and counter shifts then turn to SOFT side until sui
10. birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 51 Features amp Controls e Automatic Transmission Gear Selector The transmission gear selector is located on the left side of the vehicle L Low Gear H High Gear N Neutral R Reverse P Parking To shift from N to H or R from L to H from P to R depress the button of gear selector To shift from H to Lor N from Rto NorP it s not necessary to depress this button When shifting among N R P you must push the brake pedal 52 Features amp Controls A CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Push the brake pedal before attempting to shift into reverse or park Whenever the ATV is left unattended always place the transmission in the park position Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems e Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time If towing the vehicle is necessary shift the transmission into neutral for better mobility and to prevent damage to the belt e All Wheel Drive AWD System
11. a turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the wheels allowing turn to be made smoothly The same leaning technique should be used for turning in reverse ANOTE Practice making turns at slow speeds before attempting to turn at faster speeds AWARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never make turns at high speeds 76 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward L t 4 Driving with AWD engaged can assist in controlling 5S an the vehicle in slippery areas A CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always engage AWD when the wheels have traction or are at rest AWARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of c
12. add sufficient oil to raise it to the specified level 3 Install the oil filler bolt and tighten it to the specified torque ANOTE Oil filler bolt tightening torque 23N m Front gear case oil change 1 Place the machine on a level place 2 Place a container under the front gear case to catch the oil 3 Remove oil filler bolt and drain bolt at the bottom of front gear case and drain used oil 102 Maintenance amp Lubrication Front gear case oil change 4 Install the drain bolt and tighten it to the specified torque ANOTE Drain bolt tightening torque 10N m 5 Fill the front gear case with oil ANOTE Periodic oil change 0 28L Oil capacity 0 33L 6 Install the filler bolt as page 102 shows and tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause ANOTE AFS Be sure no foreign material enters the front gear case 103 Maintenance amp Lubrication Cooling system 1 Place the ATV ona 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 ANOTE The coolant should be between the upper and lower limit marks Cooling system 3 If the coolant is at or below the lower limit mark remove the reservoir cap add coolant to the upper limit mark install the reservoir
13. be between the upper and lower limit marks 98 Maintenance amp Lubrication Engine oil check 7 If the engine oil is at or below the lower limit mark add sufficient oil of the recommended type to raise it to the correct level 8 Insert the dipstick into the oil filler hole and then tighten it 9 Install plastic cover To change engine oil 1 Start the engine warm it up for 2 3 minutes and then stop the engine 2 Place an oil pan under the engine to collect the used oil and then remove the engine oil dipstick 3 Remove the engine oil drain bolt to drain the oil from the crankcase 99 Oil filter replacement 1 Use wrench to unscrew 3 pcs of bolts as right picture shows Then remove cover of oil filter and remove oil filter 2 Install new oil filter on it Attention Confirm if O ring is good and then install it into groove of crankcase correctively 3 Install new oil filter and use wrench to tighten 3 pcs of bolts on cover by specified torque A NOTE Tightening torque of bolt 10N m 4 Use new washer to assemble and tighten oil drain bolt as specified torque A NOTE Tightening torque of drain bolt 30 N m E A i 5 Add the specified amount of recommended engine oil and then insert Mi k the engine oil dipstick and tighten it ANOTE 2 In case of engine overhaul oil should be added
14. brake fluid level NYS can be seen through an indicator window on the side of the master cylinder When fluid level is S lower than the lower mark refill with the ees same type of brake fluid AWARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill A7 Features amp Controls ANOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If fluid level is lower than the lower mark add DOTS or DOT4 brake fluid Don t overfill AWARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the drop of boiling temperature of the brake fluid which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion A8 Features amp Controls Parking Brake When parking stop the engine and shift the gear selector Lever into the park position CAUTION When shifting the transmission in PARK always push the brake pedal Shake the vehicle forward and backward to check if the parking brake is engaged Important Safeguards SSS ooo o C cc WIZE e Never depend on
15. caution when operating on hills and follow proper operating procedures outlined in the owner s manual Sidehilling AWARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of ahill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 79 Operation 3 Steer slightly into the hill to maintain vehicle directions ANOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Shift your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary rear brakelever 80 Operation AWARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill Turning Around ona Hill AWARNING Improper hill climbing procedures cou
16. if replacing Inspect Clean every 1000km or 100 Air filter element 50H 1500 hours Replace initial replacement should be done after 750Km or 20H Every Drain water as needed check CVT outlet pipe week often if operating in wet conditions Brake pad wear 10H Monthly 100 Inspect periodically Battery 20H _ Monthly 200 Check terminals clean test Frontgearcaseoil 25H Monthly 250 Inspect level change yearly Rear gear case oil 25H Monthly 250 Inspect level change yearly Transmission oil 25H Monthly 250 Inspect level change yearly 92 Maintenance amp Lubrication Periodic maintenance chart gt General lubrication 50H 3M 500 Lubricate all fittings pivots cables etc Steering knuckle 50H 6M 500 Inspect lubricate adjust E Steering handlebar 50H 6M 500 lubricate gt Front suspension 50H 6M 500 lubricate gt Rear suspension 50H 6M 500 lubricate Gearshift 28H 1M 500 Inspect lubricate adjust m Throttle cable Switch 50H 6M 500 i SE a Drive belt oH 1500 _ ineneet edu replace I necessary Cooling system 50H 6M 500 Inspect coolant strength seasonally pressure test system yearly 93 Maintenance amp Lubrication Periodic maintenance chart Perform a break in oil change at 20 Engine oil change 100H 12M 3000 hours 750Km Fuel hose Toa too ieee toura condition Replace Wah Valve clearanc
17. injury or death An ATV is not a toy and can be hazardous to operate This vehicle handles differently from other vehicles such as motorcycles and cars Acollision or rollover can occur quickly even during routine mann euvers like turning or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating an ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under the age of 16 Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Operator Safety Safety Training When you purchased your newATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used ATV from a party other than a dealer you can request this free safety training from any authorized dealer Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined
18. on page 91 Items not listed in the chart should be lubricated at the General Lubrication interval Key points of lubrication chart gt More often under severe use such as wet or dusty conditions All Season Grease Use U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging 96 Maintenance amp Lubrication Front gear case oil SAE15W 40 SG or SAE80W 90 GL 4 Items Lube Methods Engine oil SAE15W 40 SG Use dipstick to check oil level Brake fluid DOT3 or DOT4 Keep level between Upper and Lower line see page 47 See page 102 Rear gear case oil SAE15W 40 SG or SAE80W 90 GL 4 See page 101 Ball Joint Grease 97 Maintenance amp Lubrication Lubrication recommendations Engine oil Always check and change the engine oil at the intervals outlined inthe Periodic Maintenance Chart beginning on page 93 and 94 Always change the oil filter whenever changing oil Engine oil check 1 Remove plastic cover as right picture shows 2 Position the ATV ona level surface 3 Start the engine and let it idle for 20 30 seconds Stop the engine 4 Wait afew minutes until the oil settles 5 Take oil dipstick out from and wipe off area of dipstick with a clean rag 6 Insert the dipstick in the oil filler hole and screwing it in then remove it again to check the oil level ANOTE The engine oil should
19. open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 65 Operation 6 Pull only light loads 7 During the break in period change both the oil and oil filter at 20 hours or 750km e Pre Ride Inspection AWARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it is in proper operating condition Pre Ride Checklist Item Remarks See Page Brake system lever travel Ensure proper operation 45 118 Brake fluid Ensure proper level 48 Front suspension Inspect lubricate if necessary 128 Rear suspension Inspect lubricate if necessary 128 65 Operation Pre Ride Checklist Item Remarks See Page necessary Steering Ensure free operation Tires Inspect condition and pressure 151 wheels fasteners Inspect ensure fastener tightness 122 123 Frame nuts bolts fasteners Inspect ensure fastener tightness Fuel and oil Ensure proper levels 98 Coolant level Ensure proper levels 104 Coolant hoses Inspect for leaks Throttle Ensure proper operation 115 Gear shifting Ensure proper operation Indicator lights switches Ensure proper operation 58 59 66 Ope
20. or towing Allow a greater distance for braking e Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or acci dental starting e Child or pets shall not be carried on the racks e Never touch running parts such as wheels drive shaft etc FOR MORE INFORMATION ABOUT ATV SAFETY PLEASE CONTACT WITH YOUR DEALER 13 Operator Safety Equipment Modifications We are concerned with the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on an ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifi cations to the original equipment of the vehicle create a substantial safety hazard and increase the risk of body injury The warranty on your ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power ANOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only approved accessories and familiarize yourself with their function and effect on the vehicle 14 Operator Safety AWARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator do
21. riding in the rear rack could be ejected from the vehicle unexpectedly or may contact moving components both of which can result in severe injury or death HOW TO AVOID THE HAZARD Never allow passengers to ride in the rear rack POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection 17 Operator Safety And protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe eye injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves long sleeved shirt or jacket and long pants AWARNING POTENTIAL HAZARD 18 Operator Safety Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consumption of alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs b
22. the parking brake alone if the ATV is parked on a hill Always block the wheels on the downhill side of the ATV to prevent rolling It s recommended to park the ATV ona level ground A9 Features amp Controls e Fuel Tank Fuel tank cap is located on the tail of the vehicle remove the plastic cover to locate it To open the fuel tank cap insert the ignition key into the key hole and turn clockwise The fuel tank cap can t be locked without the key inserted 50 Features amp Controls e Fuel safety AWARNING Gasoline is highly flammable and explosive under certain conditions eAlways exercise extreme caution whenever handling gasoline eAlways refuel with the engine stopped and outdoors or in a well ventilated area eNever carry a plastic container with gasoline in the racks while riding Static electricity between the rack and container could cause a spark eDo not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored eDo not overfill the tank Do not fill the tank neck elf gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time AWARNING The engine exhaust from this product contains chemicals known to cause cancer
23. the water may affect other engine parts Maintenance amp Lubrication Throttle body adjustment The throttle body is a vital part of the engine and requires very sophisticated adjustment Most adj usting 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 The throttle body 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 Check idle for stability and contact your dealer for service if necessary Engine idel adjustment AWARNING this vehicle is equipment with EFI system and no need to adjust idle or performance will be affected Contact your dealer in case abnormal idle ANOTE Engine idle 1 300 100r min Heated engine e Engine airinlet outlet 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 114 Maintenance amp Lubrication ANOTE Adjust the engine idling speed before Adjusting the throttle lever free play on Page 114 d 1 Loosen nut 2 Turn adjustment nut to lever travel l
24. to enter into air filter ANOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system 131 Clean amp Storage Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish A CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces A CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Do not use harsh detergents or high pressure washers Some dete rgents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals 132 Clean amp Storage Oil and Filter Warm the engine then stop the engine and change the oil and filter A CAUTION When drain out fuel in fuel pipe and air pipe if dashboard says only one grid of fuel left remove fuel pump connector to drain out fuelin fuel tank or else it may damage fuel pump Air Filter Air Box Inspect and clean or replace air filter Clean the air box and drain the sedi
25. 3 5L ES Without oil filter cartridge replacement oil should be added 3 3 L sta With oil filter cartridge replacement oil should be added 3 4L 6 Start the engine and warm it up for several minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 7 Turn the engine off and then check the oil level and correct it if necessary 100 Maintenance amp Lubrication Rear gear case oil The rear gear case must be checked for oil leakage before each ride If any leakage is found have your dealer check and repair the ATV Rear gear oil change 1 Place the machine on a level place 2 Place a container under the rear gear case to collect the used oil 3 Remove oil drain bolt as right picture shows and drain used oil 4 Add recommended gear oil into rear gear case 5 Install and tighten drain bolt as specified torque after adding new gear oil ANOTE Tightening torque of drain bolt 23N m ANOTE Periodic oil change 0 25L Oil capacity of rear gear case 0 30L 101 Maintenance amp Lubrication 6 Check if any oil leakage In case of leakage please find causes and remove it A Attention Be sure foreign material enters the rear gear case Front gear case oil measurement 1 Place the machine on a level place 2 Remove the oil filler bolt and check the oil level It should be up to the brim of the hole If the level is low
26. LERRALGANOER GOOG amp CFMOTO AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate eWithout first viewing owner s manual and quick start guide eWith more than one passenger eOn hills steeper than 15 degrees eOn public roads eOn paved surfaces pavement may seriously affect handling and control eWith Non CFMOTO approved accessories ALWAYS eKeep hands and feet inside vehicle eReduce speed and use extra caution when carrying a passenger e Operate slowly in reverse avoid sharp turns or sudden braking eMake sure passenger reads and understands all safety labels eWatch for branches or other hazards that could enter vehicle ALWAYS USE AN APPROVED NEVER USE DRUGS HELMET AND PROTECTIVE OR ALCOHOL GEAR Locate and Read Owner s manual Follow all INSTRUCTIONS and WARNINGS If Owner s manual is missing contact a CFMOTO dealer for replacement AWARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could resullt in serious injury or death AWARNING The engine exhaust gas from this product contains CO which is deadly gas and could cause headache giddy disgusting or lose consciousness even death INSTRUCTIONS Thank you for purchasing a CFMOTO vehicle and welcome to join our worldwide family of CFMOTO owners We prou
27. PEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for travelling down hills as described in the owner s manual ANOTE Aspecial technique is required when braking while traveling downhill See page 68 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 26 Operator Safety AWARNING POTENTIAL HAZARD Ne Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning on hills could cause X loss of control or overturn HOW TO AVOID THE HAZARD on Never attempt to turn the ATV around on any hill lh until you ve mastered the turning technique a ad on level ground as described in the owner s manual See page 67 Use extra caution when turning on any hill Avoid crossing the side of a steep hill WHEN CROSSING THE SIDE OF A HILL Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to use uphill side of the ATV 27 Operator Safety AWARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dis
28. all the coolant reservoir hose 9 Fill the recommended coolant into the radiator until it is full When filling coolant at the same time to loosen tapping screw as right picture shows in order to drain potential air bubbles inside the coolant hose until coolant goes out then tighten the screw 24 ANOTE Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Coolant capacity 3 0 L Coolant change 2 9 L Coolant reservoir capacity 0 38 0 6L 106 Maintenance amp Lubrication ACAUTION Hard water or salt water is harmful to the engine Please use CFMOTO recommended coolant 10 Install the radiator cap 11 Start the engine and let it idle for several minutes Stop the engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 12 Fill the coolant reservoir with coolant up to the upper limit 13 Install the coolant reservoir cap and check for coolant leakage ANOTE If any leakage is found have your dealer check the cooling system 14 Install the panels and the front rack 107 Maintenance amp Lubrication e Axle dust boots Check the protective boots for holes or wears If any damage is found have them replaced by your dealer e Spark plug inspection Removal 1 Remove the panel 2 Remove the spark p
29. ated in water that exceeds the footrest level take it to your dealer for service before starting the engine Driving Over Obstacles Be alert Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches AWARNING Severe injury or death can result if your vehicle comes in contact are immediately visible Travel with caution in unfamiliar terrain 84 Operation Driving in Reverse Follow these precautions when operating in reverse 1 Always avoid backing downhill 2 Back slowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing AWARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles ANOTE Your ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed Operation AWARNING Excessive throttle ope
30. cant SAE 10W30 Rear knockle upper and lower pivot Lubrication Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask your dealer to replace them Maintenance amp Lubrication ANOTE Recommended lubricant Lithium soap based grease Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel Wheel installation 1 Install the wheel and the nuts ANOTE eTapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel eThe arrow mark on the tire must point toward the rotating direction of the wheel 122 Maintenance amp Lubrication 2 Lower the ATV so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque ANOTE Wheel nut torque Front 55Nm Rear 55Nm e Battery This machine is equipped with service needless battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult your dealer ANOTE Battery specification 12V 30Ah 123 Maintenance amp Lubrication AWARNING Do not try to remove the sealing caps of the battery cells You may damage the battery A DANGER Avoid contact with skin eyes or clothing Always shield eyes when working near batt
31. cap and then install the panel ANOTE Lowest capacity of coolantreservoir 0 38 L A CAUTION Hard water or salt wateris harmful to the engine You may use soft water if you can not get distilled water A Attention If water is added have your dealer check the antifreeze content of the coolant as soon as possible The radiator fan operation is completely automatic It is switched on or off according to the coolant temperature in the radiator 104 Maintenance amp Lubrication Changing the coolant 1 Place the ATV ona 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 page 107 to prevent coolant from spilling on the footrest 3 Remove the radiator cap 4 Remove the coolant reservoir cap A DANGER After stop the engine you cannot remove cap of radiator immediately Wait fora while to cool down the coolant and then remove radiator cap Otherwise hot coolant will goes out to hurt people nearby 5 Disconnect the hose on the coolant reservoir side and then drain the coolant from the coolant reservoir 6 After draining the coolant thoroughly flush the cooling system with clean tap water 7 Replace the coolant drain bolt washer if it is damaged and then tighten the coolant drain bolt to the specified torque 105 Maintenance amp Lubrication ANOTE Coolant drain bolt tightening torque 10N m 8 Inst
32. cates the total amount of fuel is 19L When the indicator reaches the first point of the red mark fuel should be refilled as soon as possible The red mark indicates that the remaining fuel is only about 4 0L 62 Operation Break In Period The break in period for your new ATV is very important itis not only a simple action for you which is as important as a proper break in stated in manual Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully 63 Operation A CAUTION Do not load or tow cargo during the first 20 hours of use do not operate at full throttle It may damage engine parts or decrease engine life if excessively increase throttle during the first 20 hours of use Do not run engine with throttle over 1 2 open during the first 10 hours of use Do not run engine with throttle over 3 4 open during the first 10 to 20 hours of use Operate this ATV in normal condition after break in period Use of any oils other than those recommended may cause serious engine damage we recommend the use of special oil for 4 stroke engine SAE 15W 40 SG Perform the following procedures before operation 1 Fill the fuel tank with gasoline 2 Put ATV on a level surface to check the oil level Add recommended oil if necessary to maintain the oil level between the minimum and maximum level marks of the dipsticks 3 Drive slowly at first Select an
33. cedure described in this manual 11 Operator Safety e Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual e Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control e Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes e Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads e Always check for obstacles or people behind the ATV before operating in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles 12 Operator Safety e Always use the size and type of tires specified for your ATV and always maintain proper tire pressure e Never modify an ATV through improper installation or use of accessories e Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo
34. dly produce an exciting line of utility and recreational products eAll terrain vehicle ATV e Utility vehicle patrol forest protecting and hunting eMotorcycles and scooters CFMOTO acompany which is specialized in production of liquid cooled engine is the top level supplier in China Compared to same displacement of air cooled engine engine cooling effect is better oil temperature can be adjusted more freely more powerful and lower fuel consumption longer engine working life For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommen dations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the CFMOTO service manual and should be performed only by CFMOTO service dealer and technician Your CFMOTO dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only TABLE OF CONTENTS VIN Nocere ens soasasncicnes oe devs tieeecsedets as saeesbdensevscdeecsesedeweress 5 Operator Safety e eeeeeeeeeeerrererrrerererereererrrreerrrereerereeeeeseeererrrereereeseeres
35. e 100H 12M 3000 Inspect Adjust Initial 750km or 20H Fuel system 100H 12M 1000 maa ot fueltank fuel pumpand Oil filter 100H 12M 3000 Initial change 750km or 20H Radiator 200H 24M 3000 Inspect clean external surfaces Cooling hoses 100H 1000 Inspect Initial 300km or 10H Engine mounts 100H 12M 3000 Inspect Initial 300km or 10H Exhaust pipe and muffler 100H 12M 1000 Inspect 94A Maintenance amp Lubrication Periodic maintenance chart m Ignition coil 100H 12M 1000 Inspect and replace as needed mE ECU 100H 12M 1000 _ Inspect and replace as needed a Inspect for wear routing security apply gt Wirings and cables 100H 12M 1000 dielectric grease to connectors subjected to water mud etc Clutches drive a and driven pulley 100H 12M 3000 _ Inspect clean replace worn parts m Wheel bearings 100H 12M 1600 Inspect and replace as necessary gt Brake fluid 200H 24M 2000 Change every two years Initial 750km or 20H Replace every Spark plug 100H 12M 3000 6000km Idle condition Inspect every component 1300 100r min Inspect periodically adjust when parts are replaced m Toe adjustment gt Auxiliary brake Inspect daily adjust as needed m Headlight aim Adjust as needed 95 Maintenance amp Lubrication Recommended Lube Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning
36. e clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding An approved helmet can prevent a severe head injury 2 Eye protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offers the best protection for your eyes They should be kept clean and be shatterproof design A1 Safety decals and locations Safe riding gear 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 42 Features amp Controls Electrical Switches AWARNING Pressing the override button while the throttle is open can cause loss of control which may result in severe injury or death Always release the throttle before pressing the override button DOverride Button Top speed is normally limited when operating in 4WD LOCK If conditions require more engine power when proceeding press this button to override the speed limiting function See page 47 48 for a detailed explanation about the front diff lock switch and its function Releasing the button restores the speed limiting function Wh
37. efore or while operating an ATV AWARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increase the operator s chance of losing control of the ATV which can result in an accident 19 Operator Safety HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience AWARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving AWARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV 20 Operator Safety WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual AWARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator
38. er The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Turning in the limits the maximum engine power available and decreases the maximum speed of the ATV A CAUTION Do not turn the adjusting screw out more than 12mm 0 47 in Always make sure the throttle lever free play is adjusted to very easily 0 12 0 20 in 57 Features amp Controls e Main Switch Functions of the respective switch positions are as follows The engine can be started only at this position and the headlights and taillight come on when the light switch is on The key can not be removed in this position J All electrical circuits are switched off The key can be removed in this position e Indicator and Warning Lights Four wheel drive indicator aa This indicator comes on when the 2WD 4WD switch is set to the 4WD position This indicator comes on when the 2WD 4WD switch is set tothe 4WD and LOCK 4WD switch is set to LOCK 58 Features amp Controls ANOTE Due to the synchronizing mechanism in the front gear case the four wheel drive indicator may not come on until the ATV starts moving Left Turning Indicator This indicator light comes on when moving the turning switch to tn Pilot Light Indicator 002 This indicator light comes on when moving the head light switch to EQ 3 High Beam Indicator 20
39. er exceed 10 mph 16 km h while towing a load on a level surface Vehicle speed should never exceed 5mph 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill e Do not obstruct the headlight when loading the front rack Load Distribution Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warnings listed on the warning labels and never exceed the specified weights Cargo weight should be mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions 74A Operation 1 Always load the cargo as far forward as possible 2 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 3 Slow down Driving Safely Driving Procedures 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 Start the engine and allow it to warm up apply the brakes then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the brakes 75 Operation 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Making Turns To make
40. eries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Get prompt medical attention EYES Flush with water for 15 minutes and get prompt medical attention Keep batteries away from sparks flames cigarettes or other sources of ignition Ventilate when charging or using in a closed space Battery maintenance 1 When the machine is not used for a month or longer remove the battery and store it in a cool dark place Completely recharge the battery before reinstallation 2 Aspecial battery charger constant voltage ampere or constant voltage is required for recharging battery Use a conventional battery charger may shorten the battery life 3 Always make sure the connections are correct when putting the battery back in the machine 124 Maintenance amp Lubrication e Fuse replacement 1 The main fuse case and the fuse box are located under front top cover 2 If a fuse is blown turn off the main switch and install anew fuse of the specified amperage Then turn on the switches If the fuse immediately blows again consult your dealer Danger Always use a fuse of the specified rating Never use a material in place of the proper fuse 1 Spare fuse 10A 3 fuse 10A 5 Flash relay 7 Start relay 9 Brake light relay 11 2x4 lock relay 13 Headlight relay 2 S
41. es not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operator should complete the certified training course offered by dealer Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual AWARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV 15 Operator Safety WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates anATV Even though achild may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be suscep tible to accident or injury HOW TO AVOID THE POTENTIAL Operation is prohibited for anyone under 16 years of age AWARNING POTENTIAL HAZARD Carrying passengers more than the rated passenger capacity WHAT CAN HAPPEN This is a 2 personATV Only 1 passenger is allowed Carrying 2 or more passengers greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passengers 16 Operator Safety HOW TO AVOID THE HAZARD Never carry 2 or more passengers on this ATV AWARNING POTENTIAL HAZARD Carrying a passenger in the rear rack WHAT CAN HAPPEN A passenger
42. handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo e Never exceed the stated load capacity for this vehicle e Reduce speed e When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving co nditions e Weight distribution in the rear rack should be as far forward and as low as possible Carrying a high load raises the center of gravity and creates a less stable operating condition Reduce load weight when cargo is high When handling off centered loads that cannot be centered secure the load and operate with extra caution e Allloads must be secured before operation Unsecured loads may shift and create unstable oper ating conditions which could result in loss of control of the vehicle Always be sure that the rear rack is lowered 73 Operation e When operating with loads extending beyond the rack Stability and maneuverability may be adv ersely affected causing the machine to overturn e Carrying a load on only the front rack or the rear rack may cause an imbalanced condition and inc reases the possibility of vehicle overturn Balance loads proportionally between the front rack and the rearrack but do not exceed the stated load capacity e Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing down hill e Always attach the tow to the hitch point e The vehicle should nev
43. ile this button is depressed the override indicator light will come on 43 Features amp Controls Headlight Switch The headlight switch consists of 4 positions 20 20 OFF 3002 O When the switch is at this position Hi beam front pilot light tail light license plate light and instrument light are on 20 When the switch is at this position Lo beam front pilot light tail light license plate light and instrument light are on OFF When the switch is at this position tail light license plate light are off 00 When the switch is at this position front pilot light tail light license plate light and instrument light are on Turn Switch Move the switch to lt A left turn light and left turn signal indicator are on Move the switch to gt right turn light and right turn signal indicator are on Hazard Switch Depress the button front turn lights rear turn lights and turn signal indicators on dashboard are on A CAUTION Don t use the headlights with the engine turned off for more than 15 minutes The battery may disc harge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it 44 Features amp Controls Horn Button Press this button the horn will sound Engine Stop Switch When the switch is at the engine shuts off When the switch is at the engine can be started S
44. in your owner s manual This preventive maintenance program is designed to ensure that all critical com ponents on your vehicle are thoroughly inspected at specific intervals The following signal words and symbols appear throughout this manual and on your ATV Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual AWARNING The safety alert symbol indicates a potential personal injury hazard Operator Safety AWARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle ACAUTION A caution indicates a situation that may result in damage to the vehicle ANOTE Anote will alert you to important information or instructions AWARNING Serious injury or death can result if you don t follow these instructions and procedures which are outlined in further detail within your owner s manual e Read this manual and all labels carefully and follow the operating procedures described 8 Operator Safety e Never operate an ATV without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized ATV dealer to find out about the training courses nearest you e Never allow anyone under 16 years of age to operate this ATV e Ne
45. ing on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water AWARNING Leaving the keys in the ignition can lead on unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is notin use AWARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems 35 Operator Safety AWARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death AWARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep comb ustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 36 Safety decals and locations Warning decals have been placed on the ATV for your protection Read and follow the instructions on each decal carefully If a decal becomes illegible or comes off contact your dealer to purchase a replacement
46. irection 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 87 Operation This procedure should be practiced at slow speed many times in a large 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 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 orin tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too al much speed for the sharpness of the turn may cause ean Towards the ATV to tip If the ATV begins to tip over to the outside nedide ot durn while negotiating a turn lean more to the inside It may aA oe also be necessary to gradually let off on the throttle and steer to the outside of the turn to avoid tipping over a Remember Avoid higher speeds until you are thoroughly ah familiar with the operation of yourATV aa 88 Maintenance amp Lubrication Accessories Auxilia
47. ld cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 22 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn Uphill 81 Operation 1 Stop and shift the gear selector lever to the parking position while keeping body weight uphill 2 Shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever shift the gear selector lever to the low gear position and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Shift the gear selector lever to the parking position and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine while holding the brake lever shift the gear selector lever to low gear position 8 Release the brake and proceed slowly controlling speed with the brake until the vehicle is on more level ground Driving Through Water Your ATV can operate through water witha maximum recommended depth equal to the bottom of the footrests Follow these p
48. linder 2 Ignition Coil Malfunction 29 P0505 Idle Speed Control Error 30 P0562 System Voltage Low battery 31 P0563 System Voltage High Battery Troubleshooting Item No Trouble code Trouble Description 32 P0650 MIL Circuit Malfunction 33 P1693 Tachometer RPM Circuit Low Voltage 36 P1694 Tachometer RPM Circuit High Voltage 37 P0317 O2S 2 Circuit Low Voltage 38 P0318 O28 2 Circuit High Voltage 39 P0038 O2S Heater 2 Circuit High Voltage 51 P0037 O28 Heater 2 Circuit Low Voltage 52 P0500 VSS No Signal 60 P0850 Park Neutral Switch Error 61 P0445 CCP short to high 62 P0444 CCP short to low open 147 EPS Trouble Code Table Item No Trouble Code Diagnosis Solution 1 21 Main torque sensor disconnected Check the wiring harness of sensor 2 22 Main torque sensor output error volta ge is too high or low Check the wiring harness of sensor 23 Secondary Sensor disconnected Check the wiring harness of sensor 24 25 Secondary torque sensor output error voltage is too high or low Excessive difference between main and secondary torque Main torque sensor inner fault Check the wiring harness of sensor Check the wiring harness of sensor Replace the Controllor ECU Check the connection of Motor harness 7 32 Abnormal steering assist of motor Replace the controller if the problem is sti
49. ll there 8 33 Current overlod with Controller Replace the Controllor ECU 9 34 No steering assist from one side of motor Replace the Controllor ECU Excessive zero point offset of Electric 10 35 current sensor Replace the Controllor ECU 11 36 Motor voltage abnormal Check wiring harness of motor 148 EPS fault diagnosis and solution Ref No Trouble shooting Possible causes Repair procedures Improper plug connection Check the plugs and connections No steering assist 1 to handlebar Burnt fuse Replace fuse 30A Contact authorized dealer and repl ace the parts Contact authorized dealer for adjus tment or replacement Contact authorized dealer and repl ace the parts Change the terminal connection of the red and black wire Failure of Controller Motor or sensor Asymmetrical steer Improper voltage output from sensor 2 ing assist to left and right turning Controller Motor or sensor break down Wrong connections at motor terminals 3 Steering swing Controilerorsensorbreak down Contact authorized dealer for parts and replacement Low battery Recharge or replace battery L teeri i 4 s i eering Moter breakdown Contact authorized dealer for repla cement Low pressure with Front tires Inflate tires to the required pressure Motor break down Contact authorized dealer for repla cement Steering system parts wear out and big 5 Noise from system clearance exist Replace the related
50. lug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 108 Maintenance amp Lubrication Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate 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 thatis being ridden normally Do not attempt to diagnose such problems yourself 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 electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug ANOTE Specified spark plug DCPR8E NGK Installation Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specifications ANOTE Spark plug gap 0 8 0 9 mm 2 Clean the gasket surface Wipe off any grime from the threads 3 Install spark plug and tighten to specified torque 109 Maintenance amp Lubrication A NOTE Tightening torque of spark plug 20N m 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 4 Install
51. ment tube Fluid Levels Inspect the following levels and change if necessary front gear case rear gear case engine oil brake fluid change every two years or as required if fluid looks dark or contaminated coolant 133 Clean amp Storage Fog the Engine Remove spark plug and add 15 20mI SAE 15W 40 SG engine oil To access the plug hole use a section of clean hose anda small plastic squeeze bottle filled with the pre measured amount of oil A CAUTION Do this carefully If you miss the plug hole oil will drain from the spark plug cavity and appear to be an oil leak Remove plug cap and turn crankshaft to make engine run slowly Oil will be forced in and around the piston piston rings and coating the cylinder with a protective film of fresh oil If you choose not to use the above way perform the following procedure 1 Support the front end of the vehicle so the engine is level or tilted slightly rearward 2 Remove the spark plug rotate the piston to BDC and pour approximately 15 20ml oil into cylinder 3 Remove plug cap and turn crankshaft to make engine rotate slowly 4 Turn engine several times to ensure the coverage of piston rings and cylinder walls 5 Treat the fuel system with Carbon Clean 6 If fuel system Carbon Clean is not used fuel tank fuel pipe and throttle body should be completely drained of gasoline To eliminate any fuel remaining in the fuel pipe 134 Clean amp Storage Lubricate In
52. mounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill IF ALL FORWARD SPEED IS LOST Keep your weight uphill Apply the front brake When fully stopped apply the rear brake as well then shift the gear to parking IF THE ATV BEGINS ROLLING BACKWARDA Keep weight uphill Never apply engine power 28 Operator Safety Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and shift the gear to parking Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See Page 69 AWARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 29 Operator Safety AWARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD O
53. n slippery surface such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control AWARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident 30 Operator Safety HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 63 31 Operator Safety AWARNING POTENTIAL HAZARD Operation the ATV through deep or fasten following water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it is unavoidable to enter water that exceeds the recommended maximum depth see page 70 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply brakes se
54. n smaller hills before attempting larger hills e Always follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery orloose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed 10 Operator Safety e Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible e Always follow proper procedures for crossing the side of a hill 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 ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of asteep hill when possible e Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special proc edure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the pro
55. nd lead to poor brake performance 4 Be careful that water does not enter the master cylinder reservoir when refilling Water will signi ficantly lower the boiling point of the fluid and may result in vapor lock 5 Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid imme diately 6 Have your dealer check the cause if the brake fluid level goes down 117 Maintenance amp Lubrication e Brake fluid change 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 Replace the oil seals every two years Replace the brake hoses every four years e Front 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 DANGER After servicing e Make sure the brakes operate smoothly and that the free play is correct eMake sure the brakes do not drag Make sure the brakes are not spongy eAll air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by your dealer 118 Maintenance amp Lubrication e Rear brake lever free play adjustment The rear brake lever free play should be 0 5 2mm 1 Loosen the locknut 2 Turn the adjusting bolt in direction
56. nking should be as short as possible to preserve battery energy Do not crank the engine more than 10 seconds on each at tempt e f the battery is discharged disassemble the battery to recharge 5 Continue warming up the engine until it idles smoothly before starting the ATV A CAUTION See the Break In Period section prior to operating the engine for the first time 69 Operation e Gear selector operation and reverse driving A CAUTION Before shifting you must return the throttle lever to the closed position and stop the ATV Otherwise the transmission may be damaged Shifting Neutral to High 1 Return the throttle lever to the closed position and stop the ATV 2 Push the button at the right side of gear selector then shift to High by moving the gear selector along the shift guide ANOTE Make sure that the gear selector is completely shifted into position 3 Open the throttle lever gradually Shifting High to Low 1 Return the throttle lever to the closed position and stop the ATV completely 2 Apply the rear brake pedal shift to Low by moving the gear selector along the shift guide 70 mw Oo _ p gt Operation Shifting Lowto High 1 Return the throttle lever to the closed position and stop the ATV completely 2 Push the button at the right side of gear selector then shift to High by moving the gear selector along the shift guide Shifting Neut
57. on type Splashed by pressure 151 Technical specifications Items Specifications Engine oil Type Engine oil volume SAE15W 40 SG Periodic oil change Capacity 3 3L Periodic oil change 3 4L If change oil filter 3 5L If overhaul Rear Axle oil Type SAE15W 40 SG or SAE80W 90 GL 4 Volume 0 25L 0 30L Front axle oil 152 Type SAE15W 40 SG or SAE80W 90 GL 4 Volume Periodic oil change 0 28L Capacity 0 33 L Air filter Paper and wet type element Technical specifications Items Parameters Fuel type 93 octane or above unleaded gasoline Fuel tank capacity 23L Fuel reverse amount 4 0L Throttle type 0800 173000 Spark plug Type DCPR8E or NGK Spark plug gap 0 8 0 9 mm Clutch type Wet and centrifugal automatic Transmission CVT Gear shift Gear shift order Manually L H N R P Transmission CVT ratio 2 88 0 70 Final 1 333 24 18 aie Secondary 1 952 41 21 Total L 43 17 2 529 H 32 28 1 143 R 29 13 2 231 Chassis Frame Steel tube Caster angle 9 52 Kingpin offset 26 5 mm 153 Technical specifications Rear tire Items Parameters Tire Type Tubeless Size Front tire AT26 x 9 12 39J AT26 x 9 14 48J AT26 x 11 12 45J AT26 x 11 14 54J Tire pressure Front tire 45 kpa Rear tire 45 kpa Brake system Front brake Type Double disc Operation Operated by right hand Rear b
58. ons MIL Maliunc on indicator Light 158 TPS Throtle Postion Sensor IACV 4e Ar Control Vave CPS Crankshaft Postion Sensor TTMAP Nanfol Absolute Pressuerarpestris ote Pesse Sensor M a ENDE puncam bina anj Rw vel PR Pw ECU Comet Grey EGU Corrector 2 Back seser aanpapt CFMOTO ZHEJIANG CFMOTO POWER CO LTD No 116 Wuzhou Road Yuhang Economic Development Zone Hangzhou City Zhejiang Province China Fax 0086 571 89265788 Tel 0086 571 89265799 Http www cfmoto com EU1109
59. ontrol accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 77 Operation Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 22 maximum 3 Keep both feet on the footrests 4 Shift your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency action This may 22 Maxinun include quick dismounting of the vehicle If all forward speed is lost Keep your weight uphill Apply the front brake When fully stopped apply rear brake as well then shift gear selector into park position If the ATV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake When fully stopped apply the rear brake as well and then shift gear selector into park position Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described on page 81 78 Operation AWARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 22 maximum Use extreme
60. pare fuse 15A 4 fuse 15A 6 Start relay Il 8 Fuel pump relay 10 4x4 LOCK relay 12 Fan relay 14 Main fuse 30A 125 Maintenance amp Lubrication AWARNING To prevent accidental short circuit turn off the main switch when checking or replacing a fuse e Headlight bulb replacement If aheadlight bulb burns out replace it as follows 1 Remove headlight cover 2 Remove the rubber cover at the rear of the headlight by pulling it off 3 Remove the headlight lock spring 4 Pull headlight bulb out from the headlight bulb holder A DANGER 5 Wait for the bulb to cool before touching or removing it Insert a new headlight bulb into the head light bulb holder and then lock it by spring 6 Install the bulb holder by turning it clock wise 7 Install the headlight cover with the bolts 126 Maintenance amp Lubrication e Headlight beam adjustment AWARNING It is advisable to have your dealer make this adjustment Turn the adjusting screws L can raise or lower the beam Tail brake light bulb replacement If the tail brake light bulb burns out replace it as follows 1 Open rubber cover take out tail light brake and turning light 2 Insert a new tail brake light bulb push it in and the turning it clockwise 3 Install the tail brake light cover with the screws Maintenance
61. parts Improper assembly of steering column or Check and tighten all of bolts meichanical steering assembly parts 149 EPS system EPS indicator on the Dashboard will be on when EPS system is equipped to the vehicle Normally EPS indicator will be on after ignition switch is turned to ON but EPS will not work When the eng ine is started EPS indicator will be off and EPS starts to function Trouble Code Each trouble code consists of 2 digits denoted by the times of long flash and short flash of EPS indicator Times of long flash represent the tens digit Times of short flash represent the single digit Duration of long flash 2 sec Duration of short flash 1 sec Flash interval 1 sec The flash cycle will repeat after EPS indicator turns off for 3 seconds ANOTE Incase of an EPS failure do not disassemble the EPS system Check the wiring for any loosening connection Otherwise please contact an authorized dealer for service 150 Technical specifications Specifications eee CF800 2 Overall Length 2310mm Overall Width 1180mm Overall Height 1340mm Wheel Base 1480mm Minimum ground clearance 270mm Min turning radius 8000mm A e engine oil and 400kg Engine model and type 2V91W Type V twin cylinder 4 stroke liquid cooled 8 valves SOHC Bore x Stroke 91mmxX61 5mm Displacement 800ml Compression ratio 10 3 1 Starting type Electric start Lubricati
62. plication to engage clutch Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the CVT system Clutch malfunction Remove the CVT cover drain the water from CVT Contact your dealer for inspection of clutch components 138 Troubleshooting Engine doesn t turn over Possible Cause Solution Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or throttle Contact your dealer for service Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 5 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer correct spark plug gap or heat range Set gap to specs or replace plugs 139 Troubleshooting EngineStops or loses power Possible Cause Solution Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your dealer 140 Troubleshooting Engine Turns Over Fails to Start Possible Cause Solution Out of Fuel Refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel
63. rake Type Single disc Operation Operated by left hand and right foot Suspension Front suspension Rear suspension Double A arm and independent Double A arm and independent 154 Technical specifications Items Parameters Shock absorber Front shock absorber Rear shock absorber Coil spring Oil damper or Coil spring Gas Oil damper Coil spring Oil damper or Coil spring Gas Oil Wheel travel Front wheel travel 160 mm Rear wheel travel 200 mm Electric system Ignition ECU Flywheel A C magneto Headlight type Head light HS112V 35W 35W 2 Front position light W5W 12V 5Wx2 Tail light Brake light P21 5W 12V 21W 5W x2 Turn light 12V 10W Battery capacity 12V30Ah 155 Technical specifications 156 Items Parameters N indicator light Green 93 LED R indicator light Red 3 LED P indicator light Red 3 LED H indicator light Yellow 3 LED L indicator light Yellow 3 LED Dashboard light LCD Dashboard Turn indicator light Green g3 LED Hi beam indicator light Overriding indicator light 2WD 4WD indicator light Water temp indicator light Fuel indicator light EFI trouble indicator light Blue g3 LED Red 3 LED LCD LCD LCD LCD EPS specification Ref No Item Specification 1 Motor type DC Permanent Magnet Motor 2 Rated vol
64. ral N to Reverse ANOTE The gear selector cannot be shifted into reverse R without applying the rear brake 1 Return the throttle lever to the closed position and stop the ATV completely 2 Apply the rear brake pedal push the button at the right side of gear selector 3 Shift the gear from neutral N to reverse by moving the gear selector along the shift guide Oe 0a pm a ra 71 Operation ANOTE When in reverse the reverse indicator light should be on The indicator light should be on in accordance with actual gear position if the light does not come on ask your dealer to inspect Due to the synchronizing mechanism in the engine the light may not come on until ATV starts moving 4 Check behind for people or obstacles then release the rear brake pedal 5 Open the throttle lever gradually and continue to watch rear while moving backward AWARNING When you shift into reverse make sure there are no obstacles or peois safeple behind you When it is safe to proceed go slowly shifting Reverse to Park 1 Return the throttle lever to the closed position and stop the ATV completely 2 Apply the rear brake pedal 3 Shift from reverse to park by moving the gear selection along the shift guide The others gear selection refer to Page 70 72 Operation e HAULING CARGO AWARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
65. ration Pre Ride Checklist Item Remarks See Page Air filter Inspect clean 110 Air box sediment tube Drain deposits whenever visible Headlamp Check operation 126 Brake light tail lamp Check operation 127 Riding gear Wear helmet gloves protective clothing 41 67 Operation Starting the Engine Starting a Cold Engine AWARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area A CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Starting a Cold Engine 1 Apply the rear brake pedal 2 Turn ignition switch to turn stop switch to ON 3 Shift gear selector into the neutral position ANOTE e When the gear selector is in neutral position if indicator light on dashboard does not come on ask your dealer to inspect its electric circuit or adjust gear shifting system 68 Operation e Engine can be started in any gear if rear brake pedal is applied However it is recommended to shift into neutral or park before starting the engine 4 Completey close throttle lever and start the engine by pushing the start switch e f the engine fails to start release the start switch then push the start switch again Pause a few seconds before the next attempt Each cra
66. ration while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Engine brake will be executed and rear output shaft locked when gear on the parking position Parking on an Incline Avoid parking on an incline if possible If its unavoidable follow these 1 Turn the engine off 2 Place the gear selector to parking position 3 Always block the rear wheels on the downhill side as illustrated 86 Operation TURNING YOUR ATV 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 Aspecial turning 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 AWARNING Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions Operate at aslow speed and allow extra time and distance for maneuvers when in 4WD LOCK DIFF LOCK As you approach a curve slow down and begin to turn the handlebars in the desired d
67. reser senses 6 Safety decals and locations eeeeeeeeeeetesrereerrertrrrereerresrereerrererrrereeeeesrereeeeeeeees 37 Features and Controlse crrcec cee ec eee e tet ee ee een eee ee eee een eee eee eens eee een eee nee eee eee eee ees 43 Operatione cceeecereeeeeeceeeeeeeteeeeee nea eeeeeeeeeeee aa eeeeseaeeeeeeeeeeee aaa eeeeeeeeeses eee eeeaaeens 63 Maintenance amp LUbDriCations 1c crete eee te tee eteete tenet nent ene e tence ee ee Eee ee EE ene EEE EEE 89 Clean amp Storage cceescee estes tee eee eee een eee ne a eee cee eeeeen neces aaa eeeeeaeeeeee eae eeeaeeeeeeeeees 131 Troubleshootimge seseccreeeceeeeeeeeceeeeeeeeeeeceeneeeeeceeeeeeee aa eeesaeeeesseeeeeee ses eee ees 137 Specificatioms ecccereeeeeeeeeeeeecee eee eeecee see eeeeeeceeeeeeeeseeeeeeeeseeeeeeeeeeeaeeeeeeee ene ees 151 Wiring diagrarmre cceeeseeeeeeee cette eee een eee a ee eee cee eeeeee ences aaa eeeceaeeeeenaeeeeeaeeeeeeeaens 158 VEHICLE IDENTIFICATION NUMBER Record your ATV s identification numbers in the spaces provided Remove the spare key and store in a safe place Your key can be duplicated only by mating key blank with one of your existing keys So if both keys are lost the complete lock kits have to be replaced 1 Vehicle identification number Vehicle model number 6 Engine serial number Operator Safety AWARNING Failure to heed the warnings contained in this manual can result in serious
68. rmine the cause or see your dealer Key points of maintenance chart gt Perform these procedures more often for vehicles subjected to severe use E Have an authorized dealer perform these services amp DANGER Improperly performing the procedures marked with a wm could result in component failure and lead to serious injury or death Have an authorized dealer perform these services ei 90 Maintenance amp Lubrication Periodic maintenance chart Perform all services at whichever maintenance interval comes first Maintenance Interval Item Whichever comes first Remarks Hour Calendar Miles km E Steering Pre Ride gt Front suspension Pre Ride Make adjustments as gt Rear suspension Pre Ride nasred TaS FIORE Checklist on page 65 Tire Pre Ride gt Break fluid level Pre Ride p gt Brake lever pedal travel Pre Ride Brake systems Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level gt Airinlet air filter Inspect and clean if necessary gt Air box sediment tube Drain deposits when visible 91 Maintenance amp Lubrication Periodic maintenance chart Check level daily change coolant Every 2 Coolant 50H Daily 1500 years or 6000Km 200H but initial check should be done after 20H or 750Km Wi Check operation apply dielectric Headlight tail light Daily grease
69. roc edures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 82 Operation 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal ANOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 117 The following areas need special attention engine oil transmission oil front and rear gear cases and all grease fittings ANOTE If water has been ingested into the CVT follow the procedure on page 113 for drying out the CVT If your vehicle becomes immersed and it s impossible to take it to your dealer before starting it follow the steps described on page 129 Have the vehicle serviced by your dealer promptly 83 Operation AWARNING Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is oper
70. ry power outlets provide 12V power for operating accessories such as hand held spotlights Please consult with your dealer Periodic maintenance chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts please use genuine parts available from your dealer ANOTE Service and adjustments are critical If you re not familiar with safe service and adjustment proced ures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles or 20 Km per hour Vehicles subjected to severe use must be inspected and serviced more frequently 89 Maintenance amp Lubrication Severe use definition e Frequent immersion in mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue to use and dete
71. spect all cables and lubricate with Cable Lubricant Follow lubrication guidelines in the maintenance section of the service manual to completely grease and lubricate the entire vehicle with All Season Grease Battery Storage Remove battery from the vehicle and ensure that it is fully charged before placing it in storage Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers set the tires to specified air pressure and support the ATV with tires 30 40mm off the ground Be sure the storage area s well ventilated and cover the machine with a ATV cover 135 Clean amp Storage ANOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Transporting the ATV ATV can not be transported with stand up position follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Place the gear into any position except Park position block front and rear wheels to prevent ATV run 3 Never transport ATV with gear in Park position or else engine will be damaged 4 Fix both the front and rear frame of ATV at the same time prevent ATV slide or move during trans portation 5 Be sure the fuel cap oil cap and seat are installed correctly 136 Troubleshooting Drive belt and cover problems
72. table to your comfort AATTENTION After adjustment keep left and right shock absorber balance Optional 2 shock absorber adjustment Rear adjustment procedures Spring adjustment Loosen lock nut Turn adjust nut to proper hardness then tighten lock nut Damping restore adjustment Turn adjuster to SLOW side until to end and counter shifts then turn to FAST side until suitable to your comfort Damping press is not possible to adjust AATTENTION After adjustment keep left and right shock absorber balance 130 Clean amp Storage Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can becleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots ANOTE If warning and safety labels are damaged contact your dealer for replacement We do not recommend the use of a high pressure type car wash system for washing your ATV Ifa high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes warning labels air filter intake system and electric system etc Water is not allowed
73. tage 12V 3 Max Input Current to Controller 35A 4 Motor Power 380 W 5 Max Output Torque 4N m 6 Reducer Type Worm reducer 7 Reduction Ratio 21 8 Max Output Torque from Driver 80N m 9 Torque Sensor Non contact magnetic potentiometer 10 Torsion Rod Rigidity 8 N m 11 Operating Angle Of Torque Sensor 3 12 Operating Temp Range Of EPS Assy 40 60 13 Protection Degree Of EPS Assy lp67 157 Olpe Aam Sith ale eee ea Tun Switch g o m Olmus Ving Litt porestcree sateen BETS Bhi E Eep Set foiea aiga amend gaqtees Wiring Diagram weirs i dyd Ween a ty peas 2va0ah SEE SELEE Wise Al te i iiini a sl wW EY S v DSR Ei ra ks i e Tete i ge Ls coeytrerug en eeeeng sa mo coce pens obs E f ew Red ESRA URSiueed GV Grantsiow YR Yelow Srs Taw wei ange radeon EBr Gk Srenllack SBAB VM Yelowhie GIV GeonWhie GR GreenSlck WBAWhielack U Buellak BNBacuWhte BN BacoYelow WYcMhiniesow Lei green Grey Gl Grenflue GRGroaneed Sb Sky bie WicWhisve RNV Redinte BIR BackRed VIB YeawBlack LWE BlusWhie VB YelowBlack f GRGreonRed GW GrenWhie BuR BrowniRed LBBuelBiack BrG BrounGreen LAR Aght proerRed UG BuerGren WiSWhiotron Ugg greerGraon Laon greer alon 3 Sr Lgh greenbrown G18 GreyBack Ol CrangeBie SbIW Sryouelhie LB BhetBeun GP GrenPurle Abbreviati
74. tarter Switch When the main switch is turned to ON and the engine stop switch is at push this button to start the engine e Brake Front Brake Lever The front brake lever is located on the right handlebar Put it toward the handlebar to apply the front brake A5 Features amp Controls Brake Pedal and Lever Brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar They are based on the same braking system Push down on the pedal or pull the lever toward the handlebar to apply both the front and rear brakes AWARNING Operating the ATV with a spongy brake lever or pedal can result in loss of control which could cause an accident Never operate a spongy feeling brake lever or pedal Always test brake lever travel 46 Features amp Controls master cylinder fluid level before riding When squeezed the lever or pedal should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs Brake Fluid Check the brake fluid level in the front brake master cylinder and in the brake fluid reservoir before each use of the ATV The front brake master cylinder is located on the right handlebar SS The brake fluid reservoir is near the right passanger foot rest The front
75. the spark plug cap 5 Install the panel e Air filter element cleaning There is a check hose at the bottom of the air filter case If dust or water collects in this hose empty the hose and clean the air filter element and air filter case If there s a lot for water please contact your local dealer to check if any water inside crankcase 1 Remove seat and disassemble cover of air filter Remove spring and remove upper cover of air filter 2 3 Remove bolt of pipe clamp 4 Remove air filter element 5 Remove polyurethane foam of filter element Wash the air filter element gently but thoroughly in solvent Squeeze the excess solvent out of the air filter element and let it dry 110 Maintenance amp Lubrication 6 Softly clean dust on filter element 7 Ifnecessary use new filter element to replace A CAUTION Don t use liquid to wash paper filter element 8 Inspect the air filter element and replace it if damaged 9 Install air filter element and connect to hose 10 Install the air filter case cover and be sure to seal ring installed well ANOTE The air filter element should be cleaned every 50 hours It should be cleaned and lubricate more often if the machine is operated in extremely dusty areas Each time air filter element maintenance is performed check the air inlet to the air filter box for obstructions Check the air filter element rubber joint to
76. the throttle body and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine ziti Maintenance amp Lubrication A DANGER Do not start engine without air filter element Not filtered air will entre into the engine and cause engine wearing and damage In addition driving without air filter will also decrease performance and engine overheating Clean spark plug Clean spark plug while muffler and exhaust are in normal temperature 1 Remove nut 2 Remove spark plug arrester from muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts Maintenance amp Lubrication A DANGER When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system e CVT air inlet hose cleaning e f dust or water collects in the V belt cooling duct check e hose remove the hose and clean it CVT cover drain bolt After riding in water deep enough to allow it to enter the V belt case remove this bolt to drain the water from the case AWARNING f water drains from the V belt case after removing the bolt have your dealer inspect the ATV as
77. to 12 5 VDC 142 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean or Rich Fuel Mixture Cause See your dealer Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your dealer Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel 143 Troubleshooting Engine Stops or Loses Power Possible Cause Solution Out of fuel refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low batter
78. to advance the minutes EFI Indicator 45 This indicator light comes on when troubles occur in EFI system Refer to page127 for detailed information Oil Pressure Warning Indicator 46 This indicator comes on when the oil capacity or oil pressure is not enough with RPM over 1000rpm In this case please add oil If this indicator light still goes on after enough oil added please check the sensor meter and lubrication system Dashboard Coolant Temperature Indicator When the temperature indicator is in the red area of side H it indicates that the temperature is high In that case please stop the engine until the coolant temperature goes down In case the temperature frequently goes high check coolant capacity or consult the local dealer Features amp Controls A CAUTION The engine may overheat if the ATV is overloaded If this happens reduce the load to specification After restarting make sure that the temperature indicator is in the green area of side C Continuous use while the temperature indicator is in the red area of side H may cause damage to the engine Speedometer shows the riding speed In ODO mode press and hold SET to toggle between KM and MP ODO TRIP RPM Toggle Press and release SET totoggle among ODO mode TRIP mode RPM mode In TRIP mode press and hold SET to return the trip display to zero Fuel Gauge Indicate the remaining amount of the gasoline in the fuel tank F indi
79. to increase free play andin direction to decrease free play 3 Tighten the locknut If correct free play cannot be obtained ask your dealer to make that adjustment Be sure not to step on the brake pedal e Make sure the brake pedal does not move 119 Maintenance amp Lubrication e Rear brake padal hight adjustment ANOTE Adjust the rear brake before inspecting the rear brake pads The top of the brake pedal should be positioned110 120mm above the top of the footrest If not ask your dealer to adjust it A DANGER After servicing eMake sure the brakes operate smoothly and that the free play is correct eMake sure the brakes do not drag eAll air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by your dealer e Rear brake light switch The rear brake light switch which is activated by the brake pedal and brake levers is properly adju sted when the brake light comes on just before braking takes effect 120 Maintenance amp Lubrication e Rear brake light switch Check switch assembly or cable is properly fixed in case light failure Cable inspection and lubrication A DANGER 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 ANOTE Recommended lubri
80. ver permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course e Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants e Never consume alcohol or drugs before or while operating an ATV e Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience e Never attempt wheelies jumps or other stunts e Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Operator Safety e Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation e Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain conditions e Never operate on excessively rough slippery or loose terrain e Always follow proper turning procedures as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds e Always have the ATV inspected by an authorized dealer if it s been involved in an accident e Never operate on hills too steep for the ATV or for your abilities Practice o
81. veral times to dry out the pads 339 Operator Safety AWARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN TheATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safety to proceed back slowly AWARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the owner s manual for the ATV Always maintain proper tire pressure 33 Operator Safety AWARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine parts or equivalent components designed for use on this ATV and should be installed and used according to approved instructions Consult your dealer for more information 34 Operator Safety AWARNING POTENTIAL HAZARD Operat
82. witch is setto LOCK the front diff lock indicator light will flash until the front diff is locked eWhen the indicator light is flashing turning the handlebar left and right will help the front gear lock to engage eRiding before the front diff lock is properly engaged e g when the indicator light is flashing will cause the engine speed to be limited until engagement is complete eWhen the ATV is in 4WD LOCK the maximum traveling speed is limited to 35 km h 22 mph However if conditions require full engine power to be available depress the override switch to disable the 4WD LOCK speed limiter A Features amp Controls e 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 itis operating smoothly Make sure it returns to the idle position as soon as the lever is released ACAUTION Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult your dealer if you can t find or solve the problem yourself 56 Features amp Controls Speed Limit
83. y voltage Recharge battery to 12 5 VDC Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer 144 Troubleshooting PCODE LIST PCODE uses 4 digit flashing ForExample 0650 0 flashes 10 times 6 flashes 6 times 5 flashes 5 times 0 flashes 10 times Item No Trouble code Trouble Description 1 P0107 MAP Circuit Low Voltage or Open 2 P0108 MAP Circuit High Voltage 3 P0112 IAT Circuit Low Voltage 7 P0113 IAT Circuit High Voltage or Open 9 P0117 Coolant Oil Temperature Sensor Circuit Low Voltage 10 P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open 11 P0122 TPS Circuit Low Voltage or Open 12 P0123 TPS Circuit High Voltage 145 Troubleshooting 146 Item No Trouble code Trouble Description 13 P0131 O2S 1 Circuit Low Voltage 14 P0132 O2S 1 Circuit High Voltage 15 P0032 O2S 1 Heater Circuit High Voltage 16 P0031 O2S 1 Heater Circuit Low Voltage 17 P0201 Injector 1 Circuit Malfunction 18 P0202 Injector 2 Circuit Malfunction 19 P0230 FPR Coil Circuit Low Voltage or Open 20 P0232 FPR Coil Circuit High Voltage 21 P0336 CKP Sensor Noisy Signal 22 P0337 CKP Sensor No Signal 23 P0351 Cylinder 1 Ignition Coil Malfunction 24 P0352 Cy

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