Coleman 800ATV-2 Owner'S Manual Download

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Periodic Maintenance and Adjustment 8-23

1. Air filter element

5. Remove the air filter element from its
frame.

1. Frame 2. Air filter element

6. Wash the air filter element gently but

thoroughly in solvent.

WARNING

Never clean the filter cartridge with

gasoline, clean it with professional

cleaning solvent.

7. Squeeze the excess solvent out of the air
filter element and let it dry.

NOTE

Do not twist the air filter element when

squeezing it.

8. Inspect the air filter element and replace it
if damaged.

9. Apply foam air filter oil to the air filter
element.

CAUTION:

The air filter element should be wet with filter

oil but not dripping

10. Pull the air filter element over its frame.

11. Install the air filter element.

Summary of Contents for 800ATV-2

Page 1: ...POWERSPORTS OWNER S MANUAL 888 405 8725 Coleman Powersports 364 S Smith Rd Tempe AZ 85281 No one under the age of 16 should operate this ATV 800ATV 2...

Page 2: ...Owner Manual...

Page 3: ...operation or maintenance of your ATV please contact Coleman Powersports toll free 888 405 8725 IMPORTANT SAFETY MESSAGES READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE...

Page 4: ...the following symbols The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ATV operator a bystander or...

Page 5: ...TV can be started Please see page 6 2 on the warming up process When the temperature is higher than 100 F 38 and you park the ATV after operating at high speeds keep the engine running for 3 minutes a...

Page 6: ...ometer and Trip Meter Modes 4 4 Clock time adjustment 4 5 Fault Code indicator 4 7 Fuel Fuel level indicator 4 7 Left Handlebar Switches 4 8 Throttle Lever 4 13 Speed Limiter 4 15 Foot brake pedal all...

Page 7: ...off the engine 6 2 Drive Select Lever Operation and Reverse Driving 6 3 Neutral to Reverse Low 6 4 Shifting between 2WD and 4WD 6 5 Braking Parking brake Engine break in ATV break in Braking system b...

Page 8: ...Coolant Replacement 8 16 Axle Boots 8 19 Spark Plug Inspection 8 19 Air Filter Element Cleaning 8 21 Spark Arrester Cleaning 8 25 V belt Cooling Duct Check Hose 8 26 V belt Case Drain Plug 8 26 Valve...

Page 9: ...n of EPS system EPS system s inspection maintenance repair Malfunction assortment 9 1 9 1 9 1 9 2 9 3 9 3 9 4 9 4 9 10 9 10 9 12 9 15 9 16 To drive ATV at every time need to do daily inspection of EPS...

Page 10: ...Owner Manual...

Page 11: ...r from the date of purchase shown on the original sales receipt What is a Defect The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 1 year from...

Page 12: ...oleman Powersports A COPY OF YOUR SALES RECEIPT IS REQUIRED FOR WARRANTY SERVICE What this Warranty Does Not Cover This warranty does not cover the following 1 Damage due to lack or improper maintenan...

Page 13: ...sonal items Length of Implied Warranties Any implied warranties are limited to the duration set forth in this warranty Coleman Powersports does not make any claim as to the merchantability or fitness...

Page 14: ...Location of the Warning and Safety Labels 1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS...

Page 15: ...understand all of the labels on your ATV They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or come...

Page 16: ...Location of the Warning and Safety Labels 1 3...

Page 17: ...1 4 Location of the Warning and Safety Labels...

Page 18: ...Location of the Warning and Safety Labels 1 5...

Page 19: ...r instruction Take a Training Course Beginners should receive training from a certified instructor Always follow the age recommendation A child under 16 years old should never operate an ATV with an e...

Page 20: ...bars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operatin...

Page 21: ...ght down a hill where possible Brake carefully when necessary braking when going downhill may cause the ATV to roll rear end over Always follow proper procedures for crossing the side of a hill as des...

Page 22: ...d Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember wet brakes will reduce brake performance Test your brakes after leaving water If necessary...

Page 23: ...Never refuel in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the ATV in another vehicle be sure it is...

Page 24: ...ZARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operat...

Page 25: ...ndle bar 6 air filter 7 front seat 8 rear seat 9 back rest 10 carrier 11 rear bumper 12 front bumper 13 front carrier 14 front sundry box 15 ignition switch 16 auxiliary dc plug 17 steering bar part 1...

Page 26: ...ification number vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen...

Page 27: ...on number is used to identify your machine Model label The model label is affixed at the location shown in the illustration Record the information on this label in the space provided This information...

Page 28: ...spective positions are as follows 1 Ignition switch 2 OFF 3 ON ON The engine can be started only in this position and the headlights and taillights can be turned on when the light switch is on OFF All...

Page 29: ...Coolant temperature gauge 11 Engine Oil Pressure 12 Battery Charge indicator Low gear range indicator L This indicator light comes on when the drive select lever is in the L position High gear range...

Page 30: ...ngine as soon as possible when it is safe to do so and allow the engine to cool down for about 15 minutes CAUTION The engine may overheat if the ATV is overloaded If this happens reduce the load to sp...

Page 31: ...eedometer which shows the speed an odometer which shows the total distance covered a tripometer which can be cleared and then show any new distances traveled an RPM indicator which shows the revolutio...

Page 32: ...information will enable you to judge the fuel consumption To change the display from miles per hour to kilometers per hour press the right side button on the display This will also change the display...

Page 33: ...is locked When riding an ATV on muddy and slippery roads or when climbing a steep hill make sure the 4WD lock indicator is on When riding on a flat road at a comparatively high speed adjust the setti...

Page 34: ...e than one fault code they will be shown in rolling sequence When fault codes are present in order to see the time press the clock button the time will be shown Then after five seconds the fault code...

Page 35: ...to turn on the high beams Set the switch to OFF to turn off all the lights Set the switch to to turn on the parking lights and the taillights NOTE Do not use the headlights more than fifteen minutes i...

Page 36: ...ll times to stop the engine especially in an emergency The engine will not start or run when the emergency stop switch is set to Horn button Press this button The horn will sound Emergency flasher but...

Page 37: ...4WD LOCK switch 4 Wheel Drive selector switch To change from two wheel drive 2WD to four wheel drive 4WD depress the gray button on the selector switch 4 Wheel Drive LOCK switch To lock the rear diff...

Page 38: ...e only provides power to the rear wheels There are no symbols shown on either of the 4WD indicators At this time even if the surfaces are different the two rear wheels will rotate at the same speed 4...

Page 39: ...d to handle The operator could lose control HOW TO AVOID THE HAZARD Always completely stop the ATV before changing from 2WD to 4WD or from 4WD to 4WD LOCK 2WD 4WD selection 1 Selection lever switch 2...

Page 40: ...ARD When driving too fast with DIFF LOCK on WHAT CAN HAPPEN Four wheels will rotate at the same speed It is extremely difficult to turn It is easier to lose control of the ATV HOW TO AVOID THE HAZARD...

Page 41: ...e hard to operate making the ATV difficult to speed up or slow down when needed which could cause an accident HOW TO AVOID THE HAZARD Check the throttle lever before starting the engine If it does not...

Page 42: ...sting screw a No more than 12 mm WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter WHAT CAN HAPPEN The throttle cable could get damaged The ATV may go out of control The operator may h...

Page 43: ...ever is located on the left side of the handlebar Holding the lever tightly will stop the ATV Holding the lever down you may be able to set the latch to maintain the ATV brake in the on position Holdi...

Page 44: ...gear to ANY other gear The ATV will start when the gear shift is in Neutral N or when the left handle bar lever is applied and the Park P illuminates on the display 1 Drive select lever Fuel tank cap...

Page 45: ...r seat lock lever 2 After removing the rear seat press the lock catch pull up the front seat to remove it 1 Rear seat 2 Front seat lock lever 3 Front seat CAUTION To install the seat insert the projec...

Page 46: ...awstring to open the front sundry box 1 Front sundry box REAR SUNDRY BOX The rear sundry box is located under the rear plastic cover Pull up the drawstring to open the rear sundry box 1 Rear sundry bo...

Page 47: ...se the ATV may be out of balance and effect the driver s control of the ATV Front rear shock absorber adjustment The spring preload can be adjusted to match the rider s weight and riding conditions NO...

Page 48: ...load adjust the shock absorber to be the stiffest it will go WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stabilit...

Page 49: ...ion A Minimum soft E Maximum hard 1 Special wrench Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV by the ignition switch The auxiliary DC jack can be used for wo...

Page 50: ...which turns off all the lights 2 Start the engine See pages 6 1 6 2 3 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 4 When the auxiliary DC jack is not being us...

Page 51: ...ut the engine running or with the headlights turned on the battery will lose its charge and starting the engine may become difficult Do not use an automotive cigarette lighter or other accessories wit...

Page 52: ...il if necessary P5 6 Coolant reservoir Check the coolant level in the reservoir Fill with coolant if necessary P5 7 P5 8 Front Rear Differential Check for any leaks Check the oil level fill with oil i...

Page 53: ...r any fault codes on the panel repair the EFI system if necessary P12 1 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN This i...

Page 54: ...they catch or feel spongy have a dealer inspect the brake system Brake Pads Check the brake pads for wear or damage and that they are within limits See pages P8 28 P8 29 Disc Brake Rotor Check the di...

Page 55: ...ry HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not ride the ATV if you find any problems with the brakes If a problem cannot be corrected by the adjustment procedures...

Page 56: ...or pinging occurs use a different brand of gasoline or premium unleaded fuel Gasohol This ATV is equipped with an EFI system which ensures this ATV can attain the EPA and EEC standards The EFI parame...

Page 57: ...p any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and it is still very hot Engine oil Make sure the engine oil is at the...

Page 58: ...d hypoid gear oils may also be used Coolant Use the specialized antifreeze engine coolant Check the coolant level in the coolant reservoir when the engine is cold The coolant level will vary with engi...

Page 59: ...ntifreeze coolant Coolant reservoir capacity up to the maximum level mark 0 627 L 0 555 Imp qt 0 663 US qt WARNING POTENTIAL HAZARD Removing the radiator cap while the engine and radiator are still ho...

Page 60: ...ing condition Repair as necessary for proper operation Switches Check the operation of all switches Have a dealer repair as necessary for proper operation Idling High idle speed may cause engine damag...

Page 61: ...6PR 2 The tires should be inflated to the recommended pressure Recommended tire pressures Front 10 psi 0 70kgf cm 2 69 kpa Rear 10 psi 0 70kgf cm 2 69 kpa Check and adjust tire pressures when the tire...

Page 62: ...speeds under 62 mph 100 km h How to measure tire pressure Use the low pressure tire gauge which can be found in the ATV tool kit package 1 Low pressure tire gauge NOTE The low pressure tire gauge is...

Page 63: ...10 psi 0 70kpf cm 2 69 kpa 9psi 0 63kpf cm 2 62kpa 11psi 0 77kpf cm 2 76kpa Rear 10 psi 0 70kpf cm 2 69 kpa 9psi 0 63kpf cm 2 62kpa 11psi 0 77kpf cm 2 76kpa Tire wear limit When the tire tread height...

Page 64: ...er Starting a cold engine WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AV...

Page 65: ...ine refer to the Starting a cold engine section Warming the engine To obtain the maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To correctly...

Page 66: ...ngine to return to idle otherwise the transmission may be damaged Shifting Neutral to High and High to Low 1 Bring the ATV to a complete stop and allow the throttle lever to return to idle Wait for th...

Page 67: ...on on the left side of the gear shift handle 1 Bring the ATV to a complete stop and return the throttle lever to the idle position Wait for the engine to drop below 1400 rpm Apply the brakes 2 Press i...

Page 68: ...5 Apply the throttle lever gradually and continue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind...

Page 69: ...pecial attention to the following points 1 Leave enough distance for braking 2 Longer braking distance is needed when an ATV is operated at a higher speed 3 Longer braking distance is needed when the...

Page 70: ...urn to normal the ATV should not be operated 2 If the brake performance degrades you should slow down your ATV and apply the brakes repeatedly to dry them Only after the braking performance returns to...

Page 71: ...rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the ATV to a stop by applying the brakes 2 Shift the gear select...

Page 72: ...ATV Do not overload it Do not speed up quickly Always keep your speed below 25mph 40 km h After the break in period your ATV will perform better CAUTION For the first three hours if you run your engin...

Page 73: ...e operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load will not harm the engine Each full...

Page 74: ...fter the break in period Rapid brake application before the break in period may harm the brake pads Break in is required when new brake pads or brake rotors are installed Modifications Improper instal...

Page 75: ...d cargo on the carriers as close to the center of the vehicle as possible Put the cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down...

Page 76: ...rgo improperly WHAT CAN HAPPEN Will cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properl...

Page 77: ...le activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skills necessary to enjoy riding safely Before you begin to ri...

Page 78: ...requires skills acquired through practice over a period of time Take the time to learn the basic techniques and master them before attempting more difficult maneuvers No person under the age of 16 sh...

Page 79: ...e passenger on this ATV WHAT CAN HAPPEN The extra passenger s could reduce your ability to balance and control this ATV This could lead to an accident resulting in harm to you and or your passenger s...

Page 80: ...Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and incre...

Page 81: ...fits properly You should also wear eye protection goggles or a face shield gloves boots long sleeved shirt or a jacket long pants Do not operate an ATV or any vehicle after consuming alcohol or drugs...

Page 82: ...operation checks Always perform the pre operation check list on page 5 1 before riding This is for your safety and proper care of the ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before op...

Page 83: ...HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle on pages Always maintain proper tire pressure as described in the Owner s Manual WARNING POTENTIAL HAZARD Op...

Page 84: ...maximum throttle application and therefore the maximum available engine power This will decrease the top speed of the ATV Turning the screw in decreases top speed and turning it out increases top spe...

Page 85: ...load Front carrier 44 lbs 20 kg Rear carrier 77 lbs 35 kg Storage box 6 5 lbs 3 0 kg Trailer hitch Pulling load 1213 lbs f 550 kgf Tongue weight 33 lbs f 15 kgf Vertical weight on the trailer hitch p...

Page 86: ...emove a foot from the footboard your foot or leg may come into contact with the rear wheels or objects outside of the ATV which could injure you or cause an accident HOW TO AVOID THE HAZARD Always kee...

Page 87: ...on of accessories or modification of this vehicle may cause changes in handling and loss of control which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV wit...

Page 88: ...tem WHAT CAN HAPPEN Dry grass or brush or other combustible material accumulated around the engine area could catch fire Someone touching the exhaust system during or after operation could be burned H...

Page 89: ...terrain and for other hidden hazards which may cause the ATV to roll over WARNING You can come upon hidden rocks bumps or holes without enough time to react This could result in the ATV overturning o...

Page 90: ...turn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these t...

Page 91: ...no trespassing Do not ride on private property without obtaining permission Caution Select a large flat area off road to become familiar with your ATV Make sure that this area is free of obstacles ve...

Page 92: ...in contact with these components With the engine idling move the gear shift lever to the low position L or the high position H Apply the throttle slowly and smoothly The centrifugal clutch will engag...

Page 93: ...action the ATV will resist turning A special turning technique must be used to allow the ATV to make turns quickly and easily It is essential that this skill be mastered first at low speeds WARNING PO...

Page 94: ...the turn This maneuver will allow the wheels on the inside of the turn to slip slightly allowing the ATV to make the turn smoothly This procedure should be practiced at slow speeds several times in a...

Page 95: ...id higher speed turning maneuvers until you are thoroughly familiar with the operation and feel of your ATV Climbing uphill Use proper riding techniques to keep your ATV from overturning on hills Be s...

Page 96: ...y could cause loss of control or cause the ATV to overturn Always follow proper procedures for climbing hills as described in this Owner s Manual Always check the terrain carefully before you start up...

Page 97: ...ATV requires you to properly position your weight to maintain proper balance Be sure that you have mastered the basic riding skills on flat ground before attempting to cross a sloped surface Avoid slo...

Page 98: ...careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as de scribed in the Owner s Manual Avoid hills wi...

Page 99: ...have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the si...

Page 100: ...ain This means applying either the front brake or the rear brake will brake all the wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side...

Page 101: ...ould cause the vehicle to lean sharply to one side Go straight down the hill where possible Crossing through shallow water The ATV can be used to cross slow moving shallow water of up to a maximum of...

Page 102: ...Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Test your brakes after...

Page 103: ...tom of the air filter case V belt cooling duct and the gear shift lever box Also remove the V belt case drain plug to drain any water that may have accumulated Wash the ATV in fresh water if it has be...

Page 104: ...the ATV may result WARNING Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow p...

Page 105: ...d of time skill at controlled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are reduced Bear in mind that sliding ma...

Page 106: ...o the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn 3 If your ATV starts to slide sideways Steer in the direction of the slide if you have...

Page 107: ...in balance If you feel that the ATV is definitely going to tip over get off quickly on the uphill side 6 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watchi...

Page 108: ...ied Have a dealer perform service if you are not familiar with servicing an ATV WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accesso...

Page 109: ...ta and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km Mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 Hours 20 75 150 150 300 Valves Check valve clearan...

Page 110: ...talyzer Check the exhaust Replace the muffler if necessary oil filter Check for leaks around the seal Replace it if necessary Engine filter element Clean Replace if necessary Engine oil strainer Clean...

Page 111: ...sed grease Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary Lights and Switches Check operation Adjust headlight beams Since this may require special tools data and...

Page 112: ...of advanced parts such as an ECU EFI wires sensors and an implementation system Parts are shown below 1 Oxygen sensor 2 Oxygen sensor threaded sleeve 3 Exhaust pipe 1 high voltage wire 2 ignition sig...

Page 113: ...tion Tap To inject the fuel into the cylinder Inlet temperature sensor To monitor the air intake temperature to the engine Based on the temperature the ECU automatically adjusts the fuel injection Inl...

Page 114: ...ignal At the center of the EFI system this model adopts a specially designed microcomputer chip controller which controls the injection quantity by calculating the information gathered by the sensors...

Page 115: ...g the engine oil level 1 Place the ATV on a level surface 2 Start the engine to warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil settles 4 Remove the engine oil f...

Page 116: ...he dipstick into the oil filler hole and then tighten the oil filler cap Replacing the engine oil with or without oil filter cartridge replacement 1 Start the engine Warm it up for several minutes and...

Page 117: ...e the oil filter skip step 4 6 5 Apply a light coat of engine oil to the O ring of the new oil filter CAUTION Make sure to select the correct style filter with the proper sized O ring 1 O ring 6 Insta...

Page 118: ...of the recommended oil Replace the dipstick and tighten it Recommended oil Oil quantity Oil filler not replaced 1 97 US qt 1 67 lmp qt 1 9L Oil filler replaced 2 08 US qt 1 76 lmp qt 2 0L CAUTION In...

Page 119: ...check the oil level and fill it if necessary Final gear oil The final gear case must be checked for oil leaks before each ride If any leaks are found have a dealer check and repair the ATV Replacing t...

Page 120: ...s the final gear case when you check or change oil 6 Install the filler bolt and tighten it to the specified torque Tightening torque Final gear oil filler bolt 17ft lbf 2 3m kgf 23 Nm 7 Check for oil...

Page 121: ...rque Differential gear oil filler bolt 17 ft lbf 2 3m kgf 23 Nm Replacing the differential gear oil 1 Place the ATV on a level surface 2 Place a container under the differential gear case to collect t...

Page 122: ...hen tighten it to the specified torque Tightening torque Differential gear oil filler bolt 17 ft lbf 2 3m kgf 23 Nm 6 Check for oil leaks If an oil leak is found check for the source Cooling system 1...

Page 123: ...You may use soft water if you cannot get distilled water CAUTION If soft water is added have a dealer check the antifreeze content of the coolant as soon as possible The radiator fan operation is comp...

Page 124: ...olt Use a trough or a similar object as shown to prevent coolant from spilling on the footrest 1 Trough 3 Remove the radiator cap 1 the radiator cap 4 Remove the coolant reservoir cap 5 Disconnect the...

Page 125: ...radiator until it is full and then install the radiator cap Recommended antifreeze High quality ethylene glycol antifreeze Containing corrosion inhibitors for aluminum engines Antifreeze and water mi...

Page 126: ...found have a dealer check the cooling system Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by a dealer 1 Front axle boot 2 each side 1 Rear axle b...

Page 127: ...rode is a medium to light tan color for an ATV that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to a dealer You should periodically remove and inspe...

Page 128: ...f 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...

Page 129: ...filter case check hose 1 Remove the cover panels on the right side of the fuel tank 2 Remove the air filter from the ATV 3 Loosen the fasteners Remove the air filter case cover 1 Fasteners 2 Air filt...

Page 130: ...ine clean it with professional cleaning solvent 7 Squeeze the excess solvent out of the air filter element and let it dry NOTE Do not twist the air filter element when squeezing it 8 Inspect the air f...

Page 131: ...filter element maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber connection to the carburetor and manifold fittings for an airti...

Page 132: ...he bolts 2 Remove the tailpipe and the spark arrester by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove all carbon deposits from the spark arrester portio...

Page 133: ...belt cooling duct check hose Left side V belt cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and clean it V belt case drain plug After riding...

Page 134: ...engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional service technician Throttle lever adjustment NOTE ADJUSTING METHOD...

Page 135: ...for removal and installation procedures Brake fluid level checking Insufficient brake fluid may allow air to enter the brake system possibly causing the brakes to become ineffective Before riding che...

Page 136: ...mful chemical reaction and lead to poor brake performance 4 Be careful that water does not enter the master cylinder reservoirs when refilling Water will significantly lower the boiling point of the f...

Page 137: ...Replace the brake hoses every four years Change parts immediately if they are broken or leaking Front brake lever free play The front brake lever should have a free play of zero mm zero in at the lev...

Page 138: ...brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by a dealer Adjusting the parking...

Page 139: ...brake light switch activated by the brake pedal is properly adjusted and that the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Turn the...

Page 140: ...se an accident leading to personal injury If the cable cannot be smoothly pushed in or pulled after cleaning and lubricating replace the cable RECOMMENDED SAE10W30 ENGINE OIL Lubricating the brake lev...

Page 141: ...34 Periodic Maintenance and Adjustment 1 Rotation point 2 1 Rotation point 1 Rotating point Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gu...

Page 142: ...the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheels 4 Remove the wheels 1 Nut 4 Wheel installation 1 Install the wheel and the tapered nut NOTE The arrow mark on the...

Page 143: ...2 ft lbf 7 5m kgf 75 Nm Rear 55 42 ft lbf 7 5m kgf 75 Nm Battery This ATV is equipped with a sealed type battery Therefore there is no need to check the electrolyte or add distilled water to the batte...

Page 144: ...the acid far away from your skin eyes and clothes When you work near the battery wear eye protection Keep the children far away from the battery EXTERNAL Flush with water INTERNAL Drink a lot of water...

Page 145: ...tery back in the ATV Fuse replacement 1 The ignition fuse and the fuse box are located under the seat 2 If a fuse is blown turn off the ignition switch and the switch for the circuit in question Then...

Page 146: ...15A 10A 10A 5A 10A 15A 5A WARNING Using a wrong fuse will damage the electrical system possibly causing a fire NOTE To prevent an accidental short circuit turn the ignition switch off when checking o...

Page 147: ...ulb allow enough time for it to cool 5 Insert a new headlight bulb into the bulb holder by pushing it in CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise th...

Page 148: ...tall the bulb holder by pushing it in and turning it clockwise 7 Install the bulb holder cover and the cover at the rear of the headlight Replacing a taillight 1 Remove the taillight cover 1 Rubber sl...

Page 149: ...older 3 Remove the burned out bulb from the bulb holder by pushing it inward and turning it counterclockwise 4 Install a new bulb in the bulb holder by pushing it inward and turning it clockwise 5 Ins...

Page 150: ...nance requires special techniques If you encounter a problem which you cannot solve please contact a dealer WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT C...

Page 151: ...roken Repair and touch up paint as necessary 2 Replace any damaged body panels 3 Re paste on stickers and install the warning placards with rivets 2 The skid plate is damaged by an object 1 Check if t...

Page 152: ...heck whether the rotors or the disc brake pads have worn beyond limits or contaminated by oil or other material which could reduce the brake performance 3 Check if any brake lines are leaking 4 Check...

Page 153: ...t wear between the left and right side 2 Check if the brake force for the front brake has been reduced allowing the rear wheels to lock before the front wheels during braking 3 Check if there is a dif...

Page 154: ...maged 3 Check to see if the wires are damaged 3 Rear axle gearbox is inoperative 1 Check and be sure the control switch for 2WD 4WD on on the display panel is working properly 2 Check if electromagnet...

Page 155: ...front wheels and the front wheel axles are loose or damaged 3 Check to see if the internal splines on the front wheel hub or the outer splines of the front wheel axle are worn abraded or damaged 4 Ch...

Page 156: ...formed or become weak over time 3 Check and be sure the damping force is present during compression and extension of shock absorber 6 Abnormal sounds from front rear axle during operation 1 Check to s...

Page 157: ...power reduction 1 Check and see if a cylinder is not working 2 Check to be sure that an injector is NOT blocked 3 Check and clean the air filter element 4 Check to see if the muffler is blocked and cl...

Page 158: ...not start 1 Check to see if the battery charge is sufficient to make the starter motor crank 2 Check to see if the starter motor is damaged 3 Check to be sure the EFI system works properly 4 Check and...

Page 159: ...any problems during operation or maintenance please feel free to consult your local dealer ADVANTAGES OF EPS SYSTEM 1 High efficiency A traditional hydraulic power steering system is mechanical and h...

Page 160: ...on so the impact of road barriers on the steering wheel is greatly decreased 5 No pollution to environment For the traditional hydraulic power steering system the hydraulic circuit has hydraulic hoses...

Page 161: ...ATV can be taken to a service center for the correct maintenance procedures INTRODUCTION OF EPS SYSTEM What is EPS system The EPS system Electric Power Steering System is a complete set of parts inclu...

Page 162: ...sensor Temperature sensor Battery voltage sensor Mechanical reduction transmission mechanism Reducer Steering Stem Tie Rod and Ball Joint Ball Knuckle Steering Spline Connection Sleeve Steering Arm C...

Page 163: ...educer If it is found that the sensor position was changed caused by loose bolts tighten the bolts and initialize the ECU at once 3 ECU The ECU is a sophisticated electronic piece of equipment and con...

Page 164: ...shell and the surrounding environment The membrane also prevents moisture intrusion Do not remove or replace the membrane by other parts On the shell of the ECU unit there are cables with electric pl...

Page 165: ...Electric Power Steering System 9 7 4 Reducer installation Install the reducer on the frame of the ATV Install the motor and steering torque sensor on reducer Outside view of reducer...

Page 166: ...ks together with EPS system and monitors the working condition of the EPS system Faults can be displayed by the fault indicator light and the fault code indicator of the EPS system so the driver can a...

Page 167: ...code Fault style Fault indica tor light of EPS syste m 1 F00001 1 fault of steering torque sensor lit 2 F00002 2 fault of steering torque sensor lit 3 F00006 ECU overheating lit 4 F00005 low voltage...

Page 168: ...s Assemble your new ATV according the assembly instructions During assembly and installation of battery make sure the main switch ignition key is off 1 Main switch CAUTION If main switch is not off th...

Page 169: ...e Negative Wire Of EPS System Terminal Terminal CAUTION If all plug connectors are not hooked up on the ECU when the main switch ignition key is turned on the EPS may always be on off during ATV drivi...

Page 170: ...m 1 Fault indicator of EPS system CAUTION Driving the ATV with a faulty EPS system may cause an accident severe injury or even death Never operate ATV with a faulty EPS system Function of EPS system T...

Page 171: ...ltage can damage the battery Lack of voltage can also affect the reliability of the vehicles electrical system With the reduction of battery voltage the steering torque of the EPS system will be reduc...

Page 172: ...speed but also on the steering torque exerted by the driver If the driver is to impose a smaller steering torque power torque of the EPS system will be relatively small This can achieve an outstanding...

Page 173: ...ont panel cover and unplug the outlet which supplies power to the EPS system See page12 3 Take the ATV to a service center for repair of the EPS system as soon as possible EPS SYSTEM S INSPECTION MAIN...

Page 174: ...ht on the consol The ECU will then send 1 steering torque sensor fault or 2 steering torque sensor fault code to the consol When the ECU detects the storage battery s voltage is lower than 9VDC throug...

Page 175: ...roperly Inspect handlebars make sure all bolts are tight Move steering left and right inspect for looseness or squeaking If a defect is found repair or replace Steering wheel s range of free clearance...

Page 176: ...t front wheel alignment and proper beam offset Adjust if necessary see alignment instructions in this manual Turn the main switch keyed switch to the ON position Turn the handlebars left and right suc...

Page 177: ...ng System 9 19 Turn the Handlebars left to right then right to left turning should be smooth no binding no recoil forces opposite of operating force If any problems are found take your ATV to an autho...

Page 178: ...Service center for repair 3 Meter warning fault code F00005 Low voltage in storage battery Charge storage battery replace if necessary 4 Meter warning fault code F00003 Motor is damaged or drive circu...

Page 179: ...n connector 2 Power steering only works turning left or it only works turning right when the main switch turned on S N Fault phenomenon Fault point Solution 1 No meter alarm ECU damaged Service center...

Page 180: ...stem has gaps Steering system mechanical parts become loose or damaged Retighten loose bolts Replace damaged parts 2 Mechanical portion of steering works but when ECU is on the steering has gaps ECU d...

Page 181: ...arameters 3 No meter alarm EPS system s speed reducer damaged Service center for repair 5 Power steering works to turning left or right but steering becomes heavy S N Fault phenomenon Fault point Solu...

Page 182: ...sensor changed Replace sensor or go to service center for repair 2 No meter alarm Power steering is different when turning from left to right Mechanical steering system s parts are damaged Adjust rep...

Page 183: ...steering to the same direction automatically S N Fault phenomenon Fault point Solution 1 No meter alarm Sensor is loose To dealers for repair 2 No meter alarm Sensor is not loose The initialization pa...

Page 184: ...turn on the main switch ignition key check whether the fault is removed on the consol If it is not removed follow the previous steps of the initialization process Because of the different mechanical c...

Page 185: ...nical parameters EPS system working conditions 1 Working environment temperature 40 85 2 Working voltage 9 16V DC 3 The seal type IP65 4 Input shaft rotation angle large than 45 5 Wheel rotation speed...

Page 186: ...9 28 Electric Power Steering System Rated operational current 35A 3A Rated output torque 1 8N m 0 16N m...

Page 187: ...use a small brush to clean it away Use a garden hose to rinse CAUTION The use of high pressure sprayers power washers car wash sites can damage the ATV Water can enter seals wheel bearings and electr...

Page 188: ...umerous times to dry out brake pads Storage If storing ATV 60 days or longer it is important that the ATV be prepared for storage to prevent damage to the unit Drain and refill with fresh clean oil as...

Page 189: ...hin coat of oil Make sure oil does not get on any rubber parts or the seat cover of the ATV Remove and fully charge the battery Keep the battery in a dry place Charge battery once a month for battery...

Page 190: ...2 510mm 48 0 in 1 220mm 54 7 in 1 390mm 35 4in 900mm 58 7 in 1490mm 12 2 in 310mm 97in 2480mm Basic weight With oil and full fuel tank 926 lb 420kg Engine Engine type Cylinder arrangement Displacemen...

Page 191: ...API Service SE SF SG type or higher CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specific...

Page 192: ...US qt 0 10 L 0 08 Imp qt Radiator capacity including all routes 2 64 US qt 2 50 L 2 20 Imp qt Air filter Wet type element Fuel Type Fuel tank capacity Fuel reserve amount UNLEADED GASOLINE ONLY 5 3 U...

Page 193: ...n system Secondary reduction system CVT reduction ratio Transmission type Operation Reverse gear Sub transmission ratio Low High CVT belt Shaft drive 0 68 2 7 CVT belt automatic Right hand operation 5...

Page 194: ...ront suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Re...

Page 195: ...rning light Park indicator light High range indicator light Low range indicator light Differential gear lock indicator light 12 V 30 W 30 W 2 12 V 5 W 21 W 1 LED LED LED LED LED LED LED Fuses Dash boa...

Page 196: ...uit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 P0117 Coolant Oil Temperature Sensor Circuit Low Voltage KsDGDM_CoolantShortLow 117 279...

Page 197: ...n KsDGDM_INJ_CYL_B_Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor...

Page 198: ...DM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56 P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_N...

Page 199: ...ed pollutant Where a warrantable condition exists HISUN will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part...

Page 200: ...ach new 2013 HISUN brand off road vehicle A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Pr...

Page 201: ...of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the HISUN dealer HISUN shall not be li...

Page 202: ...by the owner However HISUN is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any...

Page 203: ...POWERSPORTS 888 405 8725 Coleman Powersports 364 S Smith Rd Tempe AZ 85281...

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