Coleman HS500ATV Owner'S Manual Download

Page: 7 / 193

Owner Manual

Coolant

5-7

Throttle lever

5-8

Fittings and Fasteners

5-8

Lights

5-8

Switches

5-8

Tires

5-9

How to Measure Tire Pressure

5-10

Tire Wear Limit

5-11

Operation

6-1

Starting a Cold Engine

6-1

Starting a Warming Engine

6-2

Warming Up

6-2

Drive Select Lever Operation

and Reverse Driving

6-2

Engine Break-In

6-5

Parking

6-7

Parking on a Slope

6-7

Accessories and Loading

6-8

Your Vehicle

7-1

Driving Your Vehicle

7-1

Ride With Care and Good

Judgment

7-1

Apparel

7-4

Speed Limiter

7-8

Loading and Accessories

7-8

During Operation

7-9

Modifications

7-11

Exhaust System

7-11

Be Careful Where You Ride

7-12

Turning Your ATV

7-18

Climbing Uphill

7-21

Riding Downhill

7-26

Crossing a Slope

7-28

Crossing Through Shallow

Water

7-29

Riding Over Rough Terrain

7-32

Sliding and Skidding

7-33

Periodic Maintenance and

Adjustment

8-1

Summary of Contents for HS500ATV

Page 1: ...POWERSPORTS OWNER S MANUAL 888 405 8725 Coleman Powersports 1775 E University Dr Tempe AZ 85281 colemanpowered com No one under the age of 16 should operate this ATV HS500ATV Model ...

Page 2: ...Owner Manual ...

Page 3: ...ledge needed to have safe and enjoyable ATV operation If you have any questions regarding the operation or maintenance of your ATV please consult the dealer IMPORTANT SAFETY MESSAGES READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE THE ATV WITHOUT PROPER TRAIN...

Page 4: ... following notations The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or cl...

Page 5: ...e ATV can be started Please see page 6 3 on the warming up process When the temperature is higher than 38 100 F and when you park the ATV after it has ran at high rpms keep engine running for 3 minutes at idle This will allow the radiator fan to work for 3 minutes to prevent coolant from boiling Once ATV has ran for 3 minutes at idle turn ignition switch completely off When parking the ATV and tur...

Page 6: ...ent 4 6 Four wheel drive indicator 4 6 Differential gear lock indicator 4 7 Fault code indicator 4 8 Fuel level indicator 4 8 Handlebar Switches 4 9 Throttle Lever 4 14 Speed Limiter 4 15 Front Brake Lever 4 17 Brake Pedal and Rear Brake Lever 4 17 Drive Select Lever 4 18 Fuel Tank Cap 4 18 Seat 4 19 Storage Compartment 4 19 Front Carrier 4 20 Rear Carrier 4 21 Front and Rear Shock Absorber Adjust...

Page 7: ... 5 Parking 6 7 Parking on a Slope 6 7 Accessories and Loading 6 8 Your Vehicle 7 1 Driving Your Vehicle 7 1 Ride With Care and Good Judgment 7 1 Apparel 7 4 Speed Limiter 7 8 Loading and Accessories 7 8 During Operation 7 9 Modifications 7 11 Exhaust System 7 11 Be Careful Where You Ride 7 12 Turning Your ATV 7 18 Climbing Uphill 7 21 Riding Downhill 7 26 Crossing a Slope 7 28 Crossing Through Sha...

Page 8: ... 35 V belt Cooling Duct Check Hose 8 36 V belt Case Drain Plug 8 37 Valve Clearance Adjustment 8 37 Select Lever Safety System Cable Adjustment 8 38 Throttle Lever Adjustment 8 38 Front Brake Pad Check 8 38 Checking the Rear Brake Pads 8 39 Checking the Brake Fluid Level 8 39 Brake Fluid Replacement 8 41 Front Brake Lever Free Play 8 41 Adjusting the Rear Brake Lever 8 42 Adjusting the Brake Pedal...

Page 9: ...eam Adjustment 8 53 Tail Brake Light Bulb Replacement 8 53 Check and Solution to Common Problems in Vehicle 8 55 Cleaning and Storage 9 1 Cleaning 9 1 Storage 9 3 Specifications 10 1 Fault code of Electronic Injection System 11 1 USA EPA Emissions Limited Warranty 12 1 9 10 11 12 ...

Page 10: ...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 the date of purchase shown on the sales receipt During this period of time Coleman Powersports will at its option either repair or replace any original Coleman Powersports part that is covered by this warran...

Page 11: ...al of Coleman 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 maintenance as described in this manual 2 Damage that is caused by normal use and not caused by a defect in materials or workmanship 3 Use of the product that is not consistent with the intended use as ...

Page 12: ...tems 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 for a particular purpose that would extend longer than the duration of this written warranty Check your state laws as some state laws do not allow limitations as to the duration of an implied warranty Some s...

Page 13: ...Location of the Warning and Safety Labels 1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 14: ...nderstand all of the labels on your machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your dealer ...

Page 15: ...Location of the Warning and Safety Labels 1 3 ...

Page 16: ...1 4 Location of the Warning and Safety Labels ...

Page 17: ...Location of the Warning and Safety Labels 1 5 ...

Page 18: ...instructions Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper training or instruction Take a Training Course Beginners should receive training from a certified instructor Always follow the age recommendation A child under 16 years old should never operate an ATV with engine size greater than 90cc Never allow a child under a...

Page 19: ...mpt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Al...

Page 20: ...le suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the h...

Page 21: ...ever attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at slow speeds and on level smooth terrain On extremely slippery surfaces such as ice go slow and be very cautious in order to r...

Page 22: ...specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking ...

Page 23: ...ARD Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation ...

Page 24: ...oking or while 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 kept upright Otherwise fuel may leak out of the fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you swallow some gasoline or inhale a lot of gasolin...

Page 25: ...Description and Vehicle Identification 3 1 ...

Page 26: ...rs will be needed for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER VIN 2 MODEL NUMBER 3 KEY IDENTIFICATION NUMBER Vehicle identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number NOTE The vehicle identification number VIN is used to identify your vehicle ...

Page 27: ... the respective switch positions are as follows 1 Main switch ON The engine can be started only at this position and the headlights and taillight come on when the light switch is on OFF All electrical circuits are switched off The key can be removed in this position ...

Page 28: ... Mechanical parking brake indicator light 11 Position indicator 12 Far light indicator Low Range Indicator Light L This indicator light comes on when the drive select lever is in the L position Mechanical Parking Brake Indicator Light This indicator light comes on when the mechanical parking brake is applied High Range Indicator Light H This indicator light comes on when the drive select lever is ...

Page 29: ...is safe to do so and allow the engine to cool down for about 15 minutes CAUTION The engine may overheat if the vehicle is overloaded If this happens reduce the load to specification After restarting make sure that the light is out Continuous use while the light is on may cause damage to the engine High beam indicator The light being on means headlight is at high beam mode Position light indicator ...

Page 30: ...curs in the EPS system the fault indicator light will light up At the same time the fault indicator of the EPS system will display the fault code for maintenance When the ignition switch is turned to the ON position the EPS system will automatically enter into its working state Check the meter If the fault indicator light of the EPS system is not lit the ATV can be used for regular use If the faul...

Page 31: ...edometer which shows the speed an odometer which shows the total distance covered a trip meter which can be cleared and then show any new distances traveled an RPM indicator which shows the revolutions per minute of the engine a clock an EFI fault code indicator which shows the fault code for problems with the EFI Odometer and trip meter modes On the display panel there are two large buttons one l...

Page 32: ...ter can also be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to judge 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 displayed mileage from miles to kilometers Clock time adjustment Press the left button and hold for three seconds a...

Page 33: ...n the lever is moved to the right and the yellow differential gear lock button is set to out position which means the differential is not operational and 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 settings to 2WD UNLOCK were there are no symbols in ...

Page 34: ...U will send the fault code to the instrument display and it will flash on the clock If there are more 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 returns again Only after the fault is fixed will the time show automatically The description for the...

Page 35: ... indicator 2 Fuel level warning indicator Handlebar switches 1 Light switch OFF 2 Start switch 3 Left right turning switch 4 Engine stop switch 5 Horn switch 6 Emergency light switch Light switch OFF Set the switch to to turn on the low ...

Page 36: ...l not operate properly If this should happen remove the battery and recharge it Start switch The starter motor cranks the engine when this switch is pushed CAUTION See starting instructions prior to starting the engine See pages 6 1 6 3 for details Left right turning light switch Lighten the Left right turning light respectively Engine stop switch Make sure that the engine stop switch is set to be...

Page 37: ...ar left right turning light blink simultaneously On Command four wheel drive and differential gear lock switches 1 On Command four wheel drive switch 2WD 4WD 2 Differential gear lock switch LOCK 4WD This ATV is equipped with an On Command four wheel drive switch 2WD 4WD and a differential gear lock switch LOCK 4WD Select the appropriate drive according to ...

Page 38: ...ZARD Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD Differential UNLOCK in some circumstances Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while moving may cause the vehicle to unexpectedly handle differently This could distract t...

Page 39: ...e select lever is set to position and then set the switch to 4WD When the vehicle is in 4WD the 4WD indicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle and then set the switch to 2WD the 4WD indicator will go out in the multi function display Differential gear lock switch LOCK 4WD 1 Differential gear lock switch LOCK 4WD 2 Select lever ...

Page 40: ...h to 4WD WARNING POTENTIAL HAZARD Riding too fast while the vehicle is in 4WD LOCK WHAT CAN HAPPEN All wheels turn at the same speed when the differential is locked so it takes more effort to turn the vehicle The amount of effort required is greater the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HA...

Page 41: ...position as soon as the lever is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine If it does not work smoothly check for the cause Correct the problem b...

Page 42: ... No more than 12 mm 0 47 in WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the throttle lever free play is adjusted to 3...

Page 43: ...handlebar to apply the front brake 1 Brake lever Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar Push down on the pedal or pull the lever toward the handlebar to apply the rear brake 1 Brake pedal 1 Parking brake lever ...

Page 44: ...ct lever is used to shift your machine into the low high neutral reverse and park positions Refer to pages 6 2 6 4 for the drive select lever operation 1 Drive select lever Fuel tank cap Remove the fuel tank cap by turning it counterclockwise 1 Fuel tank cap ...

Page 45: ...e rear 1 Seat 2 Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear NOTE Make sure that the seat is securely filed 1 Projection 2 2 Seat holder 2 Storage compartment The storage compartment is located under the seat ...

Page 46: ...s in the storage compartment be sure to wrap them in a plastic bag so that they will not get wet When washing the ATV be careful not to let any water enter the storage compartment 1 Storage compartment Front carrier Front carrier Maximum load limit 20kg 44lb 1 Front carrier ...

Page 47: ...justed to suit the rider s weight and riding conditions NOTE When adjusting the rear shock absorber the rear wheels need to be removed See pages 8 47 8 48 for removal and installation procedures Adjust the spring as follows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction b ...

Page 48: ...ntrol Functions 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a dealer to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Special wrench ...

Page 49: ...just the shock absorbers on the left and right side to the same setting Auxiliary DC jack The auxiliary DC jack is located at the front right side of the ATV The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack should only be used while the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the ...

Page 50: ... cap CAUTION Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the ...

Page 51: ... necessary 5 6 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 24 8 29 Final gear oil Differential gear oil Check for leakage 5 6 5 7 8 21 8 23 Throttle Check for proper throttle cable operation and free play 5 8 8 38 Wheels and tires Check tire pressure wear and damage 5 9 5 11 8 47 8 48 Fittings and fasteners Check all fittings and fasteners 5 8 Lights and...

Page 52: ...d schedules described in the Owner s Manual Front and rear brakes Brake levers and brake pedal Check that there is no free play in the front brake lever If there is free play have a dealer adjust it Check for correct free play in the rear brake lever If the free play is incorrect adjust it See page 8 42 8 43 Check for correct brake pedal height If the pedal height is incorrect have a dealer adjust...

Page 53: ...cted by a dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brake pads for wear See page 8 38 8 39 WARNING POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Alwa...

Page 54: ...use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol The ATV uses an electric fuel injection system and its emissions completely meet the requirements of re...

Page 55: ... severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and ...

Page 56: ...cified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase Recommended engine oil type and quantity See page 10 2 Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 21 8 22 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may ...

Page 57: ...ngine temperature The coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add distilled water to bring the level up to maximum level mark Change the coolant every two years See pages 8 25 8 26 for details 1CAUTION Hard water or salt water is harmful to the engine You may use soft wate...

Page 58: ...eck to see that the throttle lever operates correctly It must open smoothly and spring back to the idle position when released Have a dealer repair as necessary for proper operation Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to a dealer or refer to the Service Manual for correct tightening torque specifications Lights Check th...

Page 59: ...ommended tire pressure Front 10psi 70kpa 0 7 kgf cm 2 Rear 10psi 70kpa 0 7 kgf cm 2 Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 9psi 63 kpa 0 64kgf cm 2 Rear 9psi 63 kpa 0 64kgf cm 2 4 Use no...

Page 60: ... use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifications Recommended pressure Minimum Maximum Front 10psi 70kpa 0 70kgf cm 2 9 psi 63kpa 0 64kgf cm 2 11psi 77kpa 0 77kgf cm 2 Rear 10psi 70kpa 0 70kgf cm 2 9 psi 63kpa 0 64kgf cm 2 11psi 77kpa 0 77kgf cm 2 1 Low pressure tire gauge ...

Page 61: ...Pre Operation Checks 5 11 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit ...

Page 62: ...ask your dealer 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 AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Apply the rear brake pedal 2 Turn the main switch to ON and the engi...

Page 63: ... to operating the engine for the first time Starting a warm engine To start a warm engine refer to the Starting a cold engine section The throttle should be opened slightly Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To make sure the engine is warm start off with one third throttle for the first 3km 1 86 miles or let ...

Page 64: ...t the drive select lever is completely shifted into position 3 Open the throttle lever gradually Shifting Neutral to Reverse NOTE The drive select lever cannot be shifted into or from reverse or park without applying the rear brake 1 Bring the ATV to a complete stop and return the throttle lever to the closed position 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park ...

Page 65: ...V starts moving 4 Check behind for people or obstacles and then release the brake pedal 5 Open 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 you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obsta...

Page 66: ... Do not operate at full throttle or high speeds during the first three hours of use Use of any engine oil not mentioned in this manual will cause severe damage to the engine Engine Break In There is never a more important period in the life of your vehicle than the period between zero and 25hours For this reason we ask that you carefully read the following material Because the engine is brand new ...

Page 67: ... operate it at one set throttle position 10 25 Hours Avoid prolonged operation above 3 4 throttle Rev the vehicle freely but do not use full throttle at any time After Break In The vehicle can now be operated normally Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors C...

Page 68: ...lines If you must park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the machine to a stop by applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the...

Page 69: ...unted An accessory which will shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability to control the ATV Examples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the se...

Page 70: ...ht on trailer hitch point 30kg 66lbf Do not exceed the maximum tongue weight You can measure tongue weight with a bathroom scale Put the tongue of the loaded trailer on the scale with the tongue at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load car...

Page 71: ...turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of the ATV WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly WHAT CAN HAPPEN Could 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...

Page 72: ...ctivity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve the skill necessary to enjoy riding safely Before you begin to ride be sure you have read this Owner s Manual completely and understand the operation of the controls Pay particular attention to the safety information on pages 2 1 2 7 Please also read all caution and war...

Page 73: ...ng your ATV requires skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Not recommended for children under 16 years of age WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe inj...

Page 74: ...ssenger on this ATV WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers ...

Page 75: ... 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 increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your chances of severe injury in the event of an accident ...

Page 76: ...ycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket long pants Do not operate after consuming alcohol or drugs Operator s performance capability is reduced by the influence of alcohol or drugs ...

Page 77: ...TV Pre operation checks Always perform the pre operation checks listed on page 5 1 before riding for safety and proper care of the ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure ...

Page 78: ...E 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 on page 5 13 WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE...

Page 79: ...rew in decreases top speed and turning it out increases top speed 1 Locknut 2 Adjusting screw Loading and accessories Use extra caution when riding the ATV with additional loads such as accessories or cargo The ATV s handling may be adversely affected Reduce your speed when adding additional loads MAXIMUM LOADING LIMIT Vehicle loading limit 235kg 518 lb Total weight of cargo rider and accessories ...

Page 80: ... 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 greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer During operation Always keep your feet on the footboards during operation Otherwise your feet may contact ...

Page 81: ...leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Avoid wheelies and jumping You may lose control of the ATV or overturn WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an a...

Page 82: ...uine or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized ATV dealer Exhaust system The exhaust system on the ATV is very hot during and following operation To prevent burns avoid touching the exhaust system Park the ATV in a place where pedestrians or children are not likely to touch it WARNING...

Page 83: ...e likely to touch it BE CAREFUL WHERE YOU RIDE This ATV is designed for off road use only Riding on paved surfaces can cause loss of control WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces WHAT CAN HAPPEN ATVs are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Al...

Page 84: ...hicles WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways ...

Page 85: ... POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the A...

Page 86: ...PPEN Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD 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 kinds of terrain ...

Page 87: ...NOT use the flag pole bracket as a trailer hitch WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the ATV to make you more visible Watch carefully for other vehicles ...

Page 88: ...rakes shifting procedures and turning techniques in this area before trying more difficult terrain Always avoid riding on paved surfaces the ATV is designed for off road use only and handling maneuvers are more difficult to perform on pavement Shift to the parking position P and follow the instruction on page 6 1 to start the engine Once it has warmed up you are ready to begin riding your ATV Reme...

Page 89: ...er use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident 1CAUTION Do not shift from drive position low L to high H or vice versa without coming to a complete stop Damage to the engine or drive train may occur TURNING YOUR ATV To achieve maximum traction while riding off road in 2WD or 4WD the two rear wheels turn together at the same ...

Page 90: ...t for your skills or the conditions Operate at a slow 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 direction As you do so put your weight on the footboard to the outside of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain ...

Page 91: ...the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a turn lean more to the inside It may also be...

Page 92: ...rfaces or obstacles that might cause you to lose control WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills It is impo...

Page 93: ... follow proper procedures for climbing hills as described in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or perso...

Page 94: ... HAPPEN Could cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you 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 side of a hill Always follow proper procedures as desc...

Page 95: ... If you are in 2WD apply only the front brake When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or rear brak...

Page 96: ...ed Keep weight uphill Apply the brakes Shift to the parking position P after you are stopped If you begin rolling backwards Keep weight uphill 2WD Never apply the rear brake while rolling backwards Apply the front brake 4WD or 4WD LOCK Apply both front and rear brakes gradually When fully stopped shift to the parking position P Dismount on uphill side or to a side if pointed straight uphill Turn t...

Page 97: ...these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either th...

Page 98: ...ls as described in this Owner s Manual Note a special technique is required when braking as you go down a hill HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible ...

Page 99: ...uphill When riding on slopes be sure not to make sharp turns either up or down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you wish to travel WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of contro...

Page 100: ...ht to the uphill side of the ATV CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shallow water of up to a maximum of 35 cm 14 inches in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly and carefully ...

Page 101: ... HAZARD Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply brakes several times to let friction dry out the linings Test your brakes after leaving the water Do not continue to ride your ATV without verifying that you have regaine...

Page 102: ...hose at the bottom of the air filter case the V belt cooling duct check hose and the drive select lever box check hose 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 been operated in salt water or muddy conditions 1 Air filter case check hose ...

Page 103: ...IN Riding over rough terrain should be done with caution Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident Be sure to keep your feet firmly mounted on the footboards at all times 1 V belt case drain plug 1 Drive select lever box check hose ...

Page 104: ...or obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide If unexpected and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels...

Page 105: ...ing 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 maneuvers should always be avoided on extremely slippery surfaces such as ice since all control may be lost WARNING POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain tra...

Page 106: ...t over the front wheels for better control See pages 7 18 7 20 2 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 7 18 7 20 3 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommende...

Page 107: ...balance If the ATV starts to tip steer down the hill if there are no obstacles in your way to regain balance If you discover that the ATV is going to tip over dismount on the uphill side 6 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come ou...

Page 108: ...e while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have a dealer perform service if you are not familiar with machine service Owner s manual and tool kit It is recommended to place this ow...

Page 109: ...n requiring one take your machine to the dealer to check the torque settings and adjust them as necessary WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through im...

Page 110: ... 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 clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Crankcase breather system Check breathe...

Page 111: ...ssary Engine oil strainer Clean Drive chain Check and adjust slack alignment clean lube Brakes Check operation fluid leakage See NOTE Correct if necessary Clutch Check operation Adjust if necessary Wheels Check balance damage run out Replace if necessary Wheels bearings Check bearing assemblies for looseness damage Replace if damaged Steering system Check operation Repair if damaged Check toe in A...

Page 112: ...steners Correct if necessary Lights and a witches Check operation Adjust headlight beams Meter Checking if the function is complete and instruction isaccurate Science these lets require special tools data and technical skills Have the dealer perform the service NOTE Recommended brake fluid DOT4 Brake fluid replacement When disassembling the master cylinders or calipers replace the brake fluid Norm...

Page 113: ...of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel B 3 Panel C 1 Panel D 2 Panel E 3 Panel F 4 Panel G Panels A and D To remove 1 Remove the seat See page 4 17 for seat removal and installation procedures 2 Pull outward on the area shown and then ...

Page 114: ...aintenance and Adjustment pull upward as shown 1 Panel A 1 Panel D To install 1 Insert the panel projections in the numerical order shown in the illustration and then push inward on the area shown 2 Install the seat ...

Page 115: ...tment 8 8 1 Panel A Panel B To remove Remove the bolts To install Place the panel in the original position and install the bolts 1 Panel B 2 Bolt 2 CAUTION When installing the panel be sure not to pinch the cables or wires 1 Panel D ...

Page 116: ...9 Periodic Maintenance and Adjustment Panel C To remove 1 Remove the front carrier by removing the stay covers at the rear then by removing the bolts 1 Front carrier stay cover 2 1 Bolt 2 top 1 Bolt 2 top ...

Page 117: ...lace the panel in the original position and install the quick fasteners 2 Install the front carrier by installing the bolts and tightening them to the specified torques Tightening torques Carrier bolt top 26 Nm 2 6m kgf 19ft lbf Carrier bolt under fenders 7 Nm 0 7m kgf 5 1ft lbf 2 Install the stay covers 1 Quick fastener 2 2 Panel C ...

Page 118: ...Adjustment Panel E To remove Remove the bolts and then take the panel off To install Place the panel in the original position and then install the bolts 1 Panel E 2 Bolt 6 Panel F To remove Pull outward on the areas shown 1 Panel F ...

Page 119: ...d Adjustment 8 12 To install Place the panel in its original position Panel G To remove 1 Remove the seat See page 4 19 for seat removal and installation procedures 2 Remove the rear carrier by removing the bolts 1 Bolt 4 top ...

Page 120: ...y installing the bolts and tightening them to the specified torques Tightening torques Carrier bolt top 26 Nm 2 6m kgf 19ft lbf Carrier bolt under fenders 7 Nm 0 7m kgf 5 1ft lbf 3 Install the seat EFI system An EFI engine is completely different from an engine which uses carburetor An EFI engine consists of ECU EFI cables sensors actuators and other advanced components As the following pictures i...

Page 121: ...Periodic Maintenance and Adjustment 8 14 1 oxygen sensor assy 2 oxygen sensor threaded sleeve 3 exhaust Pipe 1 ECU 1 high voltage wire 2 ignition signal plug 3 ignition coil ...

Page 122: ... Adjustment 1 fuel injector 2 water temperature sensor 3 intake air temperature sensor pressure sensor 1 idle speed stepper motor 2 air damper degree sensor 3 air damper Air damper For the purpose of adjustment of air intake volume ...

Page 123: ... different negative pressure and opening of air damper Adjust the engine fuel injection volume can adjust the output power and output torque Water temperature sensor For testing cooling water temperature according to the temperature difference ECU will automatically revise water injection volume to ensure the smooth operation of the engine all the time Ignition signal Ignition signal arising from ...

Page 124: ...paratus cable 2 EFI cables Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart To check the engine oil level 1 Remove panel F See page 8 11 for panel removal and installation procedures 2 Place the ATV on a le...

Page 125: ...to check the oil level NOTE The engine oil should be between the minimum and maximum level marks 1 Maximum level mark 2 Minimum level mark 7 If the engine oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level 8 Insert the dipstick back into the oil filler hole and tighten filler cap 9 Install the panel ...

Page 126: ... an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip steps 5 9 if the oil filter cartridge is not being replaced 5 Remove panels D and E See pages 8 6 8 7 and 8 11 for panel removal and installation procedures 6 Remove the oil filter cartridge with an o...

Page 127: ...of engine oil to the O ring of the new oil filter cartridge NOTE Make sure the O ring is seated properly 1 O ring 8 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7m kgf 12ft lbf ...

Page 128: ... 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 13 Turn the engine off and then check the oil level and correct it if necessary 14 Install panel F Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a dealer check and repair the ATV Replacing t...

Page 129: ...f 17ft lbf 5 Fill the final gear case with the specified amount of the recommended oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25 L 0 22 Imp qt 0 26 US qt CAUTION Be sure no foreign material enters the final gear case 6 Install the filler bolt and tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3m kgf 17ft lbf 7 Check for oil leakage I...

Page 130: ...ential gear oil 2 Differential gear oil filler bolt 3 Correct oil level CAUTION Be sure no foreign material enters the differential gear case 3 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3m kgf 17ft lbf Replacing the differential gear oil 1 Place the ATV on a level surface 2 Place a container...

Page 131: ...tial gear case with the recommended oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 28 L 0 25 Imp qt 0 3 US qt CAUTION Be sure no foreign material enters the differential gear case 6 Install the differential gear oil filler bolt and then tighten it to the specified torque Tightening torque Differential gear oil filler bolt 23 Nm 2 3m kgf 17ft lbf Cooling system 1 Place the ATV o...

Page 132: ...ve panel D See pages 8 6 8 7 for panel removal and installation procedures remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then install the panel 1 Coolant reservoir tank cap 2 Maximum level mark 3 Minimum level mark Coolant reservoir capacity up to the maximum level mark 0 3 L 0 26 Imp qt 0 32 US qt CAUTION Hard water or salt water is harmful to the en...

Page 133: ... still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap 1 Place the ATV on a level surface 2 Remove panels E and F See pages 8 11 for panel removal and installation p...

Page 134: ...nd panel C See pages 8 9 for removal and installation procedures 1 Radiator cap 5 Remove the radiator cap 6 Remove panel D See pages 8 6 8 7 for panel removal and installation procedures 7 Remove the coolant reservoir cap 8 Disconnect the hose on the coolant reservoir side and then drain the coolant ...

Page 135: ... 1 0m kgf 7 2ft lbf 11 Install the coolant reservoir hose 12 Pour the recommended coolant into the reservoir to the maximum level mark and then install the reservoir cap and panel D 13 Pour the recommended coolant into the radiator until it is full and then install the radiator cap Recommended antifreeze High quality ethylene glycol antifreeze Containing corrosion inhibitors for aluminum engines A...

Page 136: ...and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 15 Check for coolant leakage NOTE If any leakage is found have a dealer check the cooling system 16 Install the panels and the front carrier 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 sid...

Page 137: ... 1 Spark plug cap 1 Spark plug wrench 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 that is being ridden normally Do not attempt to diagnose such problems yourself ...

Page 138: ...specified plug Specified spark plug DR8EA NGK Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 023 0 027 in 0 6 0 7 mm 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque a Spark plug gap Tightening torque Spark plug 17 5 Nm 1 75m kgf 12 7...

Page 139: ... 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 1 Air filter case check hose 1 Remove the seat See page 4 19 for seat removal and installation procedures 2 Remove the air filter case cover by unhooking the holders 3 Remove the air filter element 4 Remove the air filter element fro...

Page 140: ...8 33 Periodic Maintenance and Adjustment 1 Holder 5 2 Air filter case cover 1 Air filter element 1 Frame 2 Air filter element ...

Page 141: ...HE HAZARD Use parts cleaning solvent to clean the air filter element 6 Squeeze the excess solvent out of the air filter element and let it dry CAUTION Do not twist the air filter element when squeezing it 7 Inspect the air filter element and replace it if damaged 8 Apply roam air filter oil or other quality foam air filter oil to the air filter element NOTE The air filter element should be wet but...

Page 142: ...d air entering the engine CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating Spark arrester cleaning Be sure the exhaust pipe and muffler a...

Page 143: ...d cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire HOW TO AVOID THE HAZARD 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 V belt cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and cl...

Page 144: ...NOTE If water drains from the V belt case after removing the plug have the dealer inspect the ATV as the water may affect other engine parts 1 V belt case drain plug 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 p...

Page 145: ... left to a dealer Throttle lever adjustment NOTE Adjust the engine idling speed before adjusting the throttle lever free play 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle lever free play is 3 5 mm 0 12 0 20 in 3 Tighten the locknut 1 Locknut 2 Adjusting bolt a Throttle lever free play Front brake pad check Check the brake pads for damage and wear If a brake pad thickness is le...

Page 146: ... damage and wear If the thickness is less than 1 0 mm 0 04 in have a dealer replace the pads 1 Brake pad 2 Brake pad plate a Brake pad thickness Checking the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level and replenish when necessary A low brake fluid...

Page 147: ...ir is located behind panel B See page 8 8 for panel removal and installation procedures 1 Minimum level mark 1 Minimum level mark Observe these precautions When checking the fluid level make sure the top of the master cylinder reservoirs are level Use only the designated quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake performance Recommended brake flui...

Page 148: ...s or plastic parts Always clean up spilled fluid immediately Have a dealer check the cause if the brake fluid level goes down Brake fluid replacement Only trained service personnel should do complete fluid replacement Have a 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 fou...

Page 149: ... not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge A dealer should perform these procedures Adjusting the rear brake lever The rear brake lever free play should be 0 5 2 mm 0 02 0 08 in 1 Loosen the locknut 1 Locknut 2 Adjusting bolt c Rear brake lever free play 2 Turn the adjusting bolt in direct...

Page 150: ...e brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move Adjusting the brake pedal The top of the brake pedal should be positioned 72 mm 2 8 in above the top of the footrest If not ask a dealer to adjust it a Distance between brake pedal and footrest ...

Page 151: ... A dealer should perform these procedures Adjusting the rear brake light switch The rear brake light switch which is activated by the brake pedal and rear brake lever is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Remove panel B See page 8 8 for panel removal and installation procedures 2 Turn the adjustin...

Page 152: ...use an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lubricant The chain and cable lube or SAE 10W 40 motor oil Lubricating the brake levers and brake pedal Lubricate the pivoting parts NOTE To access the brake pedal pivot remove...

Page 153: ...Periodic Maintenance and Adjustment 8 46 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun ...

Page 154: ...vate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 Wheel installation 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel ...

Page 155: ... nut torque Front 55 Nm 5 5m kgf 40ft lbf Rear 55 Nm 5 5m kgf 40ft lbf Battery This machine is equipped with a sealed type 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 a dealer CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery ...

Page 156: ...mpt 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 reinstallatio...

Page 157: ...se 5 Four wheel drive fuse 6 Auxiliary DC jack fuse 7 ECU 8 Headlight fuse 9 Spare fuse 3 Specified fuses Main fuse Speedometer unit Signaling system fuse Four wheel drive fuse Auxiliary DC jack fuse ECU Headlight fuse Backup fuse 30 A 15A 10A 15A 10A 10A 15A 10A WARNING POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could l...

Page 158: ...Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the cover at the rear of the headlight by pulling it off 1 Cover 2 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover 3 Remove the headlight bulb holder by pushing it in and turning it counterclockwise 1 Headlight bulb holder ...

Page 159: ...VOID THE HAZARD Wait for the bulb to cool before touching or removing it 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 the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight ...

Page 160: ...tment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b CAUTION It is advisable to have a dealer make this adjustment 1 Headlight beam adjusting screw Tail brake light bulb replacement 1 Remove panel G See pages 8 12 8 13 for removal and installation procedures 2 Remove the bulb holder together with the bulb by turning it counterclo...

Page 161: ...b holder 3 Remove the defective 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 Install the bulb holder together with the bulb 6 Install the panel ...

Page 162: ...f you cannot repair the ATV yourself please contact your dealer WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing severe injury or property damage HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters ...

Page 163: ...en or cracked 1 Replace broken cover 2 Replace broken fender 3 Make sure to replace any label on cover or fender 2 ATV s skid plate becomes damaged from hitting an object 1 Check if the reduction gear box and differential in front and rear bridge are damaged or if there is any oil leakage 2 Check bottom of engine for damage and or oil leakage 3 Replace bottom skid plate with a new one ...

Page 164: ...g parts of calipers are deformed 2 Brake performance goes down 1 Check disk brake pads for excessive ware 2 Check to make sure there is no foreign objects such as rocks dirt etc between the brake pads and disks 3 Check if there is any leakage in brake system s oil lines or conjunctions 4 Check post rod in brake master cylinder for deformation 5 Check brake fluid lines for air to be performed by a ...

Page 165: ...ves left or right when brakes are applied 1 Check if left right brake force deviation in front brakes are within specified limit 2 Check if front brakes are not working Front brakes not working will cause the rear wheels to lock up prematurely 3 Check spring force deviation in both left and right shocks Springs should be within the specified limits 4 Check if rubber shock dampers are damaged The r...

Page 166: ...d control switch 2 Check if the differential lock control magneto plug in rear bridge reduction gear box is broken Service center can diagnose this 3 Check wire for damage 3 Rear differential will not work 1 Check control switch 2 Check if the differential lock control magneto plug in rear bridge reduction gear box is broken Service center can diagnose this 3 Check wire for damage 4 The speed disp...

Page 167: ... if surface of speed sensor is contaminated with dust S N Problems Solutions 5 Start switch on meter board won t work 1 Check if the switch is broken 2 Check if any wires are loose or broken 3 Check if the ECU in electrical injection system is broken ...

Page 168: ...nts on the ends of the steering tie rods 3 Check clearance between the gears in the steering mechanism Make sure clearance is not excessive 2 Front wheels shake excessively while operating 1 Check for worn bearings in ball joints on the ends of the tie rods 2 Check for loose or damaged ball joints on the ends of the steering tie rods 3 Check lug nuts on each wheel make sure they are tight 4 Check ...

Page 169: ...out if they are broken 2 Check the sliding bearing connecting rear bridge and rocks to find out if they are worn or loose 3 Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if they are worn or broken 4 Check lug nuts on each wheel make sure they are tight 5 Check if rubber shock damper is damaged The rubber shock damper is located between the shock and t...

Page 170: ...mit of ATV 2 Check if the springs are worn from use replace if necessary 3 Check shocks for any damage replace if necessary 6 Front bridge makes noise while operating 1 Check spline of the intermediate drive shaft for damage if damaged take to a service center for repair 2 Check splines in the left right drive shafts of front rear bridges for damage if damaged take to a service center for repair 3...

Page 171: ...Idle speed is not stable 1 Check the battery voltage for specified value 2 Check rectifier output voltage for specified value 3 Check MEUI for failure 2 Power performance is falling 1 Check if there is one cylinder not working 2 Check gasoline nozzle for blockage 3 Check and clean core of air cleaner 4 Check muffler for blockage and clean spark arrestor 3 Popping in engine 1 Check air cleaner and ...

Page 172: ...eck battery for voltage loss when temperature goes down Replace battery if necessary S N Problems Solutions 4 Engine is difficult to start at low temperature 2 If the temperature is under 18 0ºF place the vehicle in a warmer location before attempting to start 5 Coolant boils 1 Check cooling fins on radiator for blockage 2 Check the speed sensor on radiator for damage and Check fan for failure 3 C...

Page 173: ...ng properly inspect for loose or damaged wires 5 Check for fouled or damaged spark plug Replace if necessary Problems Solutions 6 Check if the ignition signal is in good condition 7 Check if the air cleaner is blocked 8 Check if the oil circuit is smooth 9 Check if the exhaust system is blocked 7 Engine single cylinder work 1 Check ECU for damage 2 Check EFI cable for damage 3 Check ignition high ...

Page 174: ...burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recommended coolant as soo...

Page 175: ...egreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job 1CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated ca...

Page 176: ...ny contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to l...

Page 177: ...uel system needs to be drained instead 2 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pi...

Page 178: ...9 4 Cleaning and Storage or more than 30 86 F NOTE Make any necessary repairs before storing the machine ...

Page 179: ...m 47 6in 1 225mm 48 2in 880mm 34 6in 1 365mm 53 7in 260mm 10 2in 3 200mm 126 0in Basic weight With oil and full fuel tank 329kg 725 lb Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system Liquid coo led 4 stroke SOHC Forward inclined single cylinder 471cm 3 84 5mm 84mm 9 4 1 Electric and recoil starter Wet sump ...

Page 180: ...e replacement API Service SE SF SG type or higher 1CAUTION 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 specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher 1 9 0L 2 01 qt 2 10 L 2 22 qt ...

Page 181: ...AE80 API GL 5 Hypoid gear oil 0 28 L 0 25 Imp qt 0 30 US qt Radiator capacity including all routes 1 80 L 1 58 Imp qt 1 90 US qt Air filter Wet type element Fuel Type Fuel tan k capacity Unleaded gasoline only 17L 4 50gal Throttle valve Type quantity DELPHI MT05 Spark plug Type manufacturer Spark plug gap DR8EA 0 6 0 7 mm 0 023 0 027 in Clutch type Wet centrifugal automatic ...

Page 182: ... system Transmission type Operation Reverse gear Sub transmission ratio low high V belt Shaft drive V belt automatic Left hand operation 1 471 2 059 1 238 Chassis Frame type Caster angle Trail Steel tube frame 5 26 mm 1 0 2 in Tire Type Size front rear Tubeless 25 8 12 26 9 12 25 10 12 26 10 12 ...

Page 183: ...gle disc brake Left hand and right foot operation Dual disc brake Right hand operation Dual disc brake Left hand and right foot operation Suspension Front 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 Rear wheel travel 130 mm 5 12 in 150 mm 5 91 in ...

Page 184: ...light type Krypton bulb Bulb voltage wattage quantity Head light Tail brake light Indicator light Neutral indicator light Reverse indicator light Coolant temperature warning 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 ...

Page 185: ...Specifications 10 7 Model HS500ATV 2 Fuses Main fuse Speedometer unit Signaling system fuse Four wheel drive fuse Auxiliary DC jack fuse ECU Headlight fuse Backup fuse 30 A 15A 10A 15A 10A 10A 15A 10A ...

Page 186: ...cuit 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 P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open KsDGDM_CoolantShortHigh 118 280 P0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow 122 290 P0123 TPS Circuit High Voltage KsDG...

Page 187: ...on 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 Noisy Signal KsDGDM_CrankNoisySignal 336 822 P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal 337 823 P0351 Cylinder 1 Ignition Coil Malfunction KsDGDM_EST_A_Fault 351 849 P0352 Cylinder 2 Ignition Co...

Page 188: ...GDM_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_NoSignal 500 1280 P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 2128 P0445 CCP short to high KsDGDM_CCP_CircuitShortHigh 445 1093 P0444 CCP short to low open KsDGDM_CCP_CircuitShortLow ...

Page 189: ...ted 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 will be repaired or replaced by HISUN This is your EMISSION CONTROL SYSTEM WARRANTY NOTICE Use of any HISUN brand vehicle in any type of competitive event completely and absolutely voids this and al...

Page 190: ...each new 2012 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 Protection Agency and the California Air Resources Board and B is free from defects in material and workmanship which cause such vehicle to fail to conform to applicable regulations of the United State...

Page 191: ...e 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 liable for any other expenses loss or damage whether direct incidental consequential or exemplary arising in connection with the sale or use of or inability to use the HISUN brand vehicle for any purpo...

Page 192: ... 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 individual The warranty period begins when the vehicle is placed into service If you have any questions regarding your warranty rights and responsibilities you should contact Hisun Motors Corp U S A...

Page 193: ...POWERSPORTS 888 405 8725 Coleman Powersports 1775 E University Dr Tempe AZ 85281 colemanpowered com ...

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