Coleman OUTFITTER 700-L Owner'S Manual Download | Manualshive

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Periodic Maintenance and Adjustment

8-36

WARNING

POTENTIAL HAZARD
Damaged control cables.
WHAT CAN HAPPEN
Corrosion  can  result  when  the  outer
covering  of  control  cables  becomes
damaged. Cables can also become frayed
or kinked. Operation of controls could be
restricted, which could cause an accident
or injury.
HOW TO AVOID THE HAZARD
Inspect  cables  frequently.  Replace
damaged cables.

Recommended lubricant:

Engine oil

Brake Pedal and Accelerator Pedal
Lubrication

Lubricate the pivoting parts.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

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Summary of Contents for OUTFITTER 700-L

Page 1: ...POWERSPORTS OWNER S MANUAL 888 405 8725 Coleman Powersports 2010 E University Drive Suite 15 Tempe AZ 85281 700 L No one under the age of 16 should operate this UTV OUTFITTER...

Page 2: ...ould operate this UTV A UTV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning driving on hi...

Page 3: ...Owner s Manual...

Page 4: ...tations The SafetyAlert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator bystander or a person inspe...

Page 5: ...has a policy of continually improving its products Due to improvements or other changes there may be some discrepancies We reserve the right to make product changes at any time without notice and with...

Page 6: ...ce where the temperature is higher than 4 F 20 C Start the UTV after the UTV has warmed up Please see page 6 3 on the warming up process engine make sure the radiator fan is on for 3 minutes before tu...

Page 7: ...Clock 4 7 Fault Codes Display of the Electronic 4 7 Fuel meter 4 7 Switches 4 8 Accelerator Pedal 4 13 Brake Pedal 4 14 Parking Brake Lever 4 15 Drive Select Lever 4 16 Fuel Tank Cap 4 16 Front Seats...

Page 8: ...Throttle FreeplayAdjustment 5 9 Steering Wheel Inspection 5 10 Seat Belts 5 10 Fittings and Fasteners 5 10 Lights 5 10 Switches 5 10 Tires 5 11 How to Measure Tire Pressure 5 12 Tire Wear Limit 5 13...

Page 9: ...aintenance Chart for the Emission Control System 8 3 General Maintenance and Lubrication Chart 8 4 Hood 8 7 Console 8 8 Engine Oil and Oil Filter Cartridge 8 9 To Check the Engine Oil Level 8 9 To Cha...

Page 10: ...Rear Knuckle Upper and Lower Pivot Lubrication 8 37 Steering Shaft Lubrication 8 37 Wheel Removal 8 38 Wheel Installation 8 39 Battery 8 40 Battery Maintenance 8 42 Fuse Replacement 8 43 Replacing He...

Page 11: ...or used in a manner not consistent with the normal and proper intended use for the vehicle This vehicle is not intended for rental or commercial use Who Can Perform Repairs Under this Warranty Repairs...

Page 12: ...not approved by Coleman Powersports 6 Tires 7 Damage or failures due to abuse neglect or misuse of the product Limitations of this Warranty This warranty does not cover and Coleman Powersports discla...

Page 13: ...Location of the Warning and Safety Labels 1 1...

Page 14: ...nd all of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or...

Page 15: ...Location of the Warning and Safety Labels 1 3 3 5 6 4...

Page 16: ...1 4 Location of the Warning and Safety Labels 7 8 9...

Page 17: ...Location of the Warning and Safety Labels 1 5 10 11 12...

Page 18: ...1 6 Location of the Warning and Safety Labels 13 14 15 16...

Page 19: ...who is too small to reach and hold the handgrip fixed before the seat Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate thi...

Page 20: ...icularly important when driving in rough terrain The front wheels will move right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrenc...

Page 21: ...in a new area Never operate the vehicle in fast flowing water or water deeper than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leavi...

Page 22: ...he vicinity of sparks open flames or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an upr...

Page 23: ...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 yo...

Page 24: ...r intake duct 5 Spark plug 6 V belt case 7 Driver seat belt 8 Driver seat 9 Passenger seat belt 10 Cargo bed release levers 11 Rear shock absorber assembly adjusting ring 12 Cargo bed 13 Tail brake li...

Page 25: ...26 Main switch 27 On Command four wheel drive and differential lock switches 28 Multi function meter unit 29 Auxiliary DC jack 30 Drive select lever 31 Parking brake lever 32 Accelerator pedal NOTE T...

Page 26: ...paces provided for assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle identificatio...

Page 27: ...ll electrical circuits are supplied with power and the headlights and taillights illuminate when the light switch is on OFF All electrical circuits are switched off The key can be removed in this posi...

Page 28: ...arting instructions prior to starting the engine See pages 6 1 6 3 for details Indicator and warning lights 1 High range indicator light H 2 Parking brake indicator light P 3 Low range indicator light...

Page 29: ...until the differential gear is locked Low range indicator light L This indicator light comes on when the drive select lever is in the L position High range indicator light H This indicator light come...

Page 30: ...The On Command differential gear lock indi cator in the On Command four wheel drive indicator also comes on when the On Command differential gear lock switch is set to the LOCK position NOTE Due to t...

Page 31: ...tarting make sure that the light is out Continuous use while the light is on may cause damage to the engine Multi Function Display Gauge 1 Left turn indicator 2 Speedometer 3 Tachometer 4 Right turn i...

Page 32: ...ode ODO and the trip meter modes A and B in the following order ODO TRIP A TRIP B ODO To reset a trip meter select it by pushing the TRIP ODO button and then push the TRIP ODO button for at least thre...

Page 33: ...ase it the clock will begin to work Fault Codes Display Of Electronic Injection System When the faults come out meter will display the fault codes to guide the repair See attachment for faults code pa...

Page 34: ...g indicator 2 Fuel meter Switches 1 Light switch OFF Light switch OFF Set the switch to to turn on the low beam and the taillights Set the switch to to turn on the high beam and the taillights Set the...

Page 35: ...happen remove the battery and recharge it On Command four wheel drive and diff erential gear lock switches 1 On Command four wheel drive switch 2WD 4 WD 2 Differential gear lock switch LOCK 4WD This v...

Page 36: ...HAZARD Changing from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD LOCK in some...

Page 37: ...he 4WD indicator will come on in the multi function meter unit display To change from 4WD to 2WD stop the vehicle be sure the select lever is set to position and then set the switch to 2WD On Command...

Page 38: ...and set the switch 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 e...

Page 39: ...ed e g when the indica tor and indicator light are flashing will cause the engine speed to be limited until engagement is complete Accelerator pedal Press the accelerator pedal down to increa se engin...

Page 40: ...speed up or slow down could cause loss of control HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engine If it does not work smoothly check for the cause Corr...

Page 41: ...he lever up completely To release the parking brake pull up on the lever press the release button and then push the lever all the way down Spring pressure helps return the lever to the released positi...

Page 42: ...lect lever is used to shift you vehicle into the low high neutral and reverse positions Refer to pages 6 4 6 6 for the drive select lever operation 1 Drive select lever Fuel tank cap Remove the fuel t...

Page 43: ...seat 3 Seat lock lever 2 To install a seat insert the projection on the rear of the seat into the seat holders and push down on the seat at the front WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAP...

Page 44: ...4 18 Control Functions Rear Seats 1 Rear seat To remove the rear seats you need to pull it up from back and then push it back...

Page 45: ...enger Always wear the seat belt while riding in the vehicle 1 Seat belt 2 2 Latch plate 2 3 Buckle 2 Seat Belt For Rear Seats 1 Driver seat 2 Passenger seat 3 Seat lock lever 2 Three point belt is pro...

Page 46: ...ks Pull up on the latch plate to make sure it is secure 1 Buckle 2 Latch plate 3 Put the lap portion of the belt low on your hips Push down on the buckle end of the belt as you pull up on the shoulder...

Page 47: ...elt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the v...

Page 48: ...To protect from damage do not put metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appropria te cushion material a Unlock b Ope...

Page 49: ...te in the original position and then hook the latches Lifting and lowering the cargo bed 1 Cargo bed release lever To lift Push down the cargo bed release lever on the left or right side of the vehicl...

Page 50: ...s are standing away from the vehicle Keep hands and fingers away from the pinch points between the bed and the frame WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause chan...

Page 51: ...ly Front and rear shock absorber adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming out o...

Page 52: ...trol 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 Specia...

Page 53: ...ich could lead to an accident HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting Trailer hitch bracket This vehicle is equipped with a 1 in receiv...

Page 54: ...work lights radios etc The auxiliary DC jack should only be used when 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 auxil...

Page 55: ...ve 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 en...

Page 56: ...ir Check coolant level Fill with coolant if necessary 5 6 8 18 8 19 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8 Seat b...

Page 57: ...erating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual Brakes Brake pedal Check for correct brake pedal free play If the brake pedal fr...

Page 58: ...sure they are working properly If the brakes do not provide proper braking performance inspect the brake system See pages 8 30 8 35 WARNING POTENTIAL HAZARD Driving with improperly operating brakes W...

Page 59: ...gasoline with a pump octane number R M 2 of 91 or higher or research octane number of 91 or hither If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fue...

Page 60: ...cially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Engine oil Make sure the engine oil is at the specified level Add oil as necessar...

Page 61: ...ximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add additional coolant to bring the level up to maximum level mark If coolant is not available add...

Page 62: ...pe before completely removing the cap Final gear oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 14 8 15 for details Recommended oil SAE 80 API GL 4 Hypoid...

Page 63: ...f the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay Adjust the freeplay If necessary WARNING Failure to check o...

Page 64: ...ches 1 5 3mm Throttle Freeplay Adjustment 1 Remove both seats Remove the middle cover of the engine see PAGE 8 9 2 Loose the nut of throttle rope on the valve Spin the throttle rope inside outside to...

Page 65: ...ate should click securely into the buckle and release when the release button is pushed firmly Wash off any dirt or mud which could affect operation Have a service center repair as necessary for prope...

Page 66: ...model Other tire combinations are not recommended Type Size Front 25 8 12 6PR Rear 25 10 12 6PR 2 The tires should be set to the recommended pressure Recommended tire pressure Front 10psi 70kpa 0 7 k...

Page 67: ...essure gauge is included as stan dard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressu...

Page 68: ...5 13 Pre Operation Checks Tire wear limit When the tire groove decreases to 0 12 in 3 mm due to wear replace the tire a Tire wear limit...

Page 69: ...r service center Starting The Engine In Low Temperatures WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the vehicle which could lead to...

Page 70: ...ly the brake 3 Shift the drive select lever into the neutral position NOTE When the drive select lever is in the neutral position N the neutral indicator light should come on If the neutral indicator...

Page 71: ...D Engine idle speed exceeds the regulated speed WHAT CAN HAPPEN Will make it difficult to select gear and lose control finally causing serious injury or even death HOW TO AVOID THE HAZARD Because of e...

Page 72: ...and the vehicle can been ridden Otherwise go on with the third step 3 Continue warming up the engine until it idles smoothly CAUTION See the Engine break in section prior to operating the engine for t...

Page 73: ...e accelerator pedal 2 Apply the brake pedal 3 Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide NOTE Please kick the brake pedal first before place gea...

Page 74: ...ot come on ask a dealer to inspect the reverse indicator light electrical circuit Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving 4 Check beh...

Page 75: ...njury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly Parking a When parking stop the engine and shift th...

Page 76: ...O AVOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the vehic...

Page 77: ...components will result in more efficient performance and longer life for these components Perform the following procedures carefully Excessive heat build up during the first three hours of operation w...

Page 78: ...tantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a dealer 0 10 Hour...

Page 79: ...the following in mind when considering an accessory or operating a vehicle which has accessories Choose only accessories designed for your vehicle Your dealer has a variety of genuine accessories Othe...

Page 80: ...ing cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An overloaded vehicle can be unstable MAXIMUM LOADING LIMIT Vehicle loading limit total weight of c...

Page 81: ...in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with controls or your ability to see where you are going D...

Page 82: ...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 vehicle Cargo should be properly distributed a...

Page 83: ...1 2 5 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry pass...

Page 84: ...senger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only The total weight of operator p...

Page 85: ...rly 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...

Page 86: ...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 even...

Page 87: ...ation before attempting more difficult maneuvers Perform the Pre Operation Checks on pages 5 1 5 11 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine O...

Page 88: ...er or go out of control if you attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slope Position yo...

Page 89: ...lightly Never open the throttle suddenly 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns Before shifting into reverse gear always check for obstacles or people behind...

Page 90: ...he side of a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hills Always check the terrain carefully before attempting any hill Use common sense...

Page 91: ...re climbing the hill first be sure you are operating in low range 4WD or if necessary with 4WD Diff Lock To climb a hill you need traction momentum and steady throttle Travel fast enough to keep your...

Page 92: ...ive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over Carefully choose your path and drive no faster than you will be able to react to obstacles that...

Page 93: ...do so slowly an carefully if the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direct...

Page 94: ...t your brakes after leaving water If necessary apply them several times to let friction dry out the linings 1CAUTION After riding your vehicle in water be sure to drain the trapped water by removing t...

Page 95: ...ry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle to your service center for service as soon as possi...

Page 96: ...7 14 Your Vehicle 1 V belt cooling duct check hose 1 Air filter case check hose 1 Drive select lever box check hose 1 V belt case drain plug...

Page 97: ...ees watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or WARNING POTENTIAL HAZARD Failure to use extra care when operati...

Page 98: ...g brake and get out to inspect the area thoroughly Look from both your approach side and the exit side If you believe you can continue safely decide the path that will allow you to get over the obstac...

Page 99: ...bstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution w...

Page 100: ...service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in t...

Page 101: ...h vehicle service WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in...

Page 102: ...ld be performed by service center as they require special tools data 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...

Page 103: ...oil filter cartridge Replace Final gear oil Check oil lever oil leakage Replace Differential gear oil Accelerator pedal Check operation and free play V belt Check operation Check for wear cracks or da...

Page 104: ...and fasteners Check all chassis fittings and fasteners Check if necessary Rear upper and lower knuckle pivots Lubricate with lithium soap based grease Drive shaft universal joint Lubricate with lithi...

Page 105: ...When disassembling the master cylinder or caliper replace the brake fluid Normality check the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace...

Page 106: ...t the hood up until it stops 1 Latch 2 1 Hood To Close Lower the hood slowly to its original position and then hook the hood latches Secure projections on the underside of the hood into slots on the b...

Page 107: ...wires are in place when closing the hood Do not drive the vehicle with the hood open unlatched or removed Console To Remove 1 Remove the seats See pages 4 17 4 18 for seat removal and installation pro...

Page 108: ...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 Place the vehicle on a level surface...

Page 109: ...mmended type to raise it to the correct level 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 8 Install the console To Change the Engine Oil With or Without Oil Filt...

Page 110: ...not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter wrench NOTE An oil filter wrench is available at a nearby service center 5 Apply a l...

Page 111: ...d torque with a torque wrench 1 Oil filler cartridge 2 Torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 30Nm 3 0m k...

Page 112: ...f CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 9 Start the engine and then l...

Page 113: ...correct level CAUTION 1 Be sure no foreign material enters the final gear case 2 Please clean the sensor every 500km period 4 Install the oil filler bolt and then tighten it to the specified torque Ti...

Page 114: ...mmended final gear oil up to the brim of the filler hole Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 25 L 0 22 lmp qt 0 26 US qt CAUTION Be sure no foreign material enters the final...

Page 115: ...erential gear oil filler bolt 2 Correct oil level 3 Differential gear oil CAUTION Be sure no foreign material enters the differential gear case 3 Install the differential gear oil filler bolt and then...

Page 116: ...the differential gear case with the recommended oil Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 32 L 0 28 lmp qt 0 34 US qt CAUTION Be sure no foreign material enters the differenti...

Page 117: ...ures 3 Check the coolant level in the coolant reservoir when the engine is cold as the coolant level varies with engine temperature NOTE The coolant should be between the minimum and maximum level mar...

Page 118: ...ce center at the intervals specified in the periodic maintenance and lubrication chart NOTE Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coo...

Page 119: ...e 1 Rear axle boot 2 each side Spark Plug Inspection Removal 1 Lift the cargo bed up See pages 4 22 for cargo bed lifting and lowering procedures 2 Remove the spark plug cap 1 Spark plug cap 3 Use the...

Page 120: ...attempt to diagnose such problems yourself Instead take the vehicle to a service center You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug t...

Page 121: ...ft lbf NOTE If a torque wrench is not available when you are installing the 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...

Page 122: ...8 for seat removal and installation procedures 2 Remove the console See page 8 8 for console removal and installation proced ures 3 Remove the air filter case cover by unho oking the holders 1 Holder...

Page 123: ...ARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use parts cleaning so...

Page 124: ...l the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover and be sure the crankcase breather hose is connected 1 Crankcase breather hose 13 Install th...

Page 125: ...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...

Page 126: ...p enough to allow water to enter the V belt case remove the drain plug to drain any water from the case NOTE If water drains from the V belt case after removing the drain plug have a service center in...

Page 127: ...remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt hole...

Page 128: ...xhaust system Valve Clearance 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 adj...

Page 129: ...ear Brake Pad Check Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wea...

Page 130: ...rake system for leakage The brake fluid reservoir is located under the hood See pages 8 7 for hood opening and closing procedures Observe these precautions When checking the fluid level make sure the...

Page 131: ...service center replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years Checking...

Page 132: ...ment of brake components requires professional knowledge These procedures should be performed by a service center Parking Brake Lever Free Play Adjustment Periodically check the parking brake lever fr...

Page 133: ...er must be released when checking and adjusting the parking brake lever free play 5 Loosen the locknut 1 Locknut 2 Adjusting nut 6 Turn the adjusting nut in direction to increase the free play or in d...

Page 134: ...hood opening and closing procedures 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light switch in place To make the brake light come on earlier turn the adju...

Page 135: ...amaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cable...

Page 136: ...and Lower Pivot Lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium soap based grease Steering Shaft Lubrication Lubricate the pivot points Recomme...

Page 137: ...g Block 1 Bearing block Lubricate the bearing block Recommended lubricant Lithium soap based grease all purpose grease Wheel Removal Loosen the wheel nuts Elevate the vehicle and place a suitable stan...

Page 138: ...oward 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 1 Tapered nut 2 Lower the vehicle so that the...

Page 139: ...th 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 service center CAUTION Do not tr...

Page 140: ...ARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or...

Page 141: ...rechar ge the battery before reinstallation CAUTION A special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery...

Page 142: ...it as follows 1 Remove the battery compartment cover by lifting it up and pulling it out 1 Battery compartment cover 2 Turn the key to OFF and turn off the electrical circuit in question CAUTION To p...

Page 143: ...10 0A 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a service center check the electrical system 6 Ins...

Page 144: ...up See pages 8 7 for hood opening and closing procedures 2 Remove the cover at the rear of the headlight by pulling it off 1 Cover at the rear of the headlight 3 Remove the headlight bulb holder cove...

Page 145: ...HAZARD A headlight bulb is hot when it is on and immediately after it is turned off WHAT CAN HAPPEN You can be burned or a fire could start if the bulb touches something flammable HOW TO AVOID THE HAZ...

Page 146: ...ll be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 7 Install the bulb holder by pushing it is and turning it...

Page 147: ...justing screw in direction To lower the beam turn the adjusting screw in direction 1 Headlight beam adjusting screw Tail Brake Light Bulb Replacement If a tail brake light bulb burns out replace it as...

Page 148: ...3 Push the defective bulb in and turn it counterclockwise to remove it from the bulb holder 4 Push a new bulb in and turn it clockwise to install in the bulb holder 5 Install the bulb holder together...

Page 149: ...any repair take it to a service center The skilled technicians at a service center ship have the tools experience and know how to properly service your vehicle Imitation parts may look like parts but...

Page 150: ...lution of Common Problems in Appearance Parts and Impact Fittings S N Problems Solutions 1 Covers are cracked 1 Repair cover at authorized service center 2 Change for new plastic covers 3 Replace the...

Page 151: ...k if the the brake dics are over worn 2 Check if the brake blocks in calipers are over worn or contaminated by dirt or debris that can reduce friction 3 Check if there is any leakage in brake system s...

Page 152: ...eft and right brake force deviation of front brake is with specified limit 2 Check if the brake force of front brake goes down which causes the rear wheels to lock up before the front wheels 3 Check i...

Page 153: ...bridge reduction gear box are broken 3 Check if the wire is broken 3 Rear differential will not work 1 Check if the control switch on meter board works well 2 Check if the differential lock control m...

Page 154: ...are broken 2 Check the main ball pins to find out if they are broken 3 Check the inner splines of front wheel hubs and outer splines of front wheel axles to find out if they are worn or broken 4 Chec...

Page 155: ...able during use 1 Check if overloaded 2 Check if the springs are two soft and need replacing 3 Check if the shock absorbers lose their damping force over time 6 Front bridge makes noise during use 1 C...

Page 156: ...n spark arrestor 3 Check tire pressure 4 Popping noise in engine 1 Check air cleaner and admission line for leak 2 Check the connection joint of exhaust pipe with engine or muffler for leak 3 Check th...

Page 157: ...be for with air 1 Check the battery charge 2 Check the battery connection 3 Check the starter for damage 4 Check if the ignition loop is in good condition 5 Check if the spark plug creating sparks 6 C...

Page 158: ...oon as possible WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO...

Page 159: ...er 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...

Page 160: ...ntain abrasives which may scratch 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 WHA...

Page 161: ...ecified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult...

Page 162: ...seat covers 8 Remove the battery and charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 32 F 0 C or more than 86 F 3...

Page 163: ...3 in 1 900 mm 74 8 in 818 mm 32 2 in 2 840mm 111 8 in 280 mm 11 0 in 5 000 mm 196 8 in Basic weight With oil and full fuel tank 543kg 1 197 lb Engine Engine type Cylinder arrangement Displacement Bor...

Page 164: ...acement API service SG type or higher JASO standard MA 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 wit...

Page 165: ...GL 5 Hypoid gear oil 0 32L 0 28 lmp qt 0 34 US qt Radiator capacity including all routes 2 50L 2 20 lmp qt 2 64 US qt Air filter Engine Intake duct Wet element Dry element Fuel Type Fuel tank capacit...

Page 166: ...ction system Transmission type Operation Reverse gear Sub transmission ratio low High V belt Shaft drive V belt automatic Right hand operation 1 471 2 059 1 238 Chassis Frame type Caster angle Trail S...

Page 167: ...ion 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 trav...

Page 168: ...ng light Parking brake indicator light On Command four wheel drive differential gear lock indicator On Command differential gear lock indicator light High range indicator light Low range indicator lig...

Page 169: ...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 170: ...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 171: ...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 172: ...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 173: ...ach 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 Pr...

Page 174: ...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 175: ...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 176: ...POWERSPORTS 888 405 8725 Coleman Powersports 2010 E University Drive Suite 15 Tempe AZ 85281...

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