Coleman POWERSPORTS HS360ATV Owner'S Manual Download Page 113

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8-15 Periodic Maintenance and Adjustment

oil level and correct it if necessary.

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 the final gear oil

1. Remove the final gear case cover by

removing the bolts.

1. Final gear case cover 2. Bolt (

2. Place the ATV on a level surface.

3. Place a container under the final gear case

to collect the used oil.

4. Remove the oil filler bolt and the drain bolt

to drain the oil.

1. Final gear oil 2. Final gear oil filler bolt 3. Proper oil level

Summary of Contents for POWERSPORTS HS360ATV

Page 1: ...POWERSPORTS OWNER S MANUAL 888 405 8725 Coleman Powersports 364 S Smith Rd Tempe AZ 85281 No one under the age of 16 should operate this ATV REV032514 POWERSPORTS POWERSPORTS HS360ATV HS400ATV...

Page 2: ...Owner s Manual...

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

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 o...

Page 5: ...this ATV When the temperature is below 20 4 F please park the ATV in the place where the temperature is higher than 20 4 F After the ATV has warmed up the ATV can be started Please see page 6 3 on th...

Page 6: ...itches 4 5 Throttle Lever 4 7 Speed Limiter 4 8 Front Brake Lever 4 10 1 Brake Pedal and Rear Brake Lever 4 10 Drive Select Lever 4 11 Recoil Starter 4 12 Fuel Tank Cap 4 12 Seat 4 12 Storage Compartm...

Page 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 20 Riding Downhill 7 25 Crossing a Slop...

Page 8: ...Brake Pad Check 8 32 Checking the Rear Brake Pads 8 32 Checking the Brake Fluid Level 8 33 Brake Fluid Replacement 8 34 Front Brake Lever Free Play 8 34 Adjusting the Rear Brake Lever 8 35 Adjusting t...

Page 9: ...Owner s Manual Cleaning 9 1 Storage 9 3 Specifications 10 1 Fault code of Electronic Injection System 11 1 USA EPA Emissions Limited Warranty 12 1 10 11 12...

Page 10: ...be performed by an authorized Coleman Powersports retailer or comparable servicing dealer How to get service under this warranty To get warranty service call Coleman Powersports at 888 405 8725 for t...

Page 11: ...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 12: ...Location of the Warning and Safety Labels 1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS...

Page 13: ...derstand 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 co...

Page 14: ...Location of the Warning and Safety Labels 1 3...

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

Page 16: ...Location of the Warning and Safety Labels 1 5...

Page 17: ...nstructions 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...

Page 18: ...pt 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 desc...

Page 19: ...e 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 yo...

Page 20: ...er 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...

Page 21: ...ecified 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 fo...

Page 22: ...RD 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...

Page 23: ...king 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...

Page 24: ...ock 9 Air filter case 10 Fuses 11 Tail brake light 12 Front shock absorber assembly spring preload adjusting ring 13 V belt cooling duct check hose 14 Oil filter cartridge 15 Engine oil dipstick 16 Re...

Page 25: ...spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 KEY IDENTIFICATION NUMBER Vehicle identification...

Page 26: ...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...

Page 27: ...m indicator Neutral Indicator Light N This indicator light comes on when the drive select lever is in the N position Reverse Indicator Light R This indicator light comes on when the drive select lever...

Page 28: ...nuous use while the light is on may cause damage to the engine Trip meter Trip meter only records while the key is in the ON position Once the key is turned off the trip meter will re set Fault code i...

Page 29: ...ometers miles driven on ATV Metric system indicator light Distance and speed is measured in km h Miles system indicator light Distance and speed is measured in mph Emergency indicator The light being...

Page 30: ...n on the high beam and the taillight Set the switch to OFF to turn off all the lights CAUTION Do not use the headlights with the engine turned off for more than thirty minutes The battery may discharg...

Page 31: ...tch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the e...

Page 32: ...tor will go out in the multi function display WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving WHAT CAN HAPPEN The ATV handles differently in 2WD than in 4W...

Page 33: ...he throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released WARNING POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle...

Page 34: ...he ATV 1 Locknut 2 Adjusting screw a 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 Impro...

Page 35: ...andlebar to apply the front brake 1 Brake lever1 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...

Page 36: ...into the forward neutral and reverse Refer to pages 6 4 6 5 for the drive select lever operation 1 Drive select lever Recoil starter Firmly grasp the handle and pull slightly until engagement can be...

Page 37: ...n WHAT CAN HAPPEN The ATV could start to move unexpectedly which could cause an accident HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake befo...

Page 38: ...upward and pull up the seat at the 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 M...

Page 39: ...e owner s manual or other documents 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 storag...

Page 40: ...Control Functions 4 15 Rear carrier Rear carrier Maximum load limit 35kg 77lb 1 Rear carrier...

Page 41: ...ear wheels need to be removed See pages 8 39 8 40 for removal and installation procedures Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction a To...

Page 42: ...wrench WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZA...

Page 43: ...sary 5 6 Coolant reservoir Check coolant level in reservoir Fill with coolant if necessary 5 7 8 19 8 23 Final gear oil Differential gear oil Check for leakage 5 6 5 7 8 15 8 16 Throttle Check for pro...

Page 44: ...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 Ch...

Page 45: ...ted 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 f...

Page 46: ...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...

Page 47: ...d 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 carefu...

Page 48: ...ified 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 M...

Page 49: ...ne is cold The coolant level will vary with engine 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 a...

Page 50: ...ver Check 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...

Page 51: ...mmended 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 be...

Page 52: ...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 Min...

Page 53: ...5 11 Pre Operation Checks 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 54: ...tand 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 c...

Page 55: ...er it is recommended to shift into neutral before starting engine 6 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold eng...

Page 56: ...ngine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 9 Continue warming up the engine until it idles smoothly and return the starter chok...

Page 57: ...g Neutral to Forward 1 Bring the ATV to a complete stop and return the throttle lever to the closed position 2 Apply the brakes then shift by moving the drive select lever along the shift guide 1 Driv...

Page 58: ...reverse indicator light should be on If the light does not come on ask a dealer to inspect the electrical circuit Due to the synchronizing mechanism in the engine the light may not come on until the...

Page 59: ...time it takes to use the first three tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result...

Page 60: ...ed However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the...

Page 61: ...ssories can affect the handling and control of your ATV Keep the following in mind when considering an accessory or operating an ATV which has accessories Choose only accessories designed for yourATV...

Page 62: ...er 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 th...

Page 63: ...hen towing a trailer Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain carefully Added...

Page 64: ...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...

Page 65: ...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 NO child under 16 years of age shou...

Page 66: ...senger 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 car...

Page 67: ...Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and incre...

Page 68: ...cle 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...

Page 69: ...V 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 operati...

Page 70: ...TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual Always maintain proper tire pressure as described in the Owner s Manual on page 5 13 WARNING POTENTIAL HAZARD Op...

Page 71: ...ew in decreases top speed and turning it out increases top speed Loading and accessories Use extra caution when riding the ATV with additional loads such as accessories or cargo The ATV s handling may...

Page 72: ...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 A...

Page 73: ...eg 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 d...

Page 74: ...ine 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 s...

Page 75: ...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 surface...

Page 76: ...icles 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...

Page 77: ...ENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You could come upon hidden rocks bumps or holes without enough time to react This could result in...

Page 78: ...PEN 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...

Page 79: ...OT 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...

Page 80: ...signed for off road use only and handling maneuvers are more difficult to perform on pavement Set the parking brake and follow the instruction on page 6 1 to start the engine Once it has warmed up you...

Page 81: ...are mounted solidly on one axle and turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resist turning A special...

Page 82: ...a large off road area with no obstacles If an incorrect technique is used your ATV may continue to go straight If the ATV doesn t turn come to a stop and then practice the procedure again If the ridin...

Page 83: ...tle slopes Try more difficult climbs only after you have developed your skill In all cases avoid inclines with slippery or loose surfaces or obstacles that might cause you to lose control WARNING POTE...

Page 84: ...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 sur...

Page 85: ...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 t...

Page 86: ...ptly If you are in 2WD apply only the front brake When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear br...

Page 87: ...y the brakes Apply the parking brake 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 When fully sto...

Page 88: ...s Improper braking may also cause a loss of traction When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear...

Page 89: ...s 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...

Page 90: ...phill 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 A...

Page 91: ...t 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 yo...

Page 92: ...HE HAZARD Never operate this ATV in fast flowing water or in water deeper than specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leavin...

Page 93: ...se 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...

Page 94: ...Your Vehicle 7 31 1 Drive select lever box check hose 1 V belt cooling duct check hose Left side 1 Storage box check hose 1 V belt case drain plug...

Page 95: ...ss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for SLIDING AND SKIDDING Care should be used when riding on loose or slippery...

Page 96: ...tion of the slide Applying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at controlled sliding can be developed The terrain...

Page 97: ...ly and be very cautious in order to reduce the chance of skidding or sliding out of control CONCLUSION 1 If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning m...

Page 98: ...5 If your ATV is traversing a sloping surface Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance If the ATV starts to tip steer down the hill if...

Page 99: ...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...

Page 100: ...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 vehicl...

Page 101: ...EM 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 Spa...

Page 102: ...e 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...

Page 103: ...cking if the function is complete and instruction is accurate EFI system Inspect it with EFI inspector Require special tools data and technical skills Have the dealer perform the service NOTE Recommen...

Page 104: ...nance described in this chapter Refer to this section each time the panel has to be removed or installed 1 Panel A Panel A To remove Remove the bolt and then take the panel off To install Place the pa...

Page 105: ...mpletely different from an engine which uses a carburetor it consist of an ECU EFI cables sensors actuators and other advanced components 1 Oxygen sensor assy 2 Oxygen sensor threaded sleeve 3 Exhaust...

Page 106: ...damper 2 Intake temperature sensor pressure sensor 3 Seat fuel injector 4 Fuel injector 5 Water temperature sensor 1 Idle speed stepper motor 2 Air damper degree sensor 3 Air damper Air damper For th...

Page 107: ...egative 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 accordin...

Page 108: ...with its own user manual 1 Diagnostic apparatus 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 t...

Page 109: ...o 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 6 If the engine oil is at or below the minimum level mark add...

Page 110: ...hen turn off 2 Place an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil d...

Page 111: ...ailable at a nearby dealer 5 Apply a light coat 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 6 Install the new oil filter cartridge...

Page 112: ...vent 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 a...

Page 113: ...e a dealer check and repair the ATV Replacing the final gear oil 1 Remove the final gear case cover by removing the bolts 1 Final gear case cover 2 Bolt 2 2 Place the ATV on a level surface 3 Place a...

Page 114: ...e final gear case with the specified amount of the recommended oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 4 L 0 42 qt CAUTION Be sure no foreign material enters the final gear...

Page 115: ...t oil of the recommended type to raise it to the specified level CAUTION Be sure no foreign material enters the differential gear case 3 Install the differential gear oil filler bolt and tighten to th...

Page 116: ...l drain bolt 10 Nm 1 0m kgf 7 2ft lbf 5 Fill the differential gear case with the recommended oil Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 28 L 0 3 qt CAUTION Be sure no foreign m...

Page 117: ...temperature NOTE The coolant should be between the minimum and maximum level marks 3 If the coolant is at or below the minimum level mark remove the reservoir cap Add coolant to the maximum level mark...

Page 118: ...ing the coolant 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 119: ...and Adjustment 1 Coolant drain bolt 1 Trough 3 Remove the radiator cap 1 Radiator cap 4 Remove the coolant reservoir cap 5 Disconnect the hose on the coolant reservoir side and then drain the coolant...

Page 120: ...f 7 2ft lbf 8 Install the coolant reservoir hose 9 Pour the recommended coolant into the reservoir to the maximum level mark and then install the reservoir cap 10 Pour the recommended coolant into the...

Page 121: ...e engine and then check the coolant level in the radiator If it is low add more coolant until it reaches the top of the radiator 12 Check for coolant leakage NOTE If any leakage is found have a dealer...

Page 122: ...ug as shown 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 col...

Page 123: ...eposits are excessive you should replace the spark plug with the specified plug Specified spark plug DR8EA NGK Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adj...

Page 124: ...leaning NOTE 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 Remove the seat See...

Page 125: ...POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode HOW TO AVOID THE HAZARD Use p...

Page 126: ...icated more often if the machine is operated in extremely dusty areas Each time air filter element maintenance is performed check the air inlet to the air filter case for obstructions Check the air fi...

Page 127: ...ve the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the ta...

Page 128: ...em 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 rem...

Page 129: ...a professional service technician Select lever safety system cable adjustment The select lever safety system cable stretches with use resulting in improper function To prevent this the cable must be a...

Page 130: ...wear If a brake pad thickness is less than 1 mm 0 04 in have a dealer replace the pads as a set a Brake pad thickness NOTE The wheels need to be removed to check the brake pads See pages 8 39 8 40 fo...

Page 131: ...ake fluid is above the minimum level and replenish when necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the...

Page 132: ...or lock Brake fluid may deteriorate painted surfaces 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...

Page 133: ...ee play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge A dea...

Page 134: ...brake pedal should be positioned 72 mm 2 8 in above the top of the footrest If not ask a dealer to adjust it WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAP...

Page 135: ...when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Remove panel A See page 8 6 for panel removal and installation procedures 2 Turn...

Page 136: ...W TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lub...

Page 137: ...d Adjustment Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel 1 Nut 4 Wheel installation 1 Install...

Page 138: ...apered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel 1 Arrow mark 1 Tapered nut 2 Lower the ATV so that the wheel is on the ground 3 Tighten...

Page 139: ...yte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Fl...

Page 140: ...ect when putting the battery back in the machine Fuse replacement 1 The main fuse and the fuse box are located under the seat 2 If a fuse is blown turn off the main switch and the switch of the circui...

Page 141: ...ld lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse CAUTION To prevent accidental short circuiting turn off the main sw...

Page 142: ...b holder tabs 1 Headlight bulb holder tab 2 WARNING POTENTIAL 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 star...

Page 143: ...fe will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 1 Do not touch the glass part of the bulb 5 Install t...

Page 144: ...cement If the tail brake light bulb burns out have a ATV dealer replace it Check and solution to Common Problems in Vehicle Here you can see some tables on the common problems which may come up when y...

Page 145: ...ncluding pilot lights from water heaters or furnaces Table1 Checks and Solutions to Common Problems in Appearance parts and impact fittings S N Problems Solutions 1 Plastic covers crack during operati...

Page 146: ...scs are deformed 2 Check if caliper hydraulic cylinders are stuck or the fixing parts of calipers are deformed 2 Brake performance goes down 1 Check if the brake discs are past the wear limit 2 Check...

Page 147: ...Front or rear brakes make scraping noise 1 Check if the brake discs are deformed 2 Check if the calipers hydraulic cylinders are stuck or the fixing parts of calipers are deformed 4 ATV pulls left or...

Page 148: ...mps don t work 1 Check if the headlight switch functions well 2 Check if the wires are broken 3 Check if the lamps or bulbs are broken 2 Vehicle cannot go into 4wd mode 1 Check if the control switch o...

Page 149: ...sor is broken 2 Check if the meter is broken 3 Check if the surface of the speed sensor is contaminated with dust or other debris S N Problems Solutions 5 Start switch on consol will not work 1 Check...

Page 150: ...broken 3 Check the clearance between the gears of the steering mechanism for excessive play 2 Front wheels shake seriously while running 1 Check axle bearings in wheels for damage 2 Check ball joints...

Page 151: ...not loose or broken 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 wheels and main axle nut on the axle f...

Page 152: ...r dampening force for failure 6 Reduction Gear box or Front Rear differential makes noise while running 1 Check if the splines on the drive shafts are worn or broken 2 Check if the splines on the left...

Page 153: ...e 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 admission line fo...

Page 154: ...r blockage 2 Check speed sensor on radiator for damage and Check for fan failure 3 Check if antifreeze meets the required specifications listed in the owner s manual 4 Check for air in the coolant loo...

Page 155: ...rt 6 Check if the air cleaner is blocked 7 Check if the oil circuit is smooth 8 Check if the exhaust system is blocked 7 Only one cylinder is working 1 Check ECU for damage 2 Check EFI cable for damag...

Page 156: ...team 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 com...

Page 157: ...rush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage and...

Page 158: ...n cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet brake...

Page 159: ...e fuel system needs to be drained 2 Remove the spark plug pour about one tablespoon of SAE 10W40 or 20W40 motor oil in the spark plug hole and reinstall the spark plug Ground the spark plug wire and t...

Page 160: ...Cleaning and Storage 9 4 or more than 30 86 F NOTE Make any necessary repairs before storing the machine...

Page 161: ...41 1in 1 130mm 44 5in 827mm 32 6in 1 260mm 49 6in 245mm 9 65in 3 000mm 118 1in Basic weight With oil and full fuel tank 276 kg 607 9 lb Engine Engine type Cylinder arrangement Displacement Bore stroke...

Page 162: ...API Service SE SF SG type or higher CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specific...

Page 163: ...5 L 0 31 Imp qt 0 37 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 tank capacity Fuel reserve amount Unleaded gasoline only 15 L...

Page 164: ...Operation First gear Primary ratio Final ratio V belt Shaft drive V belt automatic Left hand operation 1 750 0 690 2 297 3 142 10 459 Tire Type Size front rear Tubeless 25 8 12 25 10 12 Brake Front br...

Page 165: ...ont suspension Rear suspension Double wishbone Swing arm mono cross Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel trave...

Page 166: ...A C magneto YTX20L BS or GSTX20L BS 12 V 21 Ah or 12V 18Ah Headlight type Krypton bulb Bulb voltage wattage quantity Head light Tail brake light Indicator light Neutral indicator light Reverse indica...

Page 167: ...10 7 Specification Model HS400ATV 2 Fuses Main fuse Headlight fuse Ignition fuse Auxiliary DC jack fuse Four wheel drive fuse Signaling system fuse Backup fuse 30A 15A 10A 10A 3A 10A 10A...

Page 168: ...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 169: ...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 170: ...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 171: ...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 w...

Page 172: ...nts that each 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 P...

Page 173: ...an authorized HISUN dealer at its place 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 fro...

Page 174: ...ance of any maintenance or repairs 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 a...

Page 175: ...POWERSPORTS 888 405 8725 Coleman Powersports 364 S Smith Rd Tempe AZ 85281...

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Coleman POWERSPORTS HS360ATV, Owner'S Manual

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