Coleman xt260 Owner'S Manual Download

Page: 71 / 119

13. CVT SYSTEM

When To Use Low Range

The following lists provide a guideline for when to use low range

rather than high.

Low Range

Basic operation at speeds less than 7 MPH (11km/h)

Heavy pulling

Riding through rough terrain (swamps, mountains, etc.)at low

ground speeds

High Range:

Basic operation at speeds greater than 7 MPH (11km/h)

High ground speeds

Summary of Contents for xt260

Page 1: ...Always wear a helmet it could save your life 102011 Never allow anyone under the age of 16 to operate this ATV Read this manual thoroughly It contains important safety information MODEL XT260 POWERSP...

Page 2: ...maintenance and care Fully understanding this manual and following all of the instructions herein will provide the knowledge needed to have safe and enjoyable ATV operation For questions regarding ope...

Page 3: ...e lever 33 Front and Rear Brakes 34 Parking brake 35 Brake fluid level 37 Transmission gear selctor 38 Engine coolant system 39 Coolant level 39 Fuel Oil system 41 Fuel system 42 Fuel valve 42 Fuel fi...

Page 4: ...ing inspection 84 Toe alignment check 84 Front brakes 85 Rear and Auxiliary Brake 86 Caruretor Engine idle RPM Adjustment 87 Throttle cable free play adjustment 87 Spark plug 88 Oil and Filter change...

Page 5: ...orts or from an authorized Coleman Motorsports Retailer 2 This warranty does not apply to any vehicle which is used in competition or used in a manner not consistent with the normal and proper intende...

Page 6: ...man Motorsports disclaims any responsibility for 1 Loss of time or loss of use of the product 2 Transportation costs to and from the authorized center 3 Other loss or damage to other equipment or pers...

Page 7: ...unless the guest has read this manual and all product labels and ha completed a certified training course l Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lo...

Page 8: ...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 g...

Page 9: ...sudden turns or stops and do not make sudden throttle changes l Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let...

Page 10: ...ly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibilities for your personal safety the safety of others and the protection of...

Page 11: ...to convey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert involved WARNING Indicates a potential hazard which could result in...

Page 12: ...he vehicle for your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your dealer for a replacement NOTE No 15 ONLY FOR...

Page 13: ...3 SAFETY WARNING 1 2 3 7...

Page 14: ...3 SAFETY WARNING 4 8...

Page 15: ...3 SAFETY WARNING 5 6 7 9 8 9...

Page 16: ...3 SAFETY WARNING 10 11 12 13 10...

Page 17: ...3 SAFETY WARNING 14 15 ONLY FOR 4WD 16 ONLY FOR 4WD 17 11...

Page 18: ...ck operation of all indicator lights and switches 6 Engine stop switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pin...

Page 19: ...NING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPERN Operating without an approved helmet increases your chances of a sev...

Page 20: ...HAZARD Carrying a passenger on this ATV WHAT CAN HAPPERN 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 AVOI...

Page 21: ...veways WHAT CAN HAPPERN 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 Avoid operating the ATV on pavement 1...

Page 22: ...gs WHAT CAN HAPPERN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume...

Page 23: ...WHAT CAN HAPPERN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and op...

Page 24: ...AZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPERN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps 18 5...

Page 25: ...Owner s Manual WARNING POTENTIAL HAZARD Removing hand from handlebars or feet from footrests during operation Removing even one hand or foot can reduce your ability to control the ATV or could cause...

Page 26: ...dden 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 t...

Page 27: ...autious on these kinds of terrain WARNING POTENTIAL HAZARD Climbing hills improperly Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for cl...

Page 28: ...e Owner s Manual WARNING POTENTIAL HAZARD Operating on excessively steep hills The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZA...

Page 29: ...ssible WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any h...

Page 30: ...parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually...

Page 31: ...es such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPERN Yo...

Page 32: ...ops and do not make sudden throttle changes Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads WARNING POTENTIAL HAZARD Improperly operating in...

Page 33: ...use changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories a...

Page 34: ...greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers Severe injury or de...

Page 35: ...ble damage WARNING and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe inj...

Page 36: ...place Your key can be duplicated only by obtaining a key blank and having it cut by mating it with your existing key Record Key Number The vehicle frame and engine serial numbers are important for mod...

Page 37: ...lights are on and the buzzer is sounding 3 Engine Start Button To start the engine this vehicle is equipped with a reverse speed limiter system To obtain additional power while backing up depress the...

Page 38: ...l not light unless the main switch is on Indicator Lights The ATV has indicator lights The configuration of these lights differs with individual models and not every model is equipped with all the lig...

Page 39: ...icking during riding and cause an accident Always check the lever for free movement and return before starting the engine and occasionally during riding Throttle Lever Engine speed and vehicle movemen...

Page 40: ...ing temperature of the brake fluid to drop which can lead to early brake fade and the possibility of severe injury Front and Rear Brakes The front and rear brakes are located on the inside of the tigh...

Page 41: ...in loss of braking Loss of braking could cause an accident Setting the Parking Brake 1 Squeeze the left hand brake lever two or three times and hold it 2 Push the park brake lock 1 into the notches on...

Page 42: ...ng the ATV on a hill or park the ATV in a side hill position WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV An accident could result causing severe...

Page 43: ...in the master cylinder which is located on the left handlebar should be checked before each side There is an indicator window 1 on the top of the master cylinder This window will appear dark when the...

Page 44: ...ear Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always place the transmission in gear with the parking brake locked whenever the vehi...

Page 45: ...ure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant...

Page 46: ...covery bottle has run dry the level in the radiator should be inspected and coolant added if necessary NOTE Use of a non standard pressure cap will not allow the recovery system to function properly I...

Page 47: ...here gasoline is stored l Do not over fill the tank Do not fill the tank neck l If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing l Never sta...

Page 48: ...e positions OFF For vehicle storage and whenever transporting ON For normal operation NOTE here is about a 6 mile 10km range on reserve gas Always refill the gas tank as soon as possible after having...

Page 49: ...emove dipstick 1 and wipe dry with a clean cloth 4 Put dipstick into the oil tank don t screw in it remove it and read the oil level 5 Remove dipstick and check to see that the oil level is between th...

Page 50: ...still be engaged the 4WD would finally disengage when rides on a hard surface or rides in reverse The 4WD indicator light will come off when the 4WD disengage If the 4WD remain engaged after followin...

Page 51: ...ding to ensure it is in proper working order If proper inspection is not done severe injury or death could result Pre ride inspection You can tell if malfunctions in one side CV joints by pulling the...

Page 52: ...ng brake 2 Turn the fuel tank valve to ON 3 Sit on the vehicle 4 Turn the engine stop switch to RUN 5 Turn the ignition key to on apply the brake lever and press the starter button 6 Do not press the...

Page 53: ...damage to close fitted engine parts Please set a limit to half throttle during the break in periods 1 Locknut 2 Adjuster 1 Fill fuel tank 2 Check oil reservoir level indicated on dipstick Add oil if...

Page 54: ...hield offer the best protection for your eyes 3 Gloves off road style 4 Boots A pair of strong over the calf type boots with heels such as mo to cross boots 5 Clothing To protect your body long sleeve...

Page 55: ...g on level ground Maximum vertical hitch weight 25 lbs 11kg Improper loading of the front rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam with cargo U...

Page 56: ...h or the loads must be reduced to maintain stable operating conditions l LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center or gravity of the vehi...

Page 57: ...footrests and both hand on the handlebars 2 After starting the engine and allowing it to warm up shift the transmission into gear 3 Check you surroundings and determine your path of travel 4 Release...

Page 58: ...e than the inside wheels when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your weight on the outer footrest This technique alters the bal...

Page 59: ...ing quick sharp turns which can cause skids 3 Correct a skid by turns the handlebars in the direction of the skid and shifting your body weight forward 4 Never apply brakes during a skid Complete loss...

Page 60: ...verturning of the ATV could occur causing severe injury or death Whenever traveling uphill always travel straight uphill and 1 Avoid steep hills 15 maximum 2 Keep both feet on the footrests 3 Transfer...

Page 61: ...you upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel down...

Page 62: ...ehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs warning Do not t...

Page 63: ...rs full left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly down...

Page 64: ...ng rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal CAUTION Never operating the ATV through deep or fast flowing w...

Page 65: ...the fuel valve to OFF l Remove the spark plug l Loosen the carburetor drain screw 1 l Turn the engine over several times with electric start l Dry the spark plug and reinstall or replace with a new p...

Page 66: ...u ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches WARNING Not all obstacles are visible Travel with caution on trai...

Page 67: ...lowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing NOTE This ATV is equipped with a reverse speed...

Page 68: ...ransmission in gear 3 Set the parking brake 4 Shut off fuel supply 5 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown ab...

Page 69: ...ce is the responsibility of the owner Always follow recommended maintenance procedures See you dealer l The CVT housing must be securely in place during operation Failure to comply with this warning c...

Page 70: ...e temperature inside the clutch cover extends the life of the CVT components belt cover etc Adjust the center distance of the CVT 1 Remove crankcase filter cover cover protector and crankcase cover 2...

Page 71: ...when to use low range rather than high Low Range l Basic operation at speeds less than 7 MPH 11km h l Heavy pulling l Riding through rough terrain swamps mountains etc at low ground speeds High Range...

Page 72: ...lk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15minutes and get prompt medical attention Batteries produce explosive gases Keep spark...

Page 73: ...one cup water to prevent damage to the ATV Battery Installation and Connections WARNING To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable fi...

Page 74: ...operly routed NOTE l When you ATV is placed in storage for one months or more the battery should be removed charged to proper level and stored in a cool dry place l Before reusing take the battery to...

Page 75: ...Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the arrestor screw located on the bottom of the muffler pull out the arrestor the mesh 2 Clean the arres...

Page 76: ...tion intervals of important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approx...

Page 77: ...e ride Pre ride inspection item l Air Filter Pre Cleaner Daily Daily Inspect Clean Coolant Level Inspection Daily Daily Replace engine coolant Every one year l Air Box Sediment Tube Daily Daily Drain...

Page 78: ...Monthly Inspect periodically l Rear Gear case Oil 100 hrs Monthly Check monthly and change annually l Front Gear case Oil Only for 4WD 100 hrs Monthly Check monthly and change annually Engine Cylinde...

Page 79: ...Cable 50 hrs 6 months Inspect adjust lubricate replace if necessary pre ride inspection item Coolant strength 100 hrs 6 months Inspect strength seasonally Shift linkage 50 hrs 6 months Inspect adjust...

Page 80: ...s Inspect and adjust as needed Item Hours When Remarks D Fuel System 100 hrs 12 months Check for leaks at tank cap lines fuel valve filter and carburetor Replace lines every one year D Fuel Filter 100...

Page 81: ...Driven 25 hrs 3 months Inspect clean Engine mounts 25 hrs 3 months Inspect D Valve clearance 100 hrs 12 months Inspect adjust D Shift selector box H L R N 200 hrs 24 months Change grease every two yea...

Page 82: ...ill lines See 7 CONTROL As require change every two years or 200 hours 3 Transmissi on Oil SEA 80W 90GL5 See 16 MAI NTENANCE TRAN S MISSION LUB Change annually or at 100 hours 4 Rear Gear case oil SEA...

Page 83: ...ring Post Bushings Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or50hours l 8 Front Wheel bearings Grease Inspect and replace bearings if necessary Semi annually 9 Ti...

Page 84: ...16 MAINTENANCE 78...

Page 85: ...pect and replace it if necessary Monthly or 20 hours l 15 Front Gear case oil SEA 80W 90GL5 See 16 MAI NTENANCE Rear Gear case Lubrication Change annually or at 100 hours NOTE 1 More often under sever...

Page 86: ...Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or person Remark First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 5...

Page 87: ...tment Your ATV has handlebars which can be adjusted for your personal fit 1 Remove the handlebar cover 2 Loosen the four bolts 3 Adjust handlebar to desired height Be sure handlebars do not hit gas ta...

Page 88: ...s 27N m Rear M12X1 25 50Ft Lbs 69N m NOTE All nuts that have a cotter pin installed must be serviced by an authorized Dealer Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut re...

Page 89: ...g Adjustment Air Filter Service 1 Remove seat 2 Release clips and remove Cover 3 Loosen clamp and remove Filter 4 Remove fabric type pre filter from main filter Wash pre filter in soapy water and dry...

Page 90: ...not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact your dealer He she has the training and tools to Mack these adjustment Toe Alignm...

Page 91: ...ating condition How often they need checking depends upon the type of driving that has been done l Keep fluid level in the master cylinder reservoirs as described see 7 Control and part functions Norm...

Page 92: ...n the friction material is worn to 3 64 1mm l Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to be used as...

Page 93: ...ut until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 4 The standard idle RPM is 1500 10 Throttle Cable Free Play...

Page 94: ...Measure l Spark plug gap Out of specification Adjust gap Spark Plug Removal and Replacement WARNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could bu...

Page 95: ...ng below 10 F 12 AND RIDING BETWEEN 10 F 12 AND 30 F 0 when most trips are slow speed and less than 5 mph 8km h Be sure to change the oil filter whenever changing oil CAUTION Oil may be hot Do not all...

Page 96: ...vel should be checked monthly or 20 hours whichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug 1 and check the lubricant level The correct...

Page 97: ...ove transmission drain plug located on the bottom left hand side and drain the oil Catch and discard used oil properly 4 Clean and reinstall the drain plug torque to 14 ft lbs 20Nm 5 Add the correct a...

Page 98: ...he correct gearcase lubricant to use is SEA 80W 90 GL5 Weight Gear Lube Oil Changing Procedure 1 Remove drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new...

Page 99: ...re inflation may affect ATV maneuverability Do not use improper tires The use of non standard size or type tires may affect ATV handling Make certain the wheels are installed properly If wheels are im...

Page 100: ...point toward the front 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found in 16 MAINTENANCE Wheel Nut Tor...

Page 101: ...or light while riding can result in an accident causing severe injury or death CAUTION Do not service while headlight is hot Serious burns may result Do not touch a halogen lamp with bare fingers Oil...

Page 102: ...Remount the basis of the light with the bulb into the light and the cover 1 B Headlight Lamp Relpacement FOR 04 6 Use bulb 12V 35W 35W 7 Remove the cover 1 8 Dismantle the basis of the light 9 Change...

Page 103: ...he headlight beam can be adjusted up and down 1 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall 2 Measure the distance from the floor to the center of the hea...

Page 104: ...pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If...

Page 105: ...r as required if fluid looks dark or contaminated Fog the Engine Spray a light oil into the cylinder through the spark plug hole Check and Lubricate Cables Grease Inspect all cables and lubricate Batt...

Page 106: ...Turn off the engine and remove the key 2 Turn the fuel valve to off 3 Be certain the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting until secu...

Page 107: ...fe Insufficient warm up of ATV s exposed to low ambient temperatures Warm engine at least 5 min the with transmission in neutral advance throttle to approx 1 8throttle in short bursts 5 to 7 times The...

Page 108: ...TARTING THE ENGINE And check the fuel air ignition compression system Let the main switch key on while parking the ATV When stopping the engine turn off the main switch key off at once WARNING This AT...

Page 109: ...ted fuel or fuel containing Clogged air cleaner Water or foreign material element Clogged pilot jet Improper air cleaner Clogged air passage setting Improperly set pilot air s crew Clogged pilot air p...

Page 110: ...imary Loose coupler connection secondary coil Improperly grounded Faulty high tension cord Broken wire harness Broken ignition coil body POOR IDLE SPEED PERFORMANCE Carburetor Air cleaner Loose or clo...

Page 111: ...p coil Cylinder gasket broken Fuel system Carbon deposit build up Clogged fuel tank breather hole Improperly adjusted valve Clogged air cleaner element clearance Clogged jet Improperly contacted Impro...

Page 112: ...pression system Heavy carbon deposit build up Improperly adjusted valve timing Improperly adjusted valve clearance Engine oil Incorrect engine oil level Improper engine oil quality High viscosity Low...

Page 113: ...ine mount Clutch shoe see 13 CVT system Worn damaged Primary sliding sheave Seized POORSTARTING FAULTY BRAKE PERFORMANCE POOR BRAKING EFFECT V belt Worn front hub bearing Slipping oily V belt Worn bra...

Page 114: ...18 Tool 108...

Page 115: ...280kg Front Rack 18kg Rear Rack 36kg Load Capacity Combined Rider Payload 150kg Tongue Weight 11kg Tow Capacity 200kg Drive System Drive System CVT Front Tire 24X8 12 Rear Tire 24X11 10 Tire Pressure...

Page 116: ...c Starter Engine Cooling Liquid Cooled Lubrication System Wet Sump Carburetor CVK30 Ignitions T C I Spark Plug Type DR8EA NGK Electrical Equipment Battery 12V 14AH Head light 35W 35W Brake Tail Light...

Page 117: ...111...

Page 118: ...20 WIRNING DIAGRAM 112...

Page 119: ...POWERSPORTS 888 405 8725 Coleman Powersports 2010 E University Drive Suite 15 Tempe AZ 85281 113...

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