Craftsman 108.27807 Page 53 Operator'S Manual Download | Manualshive

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53

Battery Installation

1. Set the battery in its holder.

2. Install the battery vent tube. It must be free from obstructions and securely

installed. If not, battery gases could accumulate and cause an explosion. The
tube should be routed away from the frame and body to prevent corrosion.
Avoid skin contact with electrolyte; severe burns could result.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall battery cover and attach the hold down strap.

6. Verify that cables are properly routed.

NOTE:

When parking the ATV for any amount of time make sure that the main

switch (key) is turned to the “OFF” position. Doing so will prevent battery drain.

NOTE:

When your ATV is placed in storage for one month or more, the battery

should be removed, charged to proper level, and stored in a cool dry place. Before
reusing, take the battery for testing and recharging. Contact 1-800-643-7332 for
an authorized service center. When installing a new battery, make certain it is fully
charged prior to it is initial use. Using a new battery that has not been fully charged
can damage the battery resulting in a shorter life of the battery, it can also hinder
vehicle performance.

16. Exhaust System

DO NOT TAMPER WITH NOISE CONTROL SYSTEM (MUFFLER)!

Exhaust system components are very hot during and after use of ATV

.

Do not touch exhaust system components. Serious burns can
result. Be especially careful when traveling through tall grass. The potential for fire
exists.

When cleaning the spark arrester, you must follow the safe guards listed below to
avoid serious injury.

•

Do not perform this operation immediately after the engine has been run
because the exhaust system becomes very hot.

•

Keep combustible materials away from exhaust system. Fire may result.

Spark Arrester

In the state of California the spark arrester is required by law (section 4442 of the
California Public Resources Code). Other states may have similar laws. Federal

WARNING

WARNING

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Summary of Contents for 108.27807

Page 1: ... specifications for use on public roads streets highways and thoroughfares Read and have an understanding of all the instructions for proper assembly and safe operation as well as the instructions concerning the engine and all other portions of the vehicle View Operations and Safety video Be at least 16 years of age For answers to your questions about this product call 1 800 643 7332 8 a m 5 p m E...

Page 2: ...n Warnings 17 7 Vehicle Identification 27 8 Basic System Functions 28 9 Starting the Engine 39 10 Vehicle Break in Period 41 11 Riding Gear 41 12 Riding 42 13 Carrying Loads 49 14 CVT System 50 15 Battery 51 16 Exhaust System 53 17 Maintenance 54 18 Storage 72 19 Troubleshooting 74 20 Tools 77 21 System Specifications 78 22 Wiring Diagram 80 23 Warranty 81 ...

Page 3: ...tice Never make any modifications to the engine drive system mechanical or electrical systems of your ATV Never install after market parts or accessories intended to increase the speed or power of your ATV Additionally failure to follow these requirements will void the Warranty on your ATV NOTE The addition and use of certain accessories including but not limited to mowers blades sprayers winches ...

Page 4: ...rds are used throughout this manual 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 to the potential for personal injury Your safety is involved WARNING Indicates a potential hazard which could result in severe injury or death CAUTION Indicates a potential hazard which may result in minor personal injury or damage...

Page 5: ...Never permit a guest to operate this ATV unless the guest has read this manual and all product labels and has completed a certified training course Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never operate an ATV without wearing an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves boot...

Page 6: ...Always follow proper procedures for crossing the side of a hill as described in Section 12 Riding Side Hilling Avoid hills with excessively slippery or loose surfaces Shift your weight to the up side of the ATV Never attempt to turn the ATV around on any hill until you have mastered level ground turning technique described in Section 12 Riding Making Turns Avoid crossing the side of a steep hill i...

Page 7: ...er installation or use of accessories Never exceed the stated load capacity for an ATV as stated in Section 21 System Specifications Cargo should be properly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking SAFETY TRAINING We strongly recommend that all new ATV riders attend a profession...

Page 8: ...hicle for your protection Read and follow the instructions on each decal carefully In the event that any decal becomes illegible or comes off contact 1 800 643 7332 NOTE Illustrations used in this manual are for general representation only Your model may differ ...

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Page 12: ...12 Refer to Page 13 ...

Page 13: ... HC NOX ENGINE FAMILY EXHAUST EMISSION STANDARDS THIS VEHICLE CONFORMS TO CALIFORNIA ARB REGULATIONS APPLICABLE TO 2006 MODEL YEAR NEW OFF HIGHWAY RECREATIONAL VEHICLES AND IS CERTIFIED TO 1 2 GM KM HC ENGINE FAMILY EXHAUST EMISSIONS STANDARDS THE WARRANTED USEFUL LIFE OF THIS ENGINE FOR THE PURPOSE OF MEETING US EPA STANDARDS IS 60 MONTHS OR 10 000 KILOMETERS WHICHEVER OCCURS FIRST ENGINE TUNE UP...

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Page 16: ...l light Brake light check 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 pins 8 Air cleaner element check for dirt clean or replace 9 Steering check for free operation noting any unusual looseness in any area 10 Loose parts visually inspect vehicle for ...

Page 17: ...re information about the training course contact 1 800 887 2887 POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of ...

Page 18: ...nd or your passenger HOW TO AVOID THE HAZARD Never carry a passenger POTENTIAL HAZARD Operating this ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN 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 WARNING WARNING ...

Page 19: ...TV POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPEN 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 that is proper for the terrain visibility operating conditions and your experience POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accide...

Page 20: ...educe your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels causing injury or an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation POTENTIAL HAZARD Failure to use extra care when...

Page 21: ...use ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in Section 12 Riding Traveling Uphill Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill a...

Page 22: ...l Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW...

Page 23: ...y When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in Section 12 Riding Turning around on a Hill POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn H...

Page 24: ... accident HOW TO AVOID THE HAZARD Never operate the ATV through water which exceeds the recommended maximum depth in this manual see Section 12 Riding Crossing Streams Avoid operating the ATV through deep or fast flowing water Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads POTENT...

Page 25: ...ZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed for use on this ATV and should be installed and used according to instructions supplied with the part If you have questions contact 1 800 643 7332 POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improper...

Page 26: ...ving vehicle After a rollover or an accident have a qualified service dealer check the complete machine including but not limited to brakes throttle and steering for possible damage Safe operation of this rider interactive vehicle requires good judgment and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of contr...

Page 27: ...gine Serial Number left front side of engine crankcase The vehicle VIN and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required Also these numbers are essential to the recovery and identification of your ATV if it is ever stolen Frame VIN Engine Serial 1 2 ...

Page 28: ...ore in a safe place Your key can only be duplicated by obtaining a key blank and having it cut by mating it with your existing key Record key number in space below Key Number 8 Basic System Functions Electrical Switches 8 6 7 2 1 5 ...

Page 29: ...ngine Stop Switch To stop the engine 5 Override Button press the override button BEFORE backing up to obtain additional power 6 Bright Light Switch Will change the light setting from dim to bright 7 Blinker Switch Will activate both left and right blinkers 8 Horn Button Will activate the horn Never activate the override button while throttle is open as loss of control may result causing severe per...

Page 30: ...dicator Lights The ATV has indicator lights The configuration of these lights differs with individual models and not every model is equipped with all the lights This information will help you identify the lights on your machine and their function With engine running verify function of indicator lights each time ATV is used NOTE The taillight is on whenever the main switch key is in the on position...

Page 31: ... freezing temperatures can result in water freezing in the throttle cable conduit and or on the throttle mechanism This may result in the throttle sticking which can cause the engine to continue to run and result in loss of control Throttle Lever Pressing the throttle lever 1 with your thumb controls engine speed and vehicle movement The throttle lever is spring loaded and engine speed returns to ...

Page 32: ...ould feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact 1 800 643 7332 for proper diagnosis and repairs Setting the Parking Brake Always check to be sure that the parking brake has been disengaged before operating the ATV An accident could result causing severe injury if the parking brake is left on while t...

Page 33: ...liary brake when backing down a hill may cause the ATV to become unstable and tip over Your ATV has an auxiliary brake provided as a safety feature which operates a rear brake on your unit Step on the pedal located on the right footboard to operate the auxiliary brake The auxiliary brake is intended as a backup to the main brake system in the event the main system becomes inoperative Brake Fluid L...

Page 34: ...ission Gear Selector Operation Engaging a lower gear when the engine speed is too high could cause the wheels to stop rotating leading to loss of control which could lead to the possibility of death or serious injury CAUTION To change gears stop the vehicle and with the engine idling move the lever to the desired gear Shifting gears with the engine speed above idle or while the vehicle is moving c...

Page 35: ...e cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle We recommend the use of a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Always follow the anti freeze manufacturer s mixing recommenda...

Page 36: ...structions in Section 17 Maintenance for additional information CAUTION Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur Additional Fuel System Safety Instructions Always exercise extreme caution whenever handling gasoline Always refuel with the engine turned off and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in o...

Page 37: ...vehicle storage and whenever transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE The reserve supply has about a 6 mile 10km range of gas Always refill the gas tank as soon as possible after having used the reserve supply Always return valve to ON position after refueling the machine Fuel Filter The filter should be replaced every 100 hours of ope...

Page 38: ... between the full and add marks 2 Add oil as indicated by the level on the dipstick Do not overfill 4 Wheel Drive System 4WD Extremely heavy steering feel is a symptom of malfunction of the front gear case differential Loss of control could result even in 2 Wheel Drive 2WD position If you experience any of these steering symptoms contact 1 800 643 7332 for an authorized service dealer Asymmetrical...

Page 39: ... reverse The 4WD indicator light will come off when the 4WD is disengaged If the 4WD continues to remain engaged after following these instructions contact 1 800 643 7332 for an authorized service dealer NOTE Heavier steering effort and feel will be experienced when 4WD is engaged 9 Starting the Engine Never run an engine in an enclosed area Carbon monoxide exhaust gas is poisonous and can cause s...

Page 40: ...ottle more than of its full travel during the starting procedure Doing so will flood the engine and cause fouling of the spark plug Cold Weather Starting less than 40 0 F Perform starting procedure steps 1 through 5 NOTE While pressing the engine start button it may be necessary to hold the throttle lever not more than of the full travel to accommodate the auto choking system in a cold weather REM...

Page 41: ... vehicle operation and handling 4 Vary the throttle positions Do not operate at a sustained idle 5 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined earlier on the daily pre ride inspection checklist found in Section 5 Daily Pre Ride Inspection 6 Don t pull loads 7 Change oil and filter after first 20 hours or 200 miles 320 km 11 Riding Gear Safe Ri...

Page 42: ...This ATV is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance 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 balance of traction betwee...

Page 43: ...es 6 Always reduce speed and use additional caution Traveling Uphill Exercise extreme caution when traveling in hilly terrain Braking and handling are greatly affected Loss of vehicle control or overturning of the ATV could occur causing severe injury or death Whenever traveling uphill always travel straight uphill and 1 Avoid steep hills 15 incline maximum 2 Keep both feet on the footrests 3 Tran...

Page 44: ...ts 3 Steer slightly into the hill to maintain vehicle direction 4 If vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Traveling Downhill When traveling downhill do not travel at excessive speeds It is dangerous and can cause loss of vehicle control and tipping resulting in severe injury or death Whenever descending a hill always 1 D...

Page 45: ...ont of ATV 5 While holding brake lever down release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward 6 Lock the parking brake and remount ATV from the uphill side maintaining body weight uphill 7 Restart engine with transmission still in forward release the parking brake and proceed slowly controlling speed with the bra...

Page 46: ...ngine damage can result if the machine is not thoroughly inspected If it is impossible to take it to a dealer before starting follow the steps below 1 Move the ATV to dry land or at the very least to water depth not more than 8 inch 200mm 2 Turn the fuel valve selector to OFF 3 Remove the spark plug 4 Loosen the carburetor drain screw 1 5 Turn the engine over several times with electric start 6 Dr...

Page 47: ...s such as logs rocks and low hanging branches Operating in Reverse Operating your ATV in reverse can be dangerous You could hit an obstacle or person behind you or the vehicle could tip over rearward on a steep incline causing severe injury or death Avoid turning at sharp angles in reverse as tip over and severe injury may result Opening the throttle more than required may cause excessive fuel to ...

Page 48: ...rsonal injury or death NOTE This ATV is equipped with a reverse speed limiter Do not operate at wide open throttle Only open the throttle enough to maintain a desired speed Parking on an Incline Whenever the vehicle is parked on an incline 1 Turn the engine off 2 Place the transmission in gear 3 Set the parking brake 4 Shut off fuel supply 5 Avoid parking on an incline If it is necessary to park o...

Page 49: ...ing loads on one rack only increases the possibility of vehicle tip over Heavy loads can cause braking and control problems Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations which may require backing downhill All loads must be carried as low and horizontally on the racks as possible Carrying loads high and vertically on the racks raises the center of gravit...

Page 50: ...s If you experience any problems with the CVT contact 1 800 643 7332 for the name of an authorized service center The CVT housing must be securely in place during operation See illustrated parts list Low Range Use May Reduce CVT Operating Temperatures The basic operation of the CVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on th...

Page 51: ...us injury or death Battery electrolyte is poisonous KEEP OUT OF REACH OF CHILDREN It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing If contact occurs External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get promp...

Page 52: ...yte Battery Installation and Connections To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable first black negative cable last An exploding battery can cause serious injury or death CAUTION Your ATV is equipped with a 14Amp Battery This may not be sufficient to provide power for optional equipment When installing optional equipment please upg...

Page 53: ...sting and recharging Contact 1 800 643 7332 for an authorized service center When installing a new battery make certain it is fully charged prior to it is initial use Using a new battery that has not been fully charged can damage the battery resulting in a shorter life of the battery it can also hinder vehicle performance 16 Exhaust System DO NOT TAMPER WITH NOISE CONTROL SYSTEM MUFFLER Exhaust sy...

Page 54: ... perform these operations Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication intervals of important components are explained in the tables on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour...

Page 55: ...on item Auxiliary Brake Pre ride Pre ride Pre ride inspection item Tires Pre ride Pre ride Pre ride inspection item Wheels Pre ride Pre ride Pre ride inspection item Frame nuts bolts fasteners Pre ride Pre ride Pre ride inspection item Air Filter Pre Cleaner Daily Daily Inspect Clean Coolant Level Inspection Daily Daily Replace engine coolant annually Air Box Sediment Tube Daily Daily Drain deposi...

Page 56: ...t Bowl 50 hrs 6 months Drain bowl periodically and prior to storage D Throttle Cable 50 hrs 6 months Pre ride inspection item Inspect adjust lubricate replace if necessary Coolant strength 100 hrs 6 months Inspect strength seasonally Shift linkage 50 hrs 6 months Inspect adjust D Drive belt 50 hrs 6 months Inspect replace if necessary Steering 50 hrs 6 months Inspect daily lubricate Rear Axle 50 h...

Page 57: ... replaced Headlight Aim As Required As Required Adjust as necessary Lubrication Recommendations Item Lubricant Fluid Method Frequency 1 Engine Oil SAE 15W 40 Proper fluid level is 2 in illustration 1 Check level daily 2 Brake Fluid DOT 3 Only Maintain level between fill lines See Section 8 Basic System Functions Brake Fluid Level Change every two years or 200 hours 3 Transmission Oil SEA 80W 90GL5...

Page 58: ...mi annually 11 Shift Linkages Grease Locate fittings and grease Semi annually D NI Ball joints Inspect Inspect and replace it if necessary Semi annually 12 Prop Shaft Shaft Yoke Grease Locate fitting and grease Semi annually 13 Rear Axle Bearing Grease Locate fittings and grease Every 3 months or 50 hours 14 Swing Arm Bearing Grease Locate fittings and grease Monthly or every 20 hours D 15 Throttl...

Page 59: ...59 ...

Page 60: ...eriodic Maintenance Record Use the following table to record periodic maintenance work Maintenance Interval Service Date Service Dealer Remarks First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs ...

Page 61: ...ther part of machine when turned fully to the left or right 4 Torque handlebar adjuster bolts to 10 12 ft Ibs 14 16 Nm NOTE Tighten bolts so there is an equal gap at the front and rear of the handlebar block Improper gap will result in improper fit of upper part Miscellaneous Adjustments The following items should be checked occasionally for tightness or if they have been loosened during maintenan...

Page 62: ... the adjuster to increase or decrease spring tension Use supplied rear spring adjustment spanner See section 20 Tools Turn the adjustment to the right to assure proper tension 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 it 5 Reinstall pre filter over main f...

Page 63: ...gnment Check Do not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact 1 800 643 7332 to arrange for proper adjustment The recommended toe alignment is 1 8 to 1 4 3 to 6mm toe out 1 Set the handlebars in a straight ahead position and hold them in this position 2 Measure A and B A minus 3 B should be 1 16 to 1 8 1 5 to 3mm 4 If this me...

Page 64: ...is low and the diaphragm is not extended a leak is indicated and the diaphragm should be replaced Always fill the reservoir as indicated whenever the cover is loosened or removed to insure proper diaphragm operation Use DOT 3 brake fluid Check brake system for fluid leaks Check brake for excessive travel or spongy feel Check friction pads for wear damage and looseness Check security and surface co...

Page 65: ...3 Adjust the carburetor idle screw 3 in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Note The standard idle RPM is 1500 10 Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 Slide the boots off inline cable adjuster loosen adjuster locknut 2 Turn adjuster unt...

Page 66: ...o not allow hot oil to come into contact with skin as severe burns may result The recommended oil change interval is 30 hours or every 3 months whichever comes first Suggested oil change during the break in period is at 20 hours or one month whichever comes first Only use high quality detergent oil rated with API service classification SG SL The recommended oil for this ATV is 15W 40 Be sure to ch...

Page 67: ...adiator if the recovery bottle has run dry To add coolant make sure the engine is cool remove radiator pressure cap and using a funnel slowly add coolant mixture as necessary through the radiator filler neck NOTE Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement contact 1 800 643 7332 for the correct replacement part Trans...

Page 68: ...visually inspect lubricant level Lubricant should be 1 5 8 41mm below the top of the fill hole on the rear gear case and even with the fill hole on the front gear case 3 Reinstall fill plug Tighten securely 14 ft lbs 20N m Changing the Oil 1 ATV should be on level surface 2 Remove drain plug 3 Catch and discard used lubricant properly 3 Clean and reinstall the drain plug with a new sealing washer ...

Page 69: ...llow the safeguards listed below to prevent this type of situation Maintain proper tire pressure according to chart below Improper tire 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 improperly installed it could affect vehicle handling and tire wear T...

Page 70: ...he wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward correct rotation 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 specifications in the chart below Bolt Size Specification Front M10 X 1 25 20Ft Lbs 27N m Rear M12 X 1 25 50Ft...

Page 71: ...ug light from harness depress locking tabs A and remove 3 Install new light and reassemble panel Headlight Beam Adjustment The headlight beam can be adjusted up and down 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Sit in the seat S...

Page 72: ...utomotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish Transporting Whenever the ATV is to be transported the following measures should be taken 1 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 unit securely using suitable...

Page 73: ...nto the engine cylinder through spark plug hole Inspect the spark plug as detailed in Section 17 Maintenance Spark Plugs Replace or clean and re install the spark plug CAUTION Do not start the engine during the storage period This will disturb the protective film created by fogging BATTERY Remove the battery and add distilled water as required to bring fluid to the proper level After a period of t...

Page 74: ... Weak dead battery 4 Stale or dirty fuel 5 Carburetor out of adjustment 6 Loose or damaged wiring 7 Engine valves out of adjustment 1 Clean replace air filter 2 Clean replace spark plug 3 Recharge or replace battery 4 Empty fuel tank and refill tank with fresh clean fuel 5 Contact 1 800 643 7332 6 Check all wiring or contact 1 800 643 7332 7 Contact 1 800 643 7332 Will not start 1 Out of fuel 2 Fu...

Page 75: ... contact 1 800 643 7332 5 Contact 1 800 643 7332 6 Contact 1 800 643 7332 Poor idle speed performance 1 Carburetor idle screw out of adjustment 2 Improperly adjusted throttle cable 3 Dirty air filter 4 Faulty spark plug 5 Engine valves out of adjustment 1 Adjust the idle screw as detailed in Section 16 Maintenance 2 Adjust throttle cable as detailed in Section 16 Maintenance 3 Clean replace air fi...

Page 76: ...332 4 Contact 1 800 643 7332 5 Contact 1 800 643 7332 6 Contact 1 800 643 7332 Belt Burning 1 Use of high range when starting out on an incline 2 Insufficient ATV warm up 3 Towing or carrying loads in high range 4 Getting ATV stuck in mud or snow or climbing over large objects from a stopped position 1 When starting out on incline put ATV in low range 2 Warm up ATV for at least 5 minutes then with...

Page 77: ...77 20 Tools included with ATV 2 Spark Plug Wrench Open End Wrench 8 10 mm Open End Wrench 12 14 mm ...

Page 78: ... 129in Dry Weight 280kg 617lb Front Rack 18kg 39lb Rear Rack 36kg 79lb Load Capacity Combined Rider Payload 150kg 330lb Tongue Weight 54kg 120 lbs Tow Capacity 324kg 715 lbs Drive System Drive System CVT Front Tire 24X8 12 Rear Tire 24X11 10 Tire Pressure Front 27 6kPa 5PSI Tire Pressure Rear 27 6kPa 5PSI Brake System Front Brake Service Brake Rear Brake Hydraulic Disc Parking Brake All Wheel Hydr...

Page 79: ...Lubrication System Wet Sump Carburetor CVK30 Ignitions T C I Spark Plug Type DR7EA NGK Electrical Equipment Battery 12V 14AH Head light 35W 35W Brake Tail Light 21W 5W Rear Indicator 12V 1W Fan Indicator Light 12V 1W High Beam Light 12V 1W Neutral Position Light 12V 1W Heat Alarm Light 12V 1W Flasher Light 12V 10W X 4 Turn Indicator Light 12V 1W Mark Light 12V 5W ...

Page 80: ...80 22 Wiring Diagram ...

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