Crossfire 500ATV Owner'S Manual Download Page 69

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Air filter element cleaning

NOTE:

There is a check the air filter case. If dust collects

in the air filter, clean the air filter element and air

filter case, If have water in the air filter, exchange

the air filter element..

1.Remove passenger seat and driver seat.
2.Remove the right panel.
3.Remove the clip bolt.

clip bolt

1.Bolts 2.Air filter frame

4.Remove these bolts, and remove the air
filter frame.

5.Pull off the lock plate, remove the air filter

case cover.

6.Take out the air filter element.
7. Inspect the air filter element and replace

it if damaged.

Summary of Contents for 500ATV

Page 1: ...OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information This ATV should not be ridden by anyone under 16 years of age 500ATV 4 4 ...

Page 2: ...t also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your ATV please consult you dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE AN...

Page 3: ...ovides key information to make procedures easier or clearer The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates special precautions that must be taken to avoid damage to the machine Avoid damag...

Page 4: ...legal and unsafe to operate this ATV on any public street road or highway This ATV complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV ...

Page 5: ...ION AND MACHINE IDENTIFICATION 11 Identification number records 12 CONTROL FUNCTIONS 13 Main switch 13 Indicator and warning lights 14 Handlebar switches 15 Driver model turn switch 16 Throttle LeverSpeed limiter 17 Indicates a potential hazard that could result in serious injury or death ...

Page 6: ...l 19 Drive select lever 20 Fuel tank cap 20 Starter choke 21 Seat 22 Front and rear shock absorber adjustment 23 RIDING YOUR ATV 24 GETTING TO KNOW YOUR ATV 25 RIDE WITH CARE AND GOOD JUDGEMENT 25 During operation 29 BE CAREFUL WHERE YOU RIDE 32 ...

Page 7: ... PERIODIC MAINTENANCE AND ADJUSTMENT 42 Owner s manual and tool kit 42 PERIODIC MAINTENANCE LUBRICATION 43 Engine oil and oil filter cartridge 48 To check the engine oil level 48 Changing the final gear oil 52 Front gear oil replacement 53 Cooling system 54 Changing the coolant 55 ...

Page 8: ...element cleaning 60 Valve clearance adjustment 65 Throttle lever adjustment 65 Inspecting the brake fluid level 67 Cable inspection and lubrication 71 Battery 73 Replacing a headlight bulb 76 Troubleshooting 79 CLEANING AND STORAGE 80 SPECIFICATIONS 82 ...

Page 9: ...Circuit Diagram Wiring Diagram and troubleshooting chart 87 ...

Page 10: ...1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 11: ...els on your machine They contain important information for safe and proper operation of your ATV Never remove any labels from your ATV If a label becomes difficult to read or comes off a replacement label is available from your dealer 1 2 ...

Page 12: ...3 3 4 ...

Page 13: ...4 5 6 ...

Page 14: ...perate an ATV with engine size greater than 90cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely Never carry more than 1 passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never oper...

Page 15: ... for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual 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 Never go over the top of a hill at high speed Always follow proper...

Page 16: ...ly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply those several times to let friction dry out the linings Always be sure there are no obstacles ...

Page 17: ...8 dealer ...

Page 18: ... refuel while smoking or in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eye...

Page 19: ...10 ...

Page 20: ...28 V belt case 29 Fuel tank cap 30 Storage compartment and tool kit 31 Oil filter cartridge 1 Coolant reservoir 2 Drive select lever 3 Rearview mirror 4 Front storage compartment 5 V belt cooling duct check hose IN 6 V belt cooling duct check hose OUT 7 Vacuum pump 8 Spark arrester 9 Passenger seat 10 Tail brake light 11 Radiator cap 12 Auxiliary DC jack 12V 120W 10A 13 Main switch 14 Front brake ...

Page 21: ...ehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen NOTE The vehicle identification number is used to identify your machine ...

Page 22: ...itch positions are as follows The engine can be started only at this position and the headlights taillight and meter lighting come on when the light switch is on All electrical circuits are switched off without clock at meter The key can be removed in this position ...

Page 23: ...operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes The electrical circuit of the warning light can be checked according to the following procedures 1 Set the engine stop switch to and turn the key to ON 2 Shift the drive select lever into the neutral position 3 Push the start switch If the warning light does not come on while the start s...

Page 24: ...tor will not operate properly If this should happen remove the battery and recharge it Engine stop switch Make sure that the engine stop switch 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 engine stop switch is set to Start switch Make sure that you ...

Page 25: ...mounted solidly on one axle and turn together at the same speed Furthermore when riding in 4WD LOCK DIFF LOCK the front wheels also 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 turning technique must be use to allow the ATV to make turns quickly and easily It is essential that thi...

Page 26: ...le to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released POTENTIAL HAZARD Malfunction of throttle WHAT CAN HAPPEN The throttle cable could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine ...

Page 27: ...he maximum speed of the ATV 1 Locknut 2 Adjusting screw a No more than 18 mm 0 70 in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or be injured HOW TO AVOID THE HAZARD Do not turn the adjusting screw out more than 18 mm 0 70 in Always make s...

Page 28: ...ll it toward the handlebar to apply the front brake 1 Front brake lever The brake pedal is located on the right side of the ATV Push down on the pedal To apply the rear brake The brake lever is located on the left handlebar pull the lever toward and push the handlebar to apply the rear brake 1 Parking brake lever 2 Lockup bar 1 Brake pedal ...

Page 29: ...lever Fuel tank cap The drive select lever is used to shift your machine into the forward neutral and reverse 1 Drive select lever Remove the fuel tank cap by Insert key and turning it counterclockwise 1 Fuel tank cap ...

Page 30: ...Use the starter choke in reference to the figure Position Cold engine start ambient temperature below 5 C 40 F Position Cold engine start ambient temperature at 0 C 30 F 30 C 90 F and warming up position Position Cold engine start ambient temperature above 25 C 80 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed ...

Page 31: ...er seat a unscrew the seat lock bolts 2 b To remove the driver seat pull the seat lock lever upward and pull up the seat at the rear 1 Bolt 2 Bolt and nut 1 Projection 2 2 Seat holder 2 NOTE Make sure that the seat is securely fitted ...

Page 32: ...oad as follows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction b 1 Spring preload adjusting ring 2 Position indicator 1 Special wrench NOTE A special wrench can be obtained at your dealer to make this adjustment Standard position 2 1 Minimum soft 5 Maximum hard ...

Page 33: ...24 RIDING YOUR ATV Riding Your ATV ...

Page 34: ...ding your ATV requires special skills acquired through practice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity 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 Befo...

Page 35: ...this ATV at slow speeds first even if you are an experienced operator Do not attempt to operate at maximum performance until you are totally familiar with the ATV s handling and performance characteristics Not recommended for children under 16 years of age This ATV is designed to carry operator and cargo and 1 passenger ...

Page 36: ...27 ...

Page 37: ...y to balance and control this ATV Could cause an accident resulting in harm to you and or your passengers HOW TO AVOID THE HAZARD Never carry more than 1 passenger The long seat is to allow the operator and 1 passenger to shift position as needed during operation It is not for carrying more than 1 passenger ...

Page 38: ...ing even one hand or foot can re duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handle bars and both feet on the footboards of your ATV during operati...

Page 39: ...l of the ATV or overturn POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off ...

Page 40: ...hich 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 added to this vehicle should be 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 Modifications ...

Page 41: ... handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots and streets Do not ride on any public road street or high way Riding on public roads can result in collisions With other vehicles Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks ...

Page 42: ...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 op erating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain ...

Page 43: ...34 ...

Page 44: ...e of the turn opposite your desired direction and lean your upper body into the turn Use the throttle to maintain an even speed through the turn This maneuver will let the wheel on the inside of the turn slip slightly allowing the ATV to make the turn properly POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Alw...

Page 45: ... procedure again If the riding surface is slippery or loose it may help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect body movements or too much speed for the sharpnes...

Page 46: ...oper 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 brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the downhill side Avoid sudden application of either the front or rear brake because t...

Page 47: ... this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never operate the ATV on hills steeper than 25 Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on...

Page 48: ...akes after leaving the water Do not continue to ride your ATV without verifying that you have regained proper braking ability POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this ATV in fast flowing water or in water deeper than t...

Page 49: ...V in water be sure to check the trapped water at the air filter V belt cooling duct the storage compartment If necessary drain any water that may have accumulated Also if it has been operated in salt water or muddy conditions ...

Page 50: ...e the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so steep you could not walk up them easily 1 Bring the machine to a Stop by applying the brakes 2 Stop the engine 3 pull the lever toward and push lockup bar lock the handlebar to apply the rear brake 4 Always block the f...

Page 51: ... engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fires HOW TO AVOID THE HAZARD Turn off the engine when performing maintenance unless otherwise specified Have your dealer perform service if you are not familiar with machine service You are recommended to put this owner s manual in the...

Page 52: ... condition Adjust gap and clean Replace if necessary Air filter element Clean Every 20 40 hours More often in wet or dusty areas Replace if necessary Carburetor Check starter choke Adjust engine idling speed NOTE For ATVs not equipped with an odometer or an hour meter follow the month maintenance intervals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance in...

Page 53: ...akage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check fuel hose for cracks or damage Replace if necessary Engine oil Replace Warm engine before draining Engine oil filter cartridge Replace Engine oil strainer Clean Final gear oil Check for oil leakage Differential gear oil Replace every 12 months Front brake Check operation fluid leakage Correct if necessary...

Page 54: ...r cracks or damage Wheels Check balance damage runout Repair if necessary Wheel bearing Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle pivots Lubricate with lithium soap based grease Drive shaft universal j...

Page 55: ...cracks or damage Front and rear axle boots Check operation Replace if damaged Stabilizer bushes Check for cracks or damage Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Adjust headlight beams Since these items require special tools data and technical skills have your dealer perform the service ...

Page 56: ...fluid Normally check the brake fluid level and add fluid as required On the inner parts of the master cylinder and caliper replace the oil seals every two years Replace the brake hoses every four years or if Indicates a potential hazard that could cracked or damaged Indicates a potential hazard that could result in serious injury or death ...

Page 57: ...off the dipstick with a clean rag 6 Insert the dipstick in the oil filler hole screwing it in and then remove it again to check the oil level 7 If the engine oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level 8 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 9 Install the panel and bolt 1 Bolt 2 Pan...

Page 58: ...the oil filter cartridge with an oil filter wrench 7 Apply a light coat of engine oil to the O ring of the new oil filter cartridge 8 Install the new oil filter cartridge Tightening torque 17Nm or 1 7m kgf or 12 ft ibf 1 Engine oil filter cartridge NOTE Make sure the O ring is seated properly minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and...

Page 59: ...f 11 Add the specified amount of recommended engine oil and then install the engine oil filler cap and tighten it 12 Start the engine and warm it up for several Engine oil classification of the ATV Final gear oil Checking the final gear oil level Oil quantity Without oil filter cartridge replacement 2 5L 2 64 US qt With oil filter cartridge replacement 2 6L 2 75 US qt ...

Page 60: ...oil is below the brim of the filler hole add sufficient oil of the recommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten it NOTE The oil level should be at the brim of the filler hole Be sure no foreign material enters the final gear case 1 Final gear oil filler bolt 2 Correct level 3 Final gear oil ...

Page 61: ...t and then tighten it to the specified torque 23 Nm or 2 3m kgf or 16 ft ibf 5 Add the recommended final gear oil to the brim of the filler hole 6 Install the oil filler bolt and then tighten it 7 Check for oil leakage if oil leakage is found check for the cause 1 Final gear oil drain bolt Recommended oil SAE 80W 90 API GL 4 Hypoid gear oil Oil quantity 0 33L0 35 US qt Be sure no foreign material ...

Page 62: ...23 Nm or 2 3m kgf or 16 ft ibf 5 Fill the differential gear case with the specified amount of the recommended oil 6 Install the oil filler bolt and then tighten it to the specified torques 10 Nm or 1 0 m kgf or 7 2ft Ibf 7 Check for oil leakage If oil leakage is found check for the cause 1 Front gear oil drain bolt 1 Front gear oil filler bolt Recommended oil SAE 80W 90 API GL 4 Hypoid gear oil Oi...

Page 63: ...el mark 3 Maximum level mark NOTE The coolant should be between the minimum and maximum level marks Hard water or salt water is harmful to the engine you may use soft water if you can t get distilled water 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 AVOID THE HAZARD ...

Page 64: ...otrest 3 Remove the battery panel and bolt 1 Battery panel and bolt 1 Radiator cap 4 Remove the radiator cap 6 Remove coolant reservoir cap 1 Coolant reservoir hose 7 Disconnect the hose on the coolant reservoir side and then drain the coolant from the coolant reservoir 8 After draining the coolant thoroughly flush the cooling system with clean tap until it reaches the top of the radiator 14 Check...

Page 65: ...56 Hard water or salt water is harmful to the engine you may use soft water if you can t get distilled water ...

Page 66: ...57 Axle boots Check the protective boots for holes or tears If any damage is found have them replaced by your dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side ...

Page 67: ...e ideal color on the white insulator around the center electrode is a medium to light tan color for a ATV that is being ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to your dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessiv...

Page 68: ...lug and tighten it to the specified torque 17 5 Nm 1 75 m kgf 12 5 ft lbf 4 Install the spark plug cap 5 Install the panel Spark plug gap 0 6 0 7mm 0 024 0 028 in a Spark plug gap NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as po...

Page 69: ...he air filter exchange the air filter element 1 Remove passenger seat and driver seat 2 Remove the right panel 3 Remove the clip bolt 1 clip bolt 1 Bolts 2 Air filter frame 4 Remove these bolts and remove the air filter frame 5 Pull off the lock plate remove the air filter case cover 6 Take out the air filter element 7 Inspect the air filter element and replace it if damaged ...

Page 70: ...ent 8 Install the air filter element assembly 9 Install the air filter case cover by hooking the lock plate onto the air filter case 10 Install the air filter clip bolt and the air filter frame 11 Install the right panel 12 Install passenger seat and driver seat POTENTIAL HAZARD Using solvents or gasoline to clean the NOTE The air filter element should be cleaned every 20 40 hours It should be cle...

Page 71: ...ent removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating ...

Page 72: ...proximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Remove the seat 3 Then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in direction a to increase the engine speed and in direction b to decrease the engine speed 4 Install the seat Specified idle speed 150...

Page 73: ...64 The carburetor was set at the factory after many tests If the settings are disturbed by someone without sufficient technical knowledge poor engine performance and damage may result ...

Page 74: ...sted regularly This adjustment however should be left to a professional service technician 1 Loosen the locknut 2 Turn the adjusting bolt until the throttle lever free play to the Specified valve clearance 3 Tighten the locknut 1 Adjusting bolt 2 Locknut a Throttle lever free play NOTE Adjust the engine idling speed before check the throttle lever free play Specified idle speed 3 0 5 0 mm 0 12 0 2...

Page 75: ...k the brake pads for damage and wear If a brake pad thickness is less than 1 0 mm 0 04 in have your dealer replace the pads as a set a Brake pad thickness Check the brake pads for damage and wear If a brake pad thickness is less than 2 mm 0 08 in have your dealer replace the pads as a set a Brake pad thickness ...

Page 76: ...cate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage 1 Minimum level mark 1 Minimum level mark Observe these precautions When checking the fluid level make sure the top of the master cylinder reservoirs are level Use only the designated quality brake fluid Otherwise the rubber seals may deteriorat...

Page 77: ...riorate painted surfaces or plastic parts Always clean up spilled fluid immediately Have your dealer check the c cause if the brake fluid level goes d down Complete fluid replacement should be done only by trained service personnel Have your dealer replace the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brak...

Page 78: ...brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should be performed by your dealer The parking brake lever free play should be 5 7 mm 0 19 0 27 in 1 Loosen the locknut 2 Turn the adjusting bolt in direction a to increase free play and in direction b to decrease free play 3 Tighten the locknut 1 Adjust...

Page 79: ...ear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move The top of the brake pedal should be positioned 72 mm 2 83 in above the top of the footrest If not ask your dealer to adjust it a Brake pedal position ...

Page 80: ...e restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask your dealer to replace them Recommended lubricant SAE 10W30 motor oil Lubricating the brake lever and brake pedal and parking lever Lubricate the pivoting parts Recommended lubricant Lit...

Page 81: ...72 ...

Page 82: ...ry terminal Do not try to remove the sealing caps of the battery cells You may damage the battery POTENTIAL HAZARD Failure to handle batteries or battery electrolyte carefully WHAT CAN HAPPEN You could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases HOW TO AVOID THE HAZARD Avoid contact with skin eyes or clothing Always shield ...

Page 83: ...t voltage ampere or constant voltage is required for recharging a sealed type battery using a conventional battery charger may shorten the battery life 1 The main fuse and the fan fuse are under the battery panel the front driver controller fuse and the auxiliary DC jack fuse are inside the right panel 2 If a fuse is blown turn off the main switch and the switch of the circuit in question then ins...

Page 84: ...ct when putting the battery back in the machine 1 fuse box 2 Battery fuse POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rat ing Never use a material in place of the proper fuse To prevent accidental short circuiting turn off the main switch when...

Page 85: ...der by turning it counterclockwise 5 Remove the defective bulb by unhooking the headlight bulb holder tabs 6 Insert a new headlight bulb into the bulb holder and then secure the bulb by hooking the tabs onto the bulb 7 Install the headlight bulb holder by turning it clockwise 8 Install the headlight bulb holder cover at the rear of the headlight 9 Install the headlight panel 10 Install the bolts a...

Page 86: ...free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 1 Headlight bulb holder ...

Page 87: ... the beam turn the adjusting screw indirection b 1 Head beam adjusting screw 1 Remove the tail brake light bulb holder by turning it counterclockwise 2 Remove the defective bulb by unhooking the tail brake light bulb holder tabs 3 Insert a new tail brake light bulb into the bulb holder and install the tail brake light bulb holder by turning it clockwise 1 Tail brake light bulb holder ...

Page 88: ...dealership have the tools experience and know how to properly service your machine Use only genuine parts on your machine Imitation parts may look like parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame WHAT CAN HAPPEN Fuel can ignite or explode causing ...

Page 89: ...e the dirt and degreaser off with a garden hose Use only enough pressure to do the job Ⅳ Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at places Ⅴ Rinse the machine off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth Ⅵ Cle...

Page 90: ...rn the engine over several times to coat the cylinder wall with oil 3 Lubricate all control cables 4 Block up the frame to raise all wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing in a humid or salt air cover atmosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cov...

Page 91: ...eelbase 1 300 mm 51 1 in Minimum ground clearance 260 mm 10 2 in Minimum turning radius 3 500mm 137 7 in Basic weight With oil and full fuel tank 355 Kg 782 6lb Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 498 6 CC Bore stroke 92 0 75 0 mm 3 6 2 9 in Compression ratio 10 2 1 Starting system Electric ...

Page 92: ...ype Recommended engine oil classification Quantity Without oil filter cartridge replacement 2 5L 2 64 US qt With oil filter cartridge replacement 2 6L 2 75 US qt Final gear case oil Type SAE 80W 90 API GL 4 Hypoid gear oil Quantity Periodic oil change 0 33L0 35 US qt ...

Page 93: ...ilter dry element Fuel Type UNLEADED GASOLINE ONLY Fuel tank capacity 22 0 L 5 8 Gal Fuel reserve amount about 4 L 1 Gal Carburetor Type quantity PD34 1 Manufacturer KEIHIN Spark plug Type manufacturer K6RTC Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch type Dry centrifugal automatic Transmission Primary reduction system V belt ...

Page 94: ...eration Left hand operation High gear 2 16 1 Low gear 3 69 1 Reverse gear 2 7 1 Chassis Frame type Steel tube frame Caster angle 7 Trail Tire Type Tubeless Size front AT25 8 12 rear AT25 10 12 Brake Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake ...

Page 95: ...absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 124 mm 4 8 in Rear wheel travel 183 mm 7 2 in Electrical Ignition system DC C D I Generator system A C magneto Battery type Battery capacity 12V 20Ah Headlight type Bulb voltage wattage quantity Headlight 12 V 35 W 35 0 W 2 ...

Page 96: ...ator light LED 1 High gear indicator light LED 1 Low gear indicator light LED 1 Reverse gear indicator light LED 1 Coolant temperature warning light LED 1 4WD Lock drive indicator light LED 1 Fuses Battery fuse 30A Main switch fuse 10A Light fuse 20A Power output fuse 10A Fan fuse 10A ...

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Crossfire 500ATV, Owner'S Manual

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