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1.

Unpack.  Remove  shrink  wrap,  packing  straps,  and  card  board 

box cover. Remove all bolts attaching metal frame work to steel base. 
Untie  wires  holding  tire  and  wheel  assembly  to  metal  frame.  See  that 
bolts are removed that attach handle bar mounting plate and bumpers 
to  metal  frame,  if  applicable,  before  attempting  to  lift  metal  frame 
work off of base. Carefully lift metal frame work straight up to remove, 
taking care not to scuff fenders or bumpers while removing. This should 
not  be  attempted  by  one  person  alone.  Two  people,  lifting  together, 
can remove the frame work without causing damage to the ATV or harm 
to themselves. Remove  small  box  from  shipping  frame  base  containing 
all hardware, nuts, bolts, tool kit, battery and acid. 

Step#01-fig#1-Packing frame

2.

Each  ATV  is  shipped  with  a  desiccant  bag  that  is  designed  to 

absorb  moisture  during  shipping.  It  is  of  no  further  value  once  the 
shipping  container  is  opened  and  should  be  discarded  immediately  to 
avoid being played with by children or pets.

Step#02-fig#1-Desiccant bag-all models

Summary of Contents for All Terrain Vehicle 250

Page 1: ...e this bike REASSEMBLY MANUAL Note This ATV was fully assembled and tested at the CROSSRUNNER factory It was partially disassembled before shipping This manual gives specific instructions on how to fu...

Page 2: ...is ATV You will be referencing the Owner s Manual the battery service instructions and the tire pressure information sticker on the front fender as well as the Re assembly Manual during this procedure...

Page 3: ...t to scuff fenders or bumpers while removing This should not be attempted by one person alone Two people lifting together can remove the frame work without causing damage to the ATV or harm to themsel...

Page 4: ...se loss of control Use the valve core tool supplied with the ATV tool kit to tighten the valve core in each valve stem before attempting to add air Inflate the tires to seat the bead taking care not t...

Page 5: ...ned for the specific type wheel and ATV Evenly snug each lug nut by hand in a star pattern Final wheel torque must be done when ATV is sitting on flat ground DO NOT attempt to perform final wheel torq...

Page 6: ...emove bolts holding rear axle to frame base Note Packing methods may vary at times on some models Set parking brake for front wheels to prevent ATV from rolling off packing frame base Lift and support...

Page 7: ...d installing wheels carefully lower ATV release parking brake and roll off metal shipping frame onto flat level surface Reset the parking brake and perform the final wheel torque procedure Torque all...

Page 8: ...ightening handle bar mounting bolts evenly in a criss cross pattern and torque to 28 Ft Lbs Step 08 fig 1 Handlebar installation 9 Mount the shift indicator light console if so equipped to the bracket...

Page 9: ...9 Step 09 fig 1 Console wiring 10 Install rack bars on utility racks with the hardware provided Step 10 fig 1 Rack installation...

Page 10: ...e fuel line near any part of the exhaust or hot section of the engine and take care to tuck it in away from the rider s feet and legs so that it cannot be snagged Step 11 fig 1 Fuel line installation...

Page 11: ...tery and then test for proper voltage If the battery meets the voltage specs called for in the battery instructions when tested install in ATV The RED cables are positive and the GREEN cables are nega...

Page 12: ...t able to bind kink or be pinched Keep them at least 1 or more away from any contact with engine or exhaust Step 15 fig 1 Inspect hose routing 16 Inspect throttle brake and clutch cable free play adju...

Page 13: ...13 Step 16 fig 2 Front brake cable freeplay adjustment Step 16 fig 3 Rear brake cable free play adjustment...

Page 14: ...14 Step 16 fig 4 Front brake adjustment Step 16 fig 5 Rear brake adjustment...

Page 15: ...tion when selected This is tested with key on engine off Next inspect headlight and brake light operation 19 Add fuel turn fuel valve to ON position and inspect for leaks Install gas cap on fuel tank...

Page 16: ...After ATV is started closely inspect for any fuel or oil leaks Confirm parking brake holds adequately and test each gear selection for proper indication on center console Copyright North American Impo...

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