Kolpin ATV-180 Owner'S Manual Download

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OPERATION WARNINGS (cont.)

POTENTIAL HAZARD

Riding on frozen lakes and rivers.

WHAT CAN HAPPEN

Severe injury or death can result if the ATV and/or the operator break through the ice.

HOW TO AVOID THE HAZARD

Never ride your ATV on a frozen body of water.

Summary of Contents for ATV-180

Page 1: ...1...

Page 2: ...ance Keep the following information in mind while operating the ATV PROTECT YOUR SPORT Know all local and state riding laws Respect your vehicle Respect the environment and You will gain the respect o...

Page 3: ...4 Ignition Switch Lights 17 Gear Assembly 44 Pre Ride Check 18 19 Suspension 45 RIDING RULES 20 Braking Light 46 FEATURES OPERATION 21 46 RIDING OPERATION INSTRUCTIONS 47 62 Ignition Switch 21 Section...

Page 4: ...MANUAL 63 94 Tire Tire Pressure Wheel Installation 117 Operation Warning Decals 63 68 Drive Chain Inspection Adjustment 119 Operation Warnings Printed in Manual 69 94 Brake Light Lamp Replacement 121...

Page 5: ...UTIONS You should read the owner s manual and warning labels Review this information on a regular basis Riders differ in skills physical abilities and judgment Some riders may not be able to operate a...

Page 6: ...ine or in this manual be alert to the potential for personal injury This symbol indicates a potential hazard that could result in severe injury or death When you see this symbol on your machine or in...

Page 7: ...iewing this manual watching the instructional video and taking a certified ATV Safety Training course Youth ATVs are designed and intended for use by children in the following age groups ATVs with eng...

Page 8: ...on unfamiliar terrain Be alert for changes in terrain weather and ATV operating conditions Never operate on excessively rough slippery or loose terrain Avoid operating ATV on paved surfaces including...

Page 9: ...round on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures as described i...

Page 10: ...ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads Always use size and type tires specified in this manual Always maintain proper tire...

Page 11: ...nforms you that the warranty on your ATV is terminated if any non OEM equipment has been added or modifications have been made to the original ATV which increase s speed or power It is also advised th...

Page 12: ...w Kolpin Powersports ATV you need to know information about how the ATV operates and most important of all you need to know how to keep safe while operating the ATV Remember YOUR SAFETY IS THE MOST IM...

Page 13: ...VERVIEW OF Kolpin Powersports 180 Rear Brake Lever Reverse Indicator Neutral Indicator Fuel Gauge Front Brake Lever Throttle Lever Ignition Switch Light Switch Engine Stop Switch Engine Start Switch H...

Page 14: ...ition before you can start the engine When the engine is running you can stop it by sliding the Engine Stop Switch left or right to the position 2 Engine Start Switch Horn The Engine Start Switch Horn...

Page 15: ...control does not stick before you operate your ATV Read more about it on page 43 4 Transmission Neutral Indicator Green The Neutral Indicator green will light when the ATV is in Neutral The ATV canno...

Page 16: ...e handle bar to slow down or stop your ATV The right hand lever controls the front brakes The left hand lever or the auxiliary foot pedal controls the rear brake To slow down or stop squeeze both brak...

Page 17: ...is equipped with high and low beam headlights The light will not function unless the engine is running Turn the key to the headlight position to turn on headlights Select High Low beam by pressing to...

Page 18: ...nd then letting go The brake levers should come right back to where they were before you squeezed them If they go back slowly or stay on your brakes are sticking If you have a sticky throttle do not s...

Page 19: ...ns Drive chain check the drive chain slack Air cleaner check for dirt If the filter is dirty or clogged clean or replace it Steering check to be sure the steering operates freely Look for any unusual...

Page 20: ...boards Don t ride your ATV on roads or over railroad tracks Your ATV makes noise that will keep you from hearing cars trucks or trains that may be coming towards you Don t ride at night Learn where th...

Page 21: ...sition to the headlight position The headlight will not function unless the engine is running Once the engine is running the key cannot be taken out You should use this key to stop the engine by turni...

Page 22: ...When you push the Engine Stop Switch left or right to position the engine cuts off 3 ENGINE START LEVER Set the parking brake See page 27 Remember to release the park brake before driving forward Tur...

Page 23: ...with a sticky or improperly operating throttle A sticky or improperly operating throttle could cause an accident resulting in severe injury or death Always contact your dealer for service repairs when...

Page 24: ...orn switch 6 BRAKES The left hand brake activates the rear brakes the right hand brake activates the front brakes To activate the rear brakes squeeze the left hand lever toward the handlebar To activa...

Page 25: ...avel of the front and rear brake levers from their rest position to their position when you first feel tension on the cables The free play should fall between 3 8 in 10 20 mm For the front R L brakes...

Page 26: ...y Brake Your ATV has an auxiliary brake for an added safety feature It is located on the inside of the right floorboard beneath the oil plug and is operated by the right foot Use the auxiliary brakes...

Page 27: ...e lever Press the parking brake lock to hold the brake lever in place Releasing the Parking Brake Squeeze the brake lever and the park lever will release automatically Always check to be sure that the...

Page 28: ...ated on the right side of the ATV The gear shift lever has three 3 positions Forward Neutral and Reverse To Change Gears Stop ATV and hold the rear break lever keeping the engine idling Move the lever...

Page 29: ...rs The white back up lights will be illuminated when the transmission is shifted fully into Reverse Do not attempt to shift the transmission while the vehicle is moving or while operating on hilly ter...

Page 30: ...system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibrati...

Page 31: ...ngine air filter should be changed by dealer every 100 hours of operation or annually For more information see page 105 If your ATV is stored operated in salt water areas it must be rinsed with fresh...

Page 32: ...the dash The capacity of fuel tank is 2 1 gallons 8 liters Use unleaded gasoline with an octane rating of 92 or higher Fuel Gauge When the fuel gauge needle is on the red line refuel Be sure to tight...

Page 33: ...or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline on your skin or clothing immediately wash it off with...

Page 34: ...ing it opens the auto vacuum fuel valve when the engine is shut down the auto vacuum fuel valve closes Fuel Filter The Kolpin Powersports 180 ATV is equipped with an in line fuel filter This filter sh...

Page 35: ...to maintain the excellent performance of your ATV engine check the engine oil level before every use To avoid serious engine damage always refill oil reservoir when the oil level is low Running the en...

Page 36: ...rear of the seat Always make sure the seat is locked in place before riding The battery and tool set are located under the seat attached to the rear fender by a rubber strap Do not attempt to release...

Page 37: ...ct contains chemicals known to cause cancer birth defects or other reproductive harm Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time T...

Page 38: ...tallation Your ATV has an Absorbed Glass Matte AGM battery The proper battery for this ATV is YT9LBS To install the battery set the battery in its holder Connect the red wire to the terminal and the b...

Page 39: ...n EXPLOSION Never operate this ATV without the battery cables connected and tightened Loose or disconnected battery cables will spark and could cause the unit to catch on fire Never use a car to jumps...

Page 40: ...corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of 1 tablespoon baking soda and 1 cup water Rinse well with tap water and dry off with clean rags C...

Page 41: ...ery Removal Disconnect hold down straps holding the electrical box and battery in position Disconnect the Black cable first Disconnect the Red cable next Lift the battery out of the ATV Battery is sea...

Page 42: ...ade Be certain the ATV is on a level surface and the parking brake is set See page 27 Fold out the kick start lever located on the left hand side of the ATV Turn the ignition key to ON and make sure t...

Page 43: ...n to the position the throttle is affected Make sure the throttle doesn t stick The lever should come right back to where it was before you pushed it If it comes back slowly or stays open you have a s...

Page 44: ...chain properly lubricated The chain adjuster can adjust the slack Loosen the fixed bolts and adjust the slack to the proper setting After adjusting the chain don t forget to tighten the nuts 19 GEAR...

Page 45: ...g conditions Always be sure to adjust both front left and front right shock absorbers to the same position Failure to do so could result in severe injury or death Rear Suspension The rear suspension c...

Page 46: ...46 FEATURES AND OPERATION cont 21 BRAKE LIGHT The brake light operates when the rear brake lever left is pulled The bulb type for the braking light is 1157 or 12V P21 5W Rear Brake Light...

Page 47: ...Engine 51 3 ATV Break in Period 52 4 Riding 53 5 Making Turns 53 6 Hauling Cargo 54 7 Riding on Slippery Surfaces 56 8 Traveling Uphill 57 9 Side Hill Riding 58 10 Traveling Downhill 59 11 Turning Ar...

Page 48: ...hat could result in severe injury or death When you see this symbol on your machine or in this manual it means PAY ATTENTION If you don t you could get hurt very badly or even killed Your safety is in...

Page 49: ...e Check before riding ATV Engine damage could result if you do not allow your ATV adequate warm up time before operating Never run an engine in an enclosed area Carbon monoxide exhaust gas is poisonou...

Page 50: ...Snell Memorial Foundation label Eye Protection Do not depend on sunglasses for eye protection A pair of goggles or helmet face shield offers the best protection for your eyes They should be shatterpr...

Page 51: ...aximum or five seconds releasing the Starter Button when the vehicle starts If engine does not start release the Starter Button and wait five seconds then press the Starter Button for another five sec...

Page 52: ...the engine 1 Drive slowly at first Operate in an open area to familiarize yourself with the ATV s operation and handling 2 Vary the throttle position 3 Perform regular checks on fluid levels controls...

Page 53: ...n level surfaces 5 MAKING TURNS Practice making turns at slow speeds Kolpin Powersports ATVs are equipped with a solid rear axle that drives both rear wheels equally at all times This means that the w...

Page 54: ...ce speed and cargo weight to maintain stable driving conditions REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2...

Page 55: ...creates a less stable operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating conditions OPERATE ONLY WITH STABLE AND SA...

Page 56: ...ng a skid Complete loss of ATV control can result 5 Whenever possible avoid excessively slippery surfaces 6 Always reduce speed and use additional caution Failure to exercise care when operating the A...

Page 57: ...forward 4 Proceed at a steady rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismount of the ATV Do not operate this ATV on hilly te...

Page 58: ...erring your upper body weight up hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction IF THE VEHICLE BEGINS TO TIP QUICKLY TURN THE FRONT WHEEL DO...

Page 59: ...rectly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Slightly apply the front and rear brakes at the same time to help in slowing Do not travel at excessive speeds It is dan...

Page 60: ...ront 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 downward 6 Lock the parking bra...

Page 61: ...the brakes by applying light pressure to the levers until braking action is normal Do not operate your ATV through deep or fast moving water If you cannot avoid water that exceeds the recommended max...

Page 62: ...ranches 13 PARKING 1 Turn the ignition key to the OFF position 2 Set the parking brake NOTE Avoid parking on an incline If you must park on an incline always block the rear wheels on the downhill side...

Page 63: ...h if not correctly followed could result in personal injury or loss of life Read all WARNINGS in this manual carefully ALWAYS follow their instructions NOTE Warning decals have been placed on the vehi...

Page 64: ...collision can occur with a passenger passengers affect balance and steering and increase risk of losing control at speeds too fast for your skills or the conditions without proper training or instruc...

Page 65: ...age Operation of this ATV by anyone under the age of 16 increases the risk of severe injury or death Never permit children under age 16 to operate this ATV NEVER ride as a passenger Passengers can cau...

Page 66: ...ause loss of control resulting in SEVERE INJURY or DEATH MAXIMUM WEIGHT CAPACITY Gross vehicle weight including machine driver and cargo is 680 lbs TIRE PRESSURE PSI FRONT 5 REAR 3 Adjust chain as fig...

Page 67: ...nd throttle gradually Operating in REVERSE even at low speeds can be dangerous as steering becomes difficult Avoid sudden braking or sharp turns to prevent flipover When parking on grades leave the sh...

Page 68: ...68 OPERATION WARNING DECALS cont Shift pattern FORWARD NEUTRAL REVERSE...

Page 69: ...does know not how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete a certified traini...

Page 70: ...ended for their age can lead to severe injury or death of the child Even though a child may be within the age group for which some ATVs are recommended he or she may not have the skills abilities or j...

Page 71: ...atly reduces yours ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to al...

Page 72: ...ATV tires are designed for off road use Paved surfaces may seriously affect handing and control of the ATV and may cause loss of control of the ve vehicle resulting in severe injury or death HOW TO A...

Page 73: ...r highways WHAT CAN HAPPEN You can collide with another vehicle resulting in severe injury or death HOW TO AVOID HAZARD Never operate this ATV on any public street road or highway even a dirt or grave...

Page 74: ...ut an Approved helmet increases your chances of severe Head injury or death in event of an accident Operating without eye protection can result in severe Injury in event of an accident HOW TO AVOID TH...

Page 75: ...l or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and protection Could cause an accident resulting in severe injury or deat...

Page 76: ...essive speeds WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can cause an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always travel at a proper spee...

Page 77: ...eelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of rolling the vehicle and or causing an causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Never attemp...

Page 78: ...Increased possibility of an accident or equipment damage Could cause an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure...

Page 79: ...y 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 which could injure...

Page 80: ...pon hidden rocks bumps or holes without enough time to react Could result in the ATV rolling or driver losing control of the vehicle and causing an accident resulting in severe injury or death HOW TO...

Page 81: ...cause damage to terrain or loss of vehicle control or rolling the vehicle or causing an accident resulting in severe injury or death HOW TO AVOID HAZARD Do not operate on excessively rough slippery or...

Page 82: ...r could lose control of the ATV rolling the vehicle or causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for turning Practice turning at l...

Page 83: ...ZARD Always follow proper procedures for climbing hills Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight...

Page 84: ...ry or death HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner s Manual Always check the terrain carefully before you start down any hill Shift your...

Page 85: ...TO AVOID THE HAZARD Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered th...

Page 86: ...forward speed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while...

Page 87: ...he ATV You may also regain traction unexpectedly both of which may allow the ATV to overturn causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD On slippery surfaces such a...

Page 88: ...cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as larg...

Page 89: ...t POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator break through the ice HOW TO AVOID THE HAZARD Never ride your ATV...

Page 90: ...oid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth go slowly balance your weight carefully avoiding sudden movement maintain...

Page 91: ...e tires on this ATV or operation of this ATV with uneven tire pressure may cause loss of control and increases the risk of an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Alway...

Page 92: ...d cause changes in vehicle handling that could lead to an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be proper...

Page 93: ...ut not limited to brakes throttle and steering for possible damage Safe operation of this rider active vehicle requires good judgment and physical skills Persons with cognitive or physical disabilitie...

Page 94: ...through improper installation or use of non OEM accessories All parts and accessories added to this vehicle should be designed for use on this ATV and should be installed and used according to instruc...

Page 95: ...spare key and store in a safe place Your key can be duplicated only by obtaining a key blank from Kolpin Powersports and having it cut by using your existing key The Engine Serial Number and Frame VI...

Page 96: ...vere use such as operation in wet dusty or salt water areas should be inspected and serviced more frequently If you are not familiar with safe service and adjustment procedures have your local Kolpin...

Page 97: ...EMARKS Brake System Pre ride Pre ride Check Operation See pg 108 Tires Pre ride Pre ride Check inflation PSI Front 5 Rear 3 Wheels Pre ride Pre ride Check for loose nuts Frame nuts bolts fasteners Pre...

Page 98: ...ary pre ride inspection item Steering 50 hrs 6 mos Inspect daily lubricate Rear Axle 50 hrs 6 mos Inspect bearings Lube Front Suspension 50 hrs 6 mos Inspect lubricate tighten fasteners Rear Suspensio...

Page 99: ...needed Fuel System 100 hrs 12 mos Check for leaks at tank cap lines fuel valve filter and carburetor Replace lines every two years Fuel Filter 100 hrs 12 mos Replace annually Air Filter 100 hrs 12 mos...

Page 100: ...SF SG SAE 15W 40 See page 116 Change every 6 mos or 100 hrs Transmission Oil SAE 85W 140 See page 115 Change annually or at 200 hrs Drive Chain SAE 85W 140 or chain lube Lubricate as often as require...

Page 101: ...ANCE cont PERIODIC MAINTENANCE RECORD Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 hrs 25 hrs 50...

Page 102: ...102 VEHICLE MAINTENANCE cont PERIODIC MAINTENANCE RECORD Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks...

Page 103: ...pindle Nuts 42 45 ft lbs 58 62 Nm Rear Spindle Nuts 78 81 ft lbs 108 112 Nm NOTE an authorized dealer must service all nuts that have a cotter pin installed FRONT WHEEL HUB TIGHTENING Front wheel bear...

Page 104: ...AR SPRING ADJUSTMENT The rear shock absorber spring is adjusted by rotating the adjuster clockwise to one of five 5 positions to increase spring rate or counter clockwise to decrease spring rate Rear...

Page 105: ...loorboards and frame unplug taillight and remove rear body from frame to access the engine air filter 2 Loosen the screws on the air filter cover and remove cover screen and air filter 3 Clean the air...

Page 106: ...allows you to limit the speed of the vehicle according to the rider s skill and experience The throttle stop system controls how far the throttle opens To adjust loosen the jam nut turn the screw inwa...

Page 107: ...V have your dealer tighten any loose nuts and bolts you find CAMBER AND CASTER Not adjustable See your dealer TOE ALIGNMENT SEE YOUR LOCAL Kolpin Powersports dealer Do not attempt to adjust the tie ro...

Page 108: ...ay is in acceptable range The acceptable range for the front brake levers free play is 3 8 in 10 20 mm Use the adjustment knobs to change free play Check free play by measuring the travel of the free...

Page 109: ...nt nut until you reach the proper free play setting Check free play by measuring the travel of the free end of the rear brake lever from its rest position to its position when you first feel tension o...

Page 110: ...oot To adjust follow the steps below 1 Make adjustments to rear brake lever as described on page 109 2 Remove the four 4 bolts securing the right floorboard to frame and slide outward enough to access...

Page 111: ...5mm 3 2mm If adjustment is required turn the adjustment nut until the free play reaches the acceptable limit adjustment nut is protected by plastic sleeves pull the sleeves back to expose the adjustme...

Page 112: ...tely check the spark plug for correct color 1 Normal The insulator tip is gray tan or light brown There will be a few combustion deposits The electrodes are not burned or eroded This indicates the pro...

Page 113: ...plug by rotating counter clockwise 2 Reverse the procedure for spark plug installation Torque to 17 ft lbs 3 NOTE Failure to use the recommend spark plug type could cause engine damage Recommended ty...

Page 114: ...to all vinyl and plastic surfaces Add fuel stabilizer to the tank and let run for at least five 5 minutes to get additives through the entire fuel system Remove and clean air filter Before replacing a...

Page 115: ...ontainer for draining oil beneath the rear of engine 3 Remove the transmission drain plug located under rear of sprocket shaft Let drain complete 4 Remove fill plug located on left rear of engine case...

Page 116: ...etely 4 Clean and inspect oil drain plug gasket oil cap sealing O ring and oil filter screen for damager Replace if damaged 5 Install the drain plug and torque to 12 ft lbs 6 Fill with API classificat...

Page 117: ...AKE OIL ENSURE Check the brake oil tank If the brake oil to reduce under the limit You must to fill the brake oil until upper limit Be careful the brake oil when to topple into the oil tank to avoid t...

Page 118: ...pth is worn to 1 8 in 3 cm or less ATV tires can become distorted by over inflation Ballooning stretching of rubber and fiber cords Once a tire has been over inflated it will not return to its origina...

Page 119: ...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 forward rotation 2 Attach the wheel nuts and finger tighten the...

Page 120: ...g a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel DRIVE CHAIN INSPECTION AND ADJUSTMENT Regularly lubricate the drive chain with SAE 85W 140 oil or chain cable l...

Page 121: ...osen 4 rear housing mount bolts 2 Tighten chain adjust to reduce slack to recommended setting 1 2 1 in 13 mm 25 mm 3 Tighten jam nuts on chain adjuster 4 Tighten the four rear housing mount bolts Neve...

Page 122: ...lb may need to be replaced 1 From the rear of the brake light remove two screws holding lens cover in place and remove lens cover 2 Remove bulb and replace it with the recommended bulb 1157 or 12V P21...

Page 123: ...e wash to wheel bearings transmission seals body panels brakes and warning labels The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional t...

Page 124: ...1 800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1 000 feet 304 9 m increase in elevation This power cannot be regained but changes to the...

Page 125: ...ction 1 quart 1 liter TRANSMISSION Automatic CVT w reverse gear SUSPENSION FRONT Double Wishbone REAR Swing Arm BRAKE FRONT Drum REAR Drum TIRE FRONT 21 x 7 10 REAR 22 x 10 8 OVERALL DIMENSION 71 7 x...

Page 126: ...tify probable questions you may have about the operation of your ATV See your dealer with any additional questions you may have ENGINE CRANKS BUT FAILS TO START Water in Fuel Drain System No Fuel Spar...

Page 127: ...LOSES POWER Spark Plug Fouled Air Filter Clogged Contact your Dealer Engine Overheated Clean Oil Cooler Screen Clean Engine Exterior Contact Your Dealer No Fuel Fuel Vent Line Kinked Or Plugged Water...

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