LONCIN LX500ATV Page 117 Owner'S Manual Download

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PERIODIC MAINTENANCE AND ADJUSTMENT

Cooling system

1. Place the ATV on a level surface.
2. Check the coolant level in the coolant

( )
( )

Maximum levelmark

Minimum levelmark

Hard water or salt water is harmful to the engine. You
may use soft water if you cannot get distilled water.

8 14

( )

Fanel H

3. If the coolant is at or below the minimum level mark,
remove panel H remove the reservoir cap, add coolant
to the maximum level mark, install the reservoir cap,
and then install the panel.

Summary of Contents for LX500ATV

Page 1: ...is vehicle is sold for OFF ROAD USE ONLY Before operating this vehicle read all the instructions for safe assembly and operation as well as the instructions governing the engine and other portions of the vehicle Pay close attention to all caution and warning labels on the ATV MINIMUM RECOMMENDED OPERATOR AGE 16 ...

Page 2: ...ne is designed and manufactured for OFF ROAD use only It is illegal and unsafe to operate this machine on any public street road or highway This machine complies with all applicable OFF ROAD noise level and spark arrester laws and regulation in effect at the time of manufacture Please check your local riding laws and regulations before operating this machine SPECIAL MESSAGES Manufactory provides m...

Page 3: ...if instructions are not followed Indicates special precautions that must be take to avoid damage to the machine NOTE A NOTE provides key information to make precedures easier or clearer The Owner s Manual should be considered a permanent part of your ATV It should remain with the vehicle at all times and stay with the ATV if it is sold B IMPORTANT NOTICES ...

Page 4: ... manual includes important safety information It provides information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your machine please consult a dealer We wish you many years of safe and enjoyable riding While reading this manual remember WARNING In...

Page 5: ...TCH Headlight switch Start button Engine stop switch Horn button Turning signal switch On command four wheel drive and differential gear lock switch THROTTLE LEVER SPEED LIMITER BRAKE LEVER BRAKE PEDAL PARKING BRAKE LEVEL RECOIL STARTER FUEL TANK CAP DRIVE SELECT LEVER STARTER CHOKE SEAT TRAILER HITCH STORAGE COMPARTMENT FUEL LOCK SHOCK ABSORBER ADJUSTMENT D 1 1 2 1 3 1 3 1 3 1 3 2 3 3 4 1 4 1 4 1...

Page 6: ...TING A WARM ENGINE WARMING UP DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING ENGINE BRAKE IN PARKING ACCESSORIES LOADING PRE OPERATION CHECKS OPERATION E CONTENTS 4 20 5 1 5 2 5 3 5 4 5 5 5 6 5 6 5 7 5 7 5 7 5 7 5 7 5 9 5 9 6 1 6 1 6 3 6 4 6 4 6 4 6 6 6 7 6 9 6 9 7 1 7 2 7 2 7 4 7 6 7 8 7 9 7 9 RIDING YOUR ATV GETTING TO KNOW YOUR ATV RIDE WITH CARE AND GOOD JUDGEMENT APPAREL PRE OPERATION CHECK...

Page 7: ...MAINTENANCE AND ADJUSTMENT F CONTENTS 7 9 7 10 7 11 7 12 7 12 7 13 7 17 7 19 7 22 7 24 7 26 7 32 7 33 7 35 7 35 7 37 7 38 7 38 8 1 8 1 8 4 8 6 8 7 8 10 8 12 8 14 8 15 8 16 8 19 8 19 8 20 8 21 8 22 8 23 8 25 PERIODIC MAINTENANCE LUBRICATION PANEL REMOVAL AND INSTALLATION ENGINE OIL FINAL GEAR OIL DIFFERENTIAL GEAR OIL COOLING SYSTEM SPARK PLUG INSPECTION AIR FILTER CLEANING AIR CLEANER HOUSING DRAI...

Page 8: ...USTING THE BRAKE PEDAL BATTERY Battery remove Battery installation FUSE REPLACEMENT REPLACE A HEADLIGHT BULB TAIL BRAKE LIGHT BULB REPLACEMENT SPARK ARRESTER CLEANING TROUBLESHOOTING G 8 26 8 27 8 28 8 30 8 30 8 31 8 32 8 34 8 34 8 34 8 37 8 38 8 39 8 40 8 29 CLEANING AND STORAGE SPECIFICATIONS NOISE REGULATION MAINTENANCE RECORD ELECTRIC WIRING DIAGRAM CLEANING STORAGE 9 1 9 1 9 2 10 1 11 1 12 1 ...

Page 9: ...y contain im portant information for safe and proper operation of your ATV The labels should be considered as permanent parts of the vehicle If a label comes off or becomes hard to read contact your LONGTING dealer for replacements 1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS WARNING SPECIFICATION LABELS ...

Page 10: ...WARNING SPECIFICATION LABELS 1 2 1 2 Maximum Load Limit 45 Kg 100 lbs LOAD LIMIT WARNING NEVER CARRIER PASSENGER ON THIS CARRIER 3 LOAD LIMIT MAXIMUM LOAD LIMIT 90 Kg 198 lbs ...

Page 11: ...N D PROTECTIVE GEAR NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate ALWAYS READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Å Å Å Ä Å Å Without proper training or instruction At speeds too fast for your skills or the conditions On public roads a collision can occur with another vehicle With a passenger passengers affect balance and steering control Use proper riding te...

Page 12: ... closed position until the engine speed to the specified idling speed Otherwise the transmission may be damaged 7 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH OPERATING TIRE PRESSURE Recommended FRONT 32 35 32 35 4 6 5 0 REAR 27 30 27 30 3 9 4 3 LOADING Set with tires cold kpa 0 0 kgf cm psi kpa 0 0 kgf cm psi Never se...

Page 13: ...ulting in 9 WARNING Operating this ATV if you are under the age of 16 increases your changes of severe injury or death operate this ATV if you are under the age of 16 NEVER 10 WARNING Turning the ATV in 4WD LOCK DIFF LOCK takes more effort Operate at a low speed and allow extra time and distance for maneuvers to avoid loss of control ...

Page 14: ...proper training or instruction Beginners should receive training from a certified instructor Always follow the age recommendation A child under 16 years old should never operate 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 ...

Page 15: ...it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive...

Page 16: ...ble Always follow proper procedures for crossing the side of a hill as described in this manual 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 the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Never operat...

Page 17: ...y control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Always use the size and type tires sp...

Page 18: ... while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel valve is in the OFF position Otherwise fuel may leak out of the carburetor or fuel tank Gasoline is poisonous and can cause injuries If you should swallow some gasoline or...

Page 19: ...D WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Starting or running the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time Always operate your machine in an area with adequate ventilation ...

Page 20: ...ica tion number and model label information in the spaces provided for assistance when ordering spare parts from a LONGTING dealer or for reference in case the vehicle is stolen 1 FRAME SERIAL NUMBER ENGINE SERIAL NUMBER 2 3 1 FRAME NUMBER The frame serial number is stamped into the frame on the right side of the rear wheels SERIAL 1 Frame serial number 1 ...

Page 21: ...DESCRIPTION MACHINE IDNTIFICATION 3 2 ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase 1 ENGINE SERIAL NUMBER 1 ...

Page 22: ...hock absorber spring preload adjusting ring 2 Spark arrester 3 Storage compartment and tod kit 4 Air filter case 5 Front brake fluid reservoir 6 Front shock absorber spring preload adjusting ring 7 Rear brake fluid reservoir 8 Brake pedal 9 V belt case drain plug ...

Page 23: ...es 16 Engine oil dipstick 17 Recoil starter 18 Coolant reservoir 19 Drive select lever box check hose 20 V belt cooling duct check hose 21 Left handlebar switches 22 Starter choke 23 Speedometer unit 24 Main switch 25 Right handlebar switches 26 Throttle lever 27 Front brake lever 28 Auxiliary DC jack 29 Parking brake lever ...

Page 24: ...DESCRIPTION MACHINE IDNTIFICATION 3 5 NOTE The machine you have purchased may differ slightly from those shown In the figures of this manual ...

Page 25: ... The turning lights and beacon can come on at this position The key can be removed in this position ON position With the engine stop switch at run and transmission in neutral and set the parking brake the engine can be started only at this position The headlight and taillight come on when the light switch is on The key can not be removed 1 1 Ignition Switch INDICATOR LIGHT 4 1 1 2 6 5 4 3 7 8 9 ...

Page 26: ... drive select lever is in the L position 3 High range indicator light H This indicator light comes on when the drive select lever is in the H position 4 Neutral indicator light N This indicator light comes on when the drive select lever is in the N position 5 Reverse indicator light R This indicator light comes on when the drive select lever is in the R reverse position 8 High Beam Indicator The h...

Page 27: ...ntial gear lock indicator DIFF LOCK in the four wheel drive indicator also comes on when the LOCK 4WD switch is set to the 4WD LOCK position Four wheel drive indicator 2 Speedometer Indicator which shows the riding speed 3 Coolant temperature warning light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light comes o...

Page 28: ... modes Between the km h and the mph 6 Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear towards E Empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes set the fuel cock to reserve and re fuel as soon as possible 7 SELECT Button Pushing the SELECT button switches the displa...

Page 29: ...Turn Signal Switch 5 Horn Button 6 Choke Switch 2 Set the switch to to turn on the low beam and the taillight Set the switch to to turn on the high beam and the taillight Set the switch to to turn off all the lights NOTE Do not use theheadlights withthe engine turnedoff for more thanthirtyminutes The batterymaydischarge to the point that thestarter motorwill not operate properly If this should hap...

Page 30: ... RUN position the engine will be operated When the switch is in OFF position the engine will not operate The engine stop switch controls ignition and can be used at any time to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is turn to OFF position It should normally remain in the RUN position If you stop your ATV by turning the engine stop s...

Page 31: ...rn signal light will flash when the switch is operated and ignition switch is ON For turning to the left For turning to the right The instrument turn signal indicator light will also flash when the switch is operated Push the switch and it will release Ä Å The turn signal light will not release automatically Be sure to reset it after use otherwise it may affect the traffic safety The turn signal s...

Page 32: ...WD Power is supplied to the rear wheels only Four wheel drive 4WD Power is supplied to the Rear and front wheels Four wheel drive with the differential gear locked 4WD LOCK Power is supplied to the rear and front wheels when the differen tial gear is locked DIFF LOCK Unlike the 4WD mode all wheels turn at the same speed POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD LOCK DIFF LOCK or...

Page 33: ...E HAZARD CONTROL FUNCTION 4 9 1 Lever 2 On Command four wheel drive switch 2WD 4WD On Command four wheel drive switch 2WD 4WD To change from 2WD to 4WD stop the ATV and then set the switch to 4WD When the ATV is in 4WD the 4WD indicator come on in the speedometer unit display To change from 4WD to 2WD stop the ATV be sure the lever is set to position a and then set the switch to 2WD will Different...

Page 34: ...ID THE HAZARD Riding too fast while the ATV is in 4WD LOCK All wheels turn at the same speed when The differential is locked so it takes more effort to turn the ATV The amount of effort is more the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling Always ride at a slow speed when the ATV is in 4WD LOCK and allow extra tim...

Page 35: ...g movement of the throttle lever will increase the engine speed Regulate the speed of the machine by varying the throttle position Because the throttle is spring loaded the machine will decelerate and the engine will return to an idle any time the hand is removed from the throttle lever Before starting the engine check the throttle to be sure it is operating smoothly Make sure it returns to the id...

Page 36: ...Correct the problem before riding the ATV Consult a Yamaha dealer if you can t find or solve the problem yourself Speed limiter 1 Locknut 2 Adjusting screw a 12 mm 0 47 in POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Improper adjustment of the speed limiter and throttle The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident ...

Page 37: ... located on the right handlebar Pull it toward the handlebar to apply the front brake Brake pedal The brake pedal is located on the right side of the machine Push down the pedal to apply the rear brake 1 Brake pedal Parking brake lever 1 2 1 Parking brake lever 2 Lock plate ...

Page 38: ...AT CAN HAPPEN HOW TO AVOID THE HAZARD Improper use of the parking brake The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the bra...

Page 39: ...using the recoil starter for detail 1 Grasp the starter grip firmly then pull until it out slowly seats lightly 2 Pull the grip up briskly and fully 3 After the engine starts allow the starter grip to return slowly POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Starting the engine in gear and or starting the engine without setting the parking brake The ATV could start to move unexpectedl...

Page 40: ...he handlebar cover hole 1 Fuel tank cap Fuel lock The fuel cock supplies fuel from the fuel tank to the carburetor The fuel cock has three positions OFF With the lever in this position fuel will not flow Always turn the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position OFF Posi...

Page 41: ...ff the starter Choke SEAT To remove the seat pull the seat lock lever and pull up the seat at the rear right To install the seat insert the projections on the front of the seat into the seat holder and push down on the seat at the rear RES This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY After refuelling ret...

Page 42: ... Trailer Hitch STORAGE COMPARTMENT The storage compartment is located under the seat To remove the seat see page 4 16 The owner s manual should be stored in the storage compartment Be careful not to flood this area when washing your ATV or riding through water and never put any electric conduction material in the storage compartment 4 18 1 To protect from damage do not put meal products like tools...

Page 43: ...g preload can be adjusted to suit the rider s weight and riding conditions Adjust the spring preload 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 Å Å NOTE A special wrench can be obtained at a LONGTING dealer to make this adjustment 4 19 ...

Page 44: ... that will exceed the accessory socket capacity Using non LONGTING accessory socket may drain the battery or blow a fuse in this ATV s electrical system Be carful not to flood this accessory socket when washing your ATV 4 20 POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Improper shock absorber adjustment Uneven adjustment can cause poor handling and loss of stability which could lead to...

Page 45: ...LE ÅCheck for proper throttle cable operation WHEEL AND TIRES ÅCheck tire pressure wear and damage FITTINGS FASTENERS ÅCheck all fittings and fasteners LIGHT AND SWITCHES ÄCheck for proper operation BATTERY ÅCheck fluid level AXLEBOOTS POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV Increases the possibility ...

Page 46: ...t them Brake Fluid Level Front Brake Check the brake fluid level Add fluid if necessary Recommended Brake Fluid DOT4 Brake Fluid Leakage Front Brake Check to see if any brake fluid is leaking out of the hose joint or brake fluid reservoir of the front brake Apply the brake firmly for one minute If the lever moves slowing in ward there may be a leak in the brake system If there is any leakage the b...

Page 47: ... every ride Do not ride the ATV if you find any problem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the ATV inspected by a LONGTING dealer FUEL Fill the fuel tank when necessary and make sure there is sufficient gasoline in the tank 1 Fuel Neck Recommended fuel UNLEADED FUEL Fuel tank capacity Total 18L 3 8 lmp gal 4 6 US gal Reserve 4...

Page 48: ...fuel will give you longer spark plug life and reduced maintenance cost Use unleaded fuel only because it produces fewer engine and spark plug deposits and extends the life of the exhaust system Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank GASOHOL There are two types of gasohol containing ethanol and that containing meth anol ...

Page 49: ...t from the engine Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot ENGINE OIL Make sure the engine oil is at the specified level Add oil as necessary Check for leaks Recommended engine transm...

Page 50: ...rial enters the crankcase FINAL GEAR OIL Make sure the final gear oil is at the specified level Add oil as necessary Recommended Oil SAE 80 API GL 4 Hypoid gear oil If desired and SAE80W90hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used THROTTLE LEVER Check to see that the throttle lever operates correctl...

Page 51: ...peration of the headlight switch engine stop switch and any other switches Repair as necessary for proper operation BATTERY Check fluid level and fill it necessary Used only distilled water if refilling is necessary TIRES WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure Use of improper tires on this ATV...

Page 52: ...des 3 Tire pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions The following are minimums Front 32kpa 0 32 kgf cm 4 6 psi Rear 27 kpa 0 27 kgf cm 3 9 psi FRONT 32 35 32 35 4 6 5 0 REAR 27 30 27 30 3 9 4 3 kpa 0 0 kgf cm psi kpa 0 0 kgf cm psi 4 Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast...

Page 53: ...w pressure tire gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect NOTE TIRE WEAR LIMIT When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire 5 9 ...

Page 54: ...you do not understand ask your LONTING dealer OPERATION WARNING Indicates a potential hazard that could result in serious injury or death STARTING A COLD ENGINE WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Freezing control cables in cold weather You could be unable to control the ATV which could lead to an accident or collision When riding in cold weather always make sure all c...

Page 55: ...the rear brake lever is applied However it is recommended to shift into neutral before starting the engine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5C 40F Position 2 Cold engine start ambient temperature at 0C 30F 30C 90F and warming up position Position 3 Cold engine start ambient temperature above 25C 80F and warm engine start posi...

Page 56: ...he engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in position 2 keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to position 3 before riding See the Engine Brake In section...

Page 57: ... start a warm engine refer to the Starting a cold engine section The choke knob should not be used The throttle should be opened slightly WARMING UP To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see whether or not the engine is warm check if it responds to the throttle normally with the starter choke knob turned off Drive selec...

Page 58: ...pply the brake pedal then shift by moving the drive select lever along the shift guide 3 Open the throttle lever gradually NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a LONGTING dealer to inspect the machine 4 Check behind you for people or obstacles then release the rear brake pedal 5 Open the throttle lever gradually and continue to watch to th...

Page 59: ...aterial Because the engine is brand new you must not put an excessive load on it for the first 20 hours the various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under ...

Page 60: ...sition 2 10 20 hours Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occasionally PARKING When parking stop the engine and shift into neutral Turn the fuel lock to OFF and apply the parking brake The rear brake lever has one locked position that allow ...

Page 61: ...park on an incline place the machine transversely across the incline put the ATV in low gear 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 in low gear 2 Stop the engine 3 With the brake lever and pedal applied apply t...

Page 62: ...ed An accessory which can shift position or come off while you are riding could affect your ability to control the ATV Do not mount an accessory where it could interfere with your ability your to control the ATV Examples include but are not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the s...

Page 63: ...height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo on the carriers as close to the center of the vehicle as possible Put cargo at the rear of the front carrier and at the front of the rear carrier Center the load from side to side Tie down cargo secure...

Page 64: ...N HAPPEN HOW TO AVOID THE HAZARD Overloading this ATV or carrying or towing cargo improperly Could cause changes in vehicle handling which could lead to an accident Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking 6 11 ...

Page 65: ...RIDING YOUR ATV RIDING YOUR ATV 7 1 ...

Page 66: ...yable 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 Before you begin to ride be sure you have read this Ownre s Manual completely and understand the operation of the controls Pay particular attention to the safety information Please also read all caution and warning label...

Page 67: ...o not attempt to operate at maximum performance until you are totally familiar with the machine s handling and performance characteristics Take the time to learn the basic techniques well before attempting more difficult maneuvers Not recommended for children under 16 year of age Riding your ATV requires skills acquired through practice over a period of time WARNING POTENTIAL HAZARD WHAT CAN HAPPE...

Page 68: ...pproved motorcycle helmet eye protection and protective clothing WHAT CAN HAPPEN O p e r a t i n g w i t h o u t a n a p p r o v e d m o t o r c y c l e he l met in cr eas es y our chances of a severe head injury or death in the event of an accident O pe ra ti n g w i t ho ut ey e protection can result in an accident and increases your chances of a severe injury in the event of an accident To be c...

Page 69: ... gloves boots long sleeved shirt or jacket Long pants HOW TO AVOID THE HAZARD Do not operate after consuming alcohol or drugs WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV after consuming alcohol or drugs Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident Never consume ...

Page 70: ...bility to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers PRE OPERATION CHECKS Always perform the pre operation checks before riding for safety and proper care of the machine 7 6 This is just for basic styl...

Page 71: ...spection and maintenance procedures and schedules described in the Owner s Manual WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure Use of improper tires on this ATV or operation of this ATV with improper or uneven tire pressure may cause loss of control increasing your risk of an accident Always use the...

Page 72: ...rol of the ATV which can result in an accident Always go at a speed that is proper for the terrain visibility and operating conditions and your experience SPEED LIMITER For riders inexperienced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiter limits the power and top speed of the machine Turning the screw in decreases top speed and turning...

Page 73: ...e weight 220 Kg 485 lb Front Carrier 45 Kg 100 lb Rear Carrier 90 Kg 198 lb Storage Box 2 0 Kg 4 4 lb Pulling load Total Weight of trailer and cargo 550 Kgf 1212 lbf Tongue Weight Vertical Weight on trailer hitch point 15 Kgf 33 lbf Loading and Operational Guidelines This ATV is not designed to carry or tow a trailer If you decide to add accessories to allow you to carry cargo or tow a trailer use...

Page 74: ...o perly Could cause changes in vehicle handling stability and braking which could lead to an accident Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer ACCES...

Page 75: ...pacity A blown fuse could cause a loss of lights or engine power MODIFICATIONS WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV with improper modifications Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident Never modify this ATV through improper installation or use ...

Page 76: ... following operation To prevent burns avoid touching the exhaust system Park the machine in a place where pedestrians or children are not likely to touch it WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Hot exhaust system Dry grass or brush or other combustible material accumulated around the engine areas could catch fire Do not operate idle or park the ATV in dry grass or other...

Page 77: ...ARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV on paved surfaces ATV are designed for off road use only Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets 7 13 ...

Page 78: ...es WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV on public streets roads or highways You can collide with another vehicle Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways 7 14 ...

Page 79: ...POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the AT...

Page 80: ...slippery or loose terrain Could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 7 16 ...

Page 81: ...ZARD Operating in areas where you might not be seen by other off road vehicles You could be in a collision You could be injured Always mount a caution flag on the machine to make you more visible Watch carefully for other vehicles FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only Do not ride in areas posted no trespassing Do not ride on p r i v a t e p r o p e r...

Page 82: ...al Remember that the engine and exhaust pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling to the L position and then release the parking brake Apply the throttle slowly and smoothly The centrifugal clutch will engage and you will start to accelerate apply the throttle smoothly Use this same procedure as you mov...

Page 83: ...can cause the tire to lose traction reducing control and increasing the possibility of an accident WARNING POTENTIAL HAZARD WHAT CAN HAPPENED HOW TO AVOID THE HAZARD Engaging a lower gear when the engine speed is too high The wheel could stop rotating This could cause loss of control an accident and injury It could also cause engine or drive train damage Make sure the engine has sufficiently slowe...

Page 84: ...d your foot or leg may come into contact with the rear wheels which could injure you or cause an accident Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation Removing even one hand or foot can reduce you ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from a footboard your foot or leg may...

Page 85: ...pting wheelies jumps and other stunts 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 Avoid wheelies and jumping You may lose control of the ATV or overturn 7 21 ...

Page 86: ...y ATV could go out of control causing a collision or over turn Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions Do not turn at excessive speeds As you approach a curve slow down and begin to turn the handlebars in the desired dire...

Page 87: ... 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 sharpness of the turn may cause the ATV to tip If the ATV begins to tip over to the outside while negotiating a...

Page 88: ...rected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control can usually be regained if there is room to do so by steering in the direction of the slide Applying the brakes or accelerating is not recommende...

Page 89: ...faces such as ice since all control may be lost WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Skidding or sliding improperly You may lose control of this ATV You may also regain traction unexpectedly which may cause the ATV to overturn Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go...

Page 90: ...NTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating on excessively steep hills The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills It is important when climbing a hill to make sure that tour weight is transferr...

Page 91: ...his 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 go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 7 27 ...

Page 92: ...ng hills or turning on hills Could cause loss of control or cause the ATV to overturn Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as describ...

Page 93: ...ver backwards Instead dismount the ATV immediately on the uphill side WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill Could result in ATV overturning Maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you b...

Page 94: ... downhill beside the vehicle so you can reach the brake lever with your right hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the hill using the front brake lever to control speed 5 If you lose control of the ATV for your safety get away from the vehicle If the hill is too steep or too slippery or if you have any doubt whether you...

Page 95: ...RIDING YOUR ATV 7 31 ...

Page 96: ... a loss of traction Whenever possible ride your ATV straight downhill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Going down a hill improperly Could cause loss of control or cause the ATV to over turn Always...

Page 97: ...r balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slippery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When rid...

Page 98: ...ly crossing hills or turning on hills Could cause loss of control or cause the ATV to overturn Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures a...

Page 99: ...acles Could cause loss of control or a collision Could cause the ATV to overturn Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving shallow water of up to ...

Page 100: ... loss of traction and loss of control which could lead to an accident Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner s Manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If nece ssary apply them several times to let friction dry out the pads or lining 7 36 ...

Page 101: ...pd water by removing the check hose at the bottom of the air filter case Wash the ATV in fresh water if it has been operated in salt water or muddy condition PARKING Always choose a level place to park After bringing your ATV to a stop hold the brakes while you shift into neutral Then set the parking brake and turn the ignition switch OFF If you re through riding for the day also turn the fuel val...

Page 102: ...rn If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is not recommended until you have corrected the slide If your ATV can t make it up a hill you are trying to climb Turn the ATV around if you still have forward speed If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV star...

Page 103: ...ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability 7 39 ...

Page 104: ...TIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Servicing an engine while it is running Moving parts can catch clothing or parts of the body causing injury Electrical components can cause shocks or can start fire Turn off the engine when performing maintenance unless otherwise specified Have LONGTING dealer perform service if you are not familiar with machine service OWNER S MANUAL TOOL KIT Yo...

Page 105: ...y extensive work requiring additional tools should be performed by your authorized dealer The tool kit includes the following items 1 Air pressure gauge 2 Spark plug wrench 3 13 15 mm wrench 4 Standard Phillips screwdriver 5 Screwdriver handle 6 Tool bag 7 8 10 mm wrench 8 10 12 mm wrench 9 6mm inner hexagonal 10 Pliers 8 2 ...

Page 106: ...r machine to a LONGTING dealer to check the torque setting and adjust them as necessary WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV with improper modifications Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situation could lead to an accident Never modify this ATV through improper installation...

Page 107: ...PERIODIC MAINTENANCE AND ADJUSTMENT PERIODIC MAINTENANCE LUBRICATION 8 4 ...

Page 108: ...PERIODIC MAINTENANCE AND ADJUSTMENT 8 5 ...

Page 109: ...N The panels illustrated need to be removed to perform some of the maintenance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A 2 Panel B 3 Panel C 1 Panel D 2 Panel E 3 Panel F 4 Panel G 8 6 ...

Page 110: ...ap and wipe off the dipstick with a clean rag 5 Remove the engine oil filler cap and wipe off the dipstick with a clean rag he oil level 6 Insert the dipstick in the oil filler hole without screwing it in and then remove it again to check the oil level 1 Panel F The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the ...

Page 111: ...he dipstick into the oil filler hole and then tighten the oil filler cap 9 Install the panel 1 Remove panel F 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 4 Remove the engine oil drain bolt to drain the oil from the crankcase Engine Oil Replacement and Oil Filter Cleaning...

Page 112: ...il filter wrench and then tighten it to the specified torque with a torque wrench 9 Install panels D and E 10 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Drain bolt engine 30Nm 3 0m kgf 22ft lbf 11 Add the specified amount of recommended engine oil and then install the engine oil filler cap and tighten it Oil quantity Without oil filter element r...

Page 113: ...arm it up for several minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 13 Turn the engine off and then check the oil level and correct it if necessary 14 Install panel F Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a Lonting dealer check and repair the A...

Page 114: ...ended oil 6 Install the filler bolt and tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 16 ft lbf Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 25L 0 22 Imp qt 0 26US qt Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 16 ft lbf Be sure no foreign material...

Page 115: ... the recommended type to raise it to the specified level 3 Install the differential gear oil filler bolt 1 Differential gear oil 2 Differential gear oil filler bolt 3 Specified level Be sure no foreign material enters the dif ferential gear case Differential gear oil replacement 1 Place the ATV on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove...

Page 116: ...ith the recommended oil Tightening torque Differential gear oil drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf 6 Install the differential gear oil filler bolt and then tighten it to the specified torque 7 Check for oil leakage If oil leakage is found check for the cause Be sure no foreign material enters the differential gear case Tightening torque Differential gear oil filler bolt 23 Nm 2 3 m kgf 16 ft lb...

Page 117: ...velmark 2 Minimum levelmark Hard water or salt water is harmful to the engine You may use soft water if you cannot get distilled water 8 14 1 1 2 1 Fanel H 3 If the coolant is at or below the minimum level mark remove panel H remove the reservoir cap add coolant to the maximum level mark install the reservoir cap and then install the panel ...

Page 118: ... not attempt to diagnose such problems yourself Instead take the machine to a LONGTING 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 excessive you should replace the spark plug with one of the proper type Standard spark plug DPR7EA 9 NGK 8 15 Before installing the spar...

Page 119: ...e cleaned periodically If the ATV is ridden in dusty areas the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule If the ATV is submerged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine 1 Remove the seat 2 Remove the air filter case cover b unhooking the holders 8 16 1 Air ...

Page 120: ...ressed air as shown If the air filter element is damaged replace it 6 Wash the foam cover gently but thoroughly in water or solvent WARNING Potential Hazard What Can Happen Using low flash point solvents or gasoline to clean the foam cover Low flash point solvents or gasoline can catch fire or explode How To Avoid The Hazard Use parts cleaning solvent to clean the foam cover 8 17 7 Squeeze the exc...

Page 121: ...the ATV is operated in extremely dusty areas Each time air filter element maintenance is performed check the air inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal Tighten all fittings securely to avoid the possibility of unfiltered air enter ing the engine 8 18 Never operate the engine with the air f...

Page 122: ...l the drain tube securing it with the clip 2 1 Drain tube 2 Clip 3 Air cleaner housing CARBURETOR ADJUSTMENT The carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to our dealer who has the professional knowledge and experience to do so However the idling speed may be performed by the owner as a part of the usual maintenance routine 8 ...

Page 123: ... 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 panel D 3 Connect the tachometer and set the idle to the specif ied idling speed by adjusting the throttle stop screw Turn the screw in to increase engine speed and out to decrease engine speed 4 Install the panel Specified idle speed 1 200 1 400 r min 8 20 1 Throttle stop ...

Page 124: ... bolt until the throttle lever free play Is 3 5 mm 0 12 0 20 in 3 Tighten the locknut 8 21 1 Locknut 2 Adjusting bolt a Throttle lever free play Select lever safety system cable adjustment The select lever safety system cable stretches with use resulting in improper function To prevent this the cable must be adjusted regularly This adjustment however should be left to a Lonting dealer ...

Page 125: ...ess is less than 1mm 0 04 in have a LONGTING dealer replace the pads as a set 8 22 1 Brake pad a Brake pad thickness Checking the rear brake pads Check the brake pads for damage and wear If the thickness is less than 1 0 mm 0 04 in have a Lonting dealer replace the pads 1 Brake pad 2 Brake pad plate a Brake pad thickness ...

Page 126: ...riding check that the brake fluid is above the minimum level and replenish when necessary A low brake fluid level may indicate 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 The rear brake fluid master cylinder reservoir is located behind panel B 1 Minimum level mark 1 Minimum level mark ...

Page 127: ...tation Avoid contacting brake fluid with the skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed Å Å Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the bo...

Page 128: ...cted periodically The system must be inspected frequently to ensure there are no fluid leaks If the brake lever travel become excessive and the brake pads are not worn beyond the recommended limit There is probably air in the brake system and it must be bled See your authorized dealer for this service 8 25 Å Å Ä To prevent damage to the brake system use only fluid from a sealed container Never all...

Page 129: ...AT CAN HAPPEN HOW TO AVOID THE HAZARD Operating with improperly serviced or adjusted brakes You could lose braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires prof...

Page 130: ...ut 2 Turn the adjusting bolt in direction a to increase free Play and in direction b to decrease free play 3 Tighten the locknut If correct free play cannot be obtained ask a LONGTING dealer to make that adjustment 1 Locknut 2 Adjusting bolt c Rear brake lever free play NOTE When adjusting the rear brake lever free play Be sure not to step on the brake pedal Make sure the brake pedal does not move...

Page 131: ...mproperly serviced or adjusted brakes You could lose braking ability which could lead to an accident After servicing Make sure the brakes operate smoothly and that the free play is correct Make sure the brakes do not drag All air must be bled from the brake system R e p l ac e m e nt o f br a k e c o m p on e n t s r e q ui r e s professional knowledge These procedures should be performed by our d...

Page 132: ...ht comes on just before braking takes effect If necessary adjust the brake light switch as follows 1 Remove panel B 2 Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 3 Install the panel 1 Rear brake light switch 2 Adjust...

Page 133: ...kinked Operation of controls could be restricted which could cause an accident or injury Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask our dealer to replace them Recommended lubricant LONGTING chain and cable lube or SAE 10W40 motor oil WHEEL REMOVAL 1 Elevate the wheel by placing a suitable stand under the ...

Page 134: ... Install the wheel and the nuts NOTE l l Tapered nuts are used for both the front and rear wheels Install the nut with its tapered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel 1 Arrow Mark 1 Tapered Nut 8 31 1 1 ...

Page 135: ...y leading to an accid ent Carefully follow the instructions in this Owner s Manual when installing BATTERY Your ATV battery is located in a compartment under the seat The battery is sealed so it is not necessary to check the electrolyte level or add distilled water If the battery seems weak see your authorized LONGTING dealer for information on recharging or replacement If you replace the battery ...

Page 136: ...ing open flames or sparks near the battery Gases may explode and possibly cause injury Do not allow open flames or sparks near the battery NOTE When the ATV is to be stored for an extended period remove the battery from the vehicle and charge it fully Then store it in a cool dry place If the battery is to be left on the vehicle disconnect the negative cable from the battery terminal Battery posts ...

Page 137: ...then disconnect the positive terminal lead 2 4 Remove the battery Battery Installation 1 Install in the reverse order of removal 2 Make sure the battery is installed upright 3 Check all bolts and other fasteners are secure 4 After installing the battery check to see if the battery cables are routed correctly 5 Install the seat FUSE REPLACEMENT The fuse box stored in the battery compartment under t...

Page 138: ...r replacing a fuse 1 main Fuse Box Cap 2 Remove the seat 3 Open the fuse box cap 4 Pull the old fuse out of the fuse holder 5 Push the new fuse in to the fuse holder 6 Close the fuse box cap and install seat 8 35 1 Main Fuse 1 1 1 Specified Fuse Box Cap 1 2 3 4 5 6 2 1 Auxiliary DC jack fuse Four wheel drive fuse 3 Headlight fuse 4 Ignition fuse 5 Spare fuse 6 Spare fuse ...

Page 139: ...mage to the electrical system which could lead to a fire HOW TO AVOID THE HAZARD Always use a fuse of the specified rating Never use a material in place of the proper fuse Specified fuses Main fuse 20A Headlight fuse 10A Ignition fuse 10A Backup fuse 10A 10A 5A Auxiliary DC jack fuse 10A Four wheel drive fuse 5A Spare fuse Spare fuse ...

Page 140: ...y pulling it off 2 Turn the bulb holder counterclockwise to remove the defective bulb 3 Put a new bulb into position and secure it in place with the bulb holder 4 Install the bulb holder 5 Install the headlight cover 8 37 1 2 3 4 1 Cover 2 Headlight bulb holder 3 Headlight bulb 4 Headlight bulb holder Position 5 Headlight bulb holder turning 6 Headlight bulb turning 6 5 ...

Page 141: ...b holder by pushing it inward and turning it clockwise 8 38 WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD The headlight bulb is hot when it is on and immediately after it is turned off You can be burned or a fire could start if the bulbtouches something flammable Wait for the bulb to cool before touching or removing it 6 Install the bulb holder together with the bulb 1 2 3 1 Tai...

Page 142: ...osits from the spark arrester portion of the tailpipe 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install and tighten the bolts WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Improper cleaning of the spark arrester Could injure the eyes Could cause burns Could cause carbon monoxide poisoning possibly leading to death Could start a fire When cleaning the spar...

Page 143: ...y service your machine Imitation parts may look like our parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Checking the fuel system while smoking or near an open flame Fuel can ignite or explode causing severe injury or property damage Do not smoke when checking the...

Page 144: ...PERIODIC MAINTENANCE AND ADJUSTMENT 8 41 ...

Page 145: ...kets or wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes trans mission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 Once...

Page 146: ...have reduced stopping ability increasing the chance of an accident Test the brakes after washing Apply the brakes several times at slow speeds to let friction dry out the linings STORAGE Before storing your ATV for an extended time be sure you thoroughly check the vehicle for needed repairs and have them corrected Otherwise the repairs may be forgotten by the time you remove the vehicle from stora...

Page 147: ...ot overfill the tank Be careful not to spill fuel when refueling After refueling make sure the fuel fill cap is closed properly and securely If any fuel is spilled make sure the area is dry before starting he engine WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Prolonged contact of fuel with the skin Breathing fuel vapor The fuel can cause skin irritation Fuel vapor could cause ...

Page 148: ...WARNING POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Allowing open flames or sparks near the battery Gases may explode and possibly cause injury Do not allow open flames or sparks near the battery 5 Wash and dry the ATV and wax all painted surfaces 6 Inflate the tires to their recommended pressures 7 Place the ATV on blocks to raise all four tires off the ground 8 Lbricate all control ...

Page 149: ...Engine Type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Starting system Lubrication system Liquid cooled 4 stroke SOHC Forward inclined single cylinder 493 cc 87 5x82mm 10 2 1 Electric and recoil Starter Pressure spray Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter cartridge replacement Wit...

Page 150: ...lt Shaft drive Left hand operation 9 79 39 12 14 96 59 774 8 98 35 93 V belt automatic Final gear case oil Differential gear case oil Type Quantity Type Quantity SAE80 API GL 4 Hypoid gear oil 0 25L 0 22 Imp qt 0 26US qt Frame Frame Type Caster Angle Trail Steel Tube 3 21mm Tire Type Front Tire Rear Tire Tubeless AT25X8 12 AT22X10 12 Air Filter Dry element Fuel Type Tank Capacity Reserve Capacity ...

Page 151: ... Generator System AC Magneto Battery Type Voltage Capacity GTX20L BS 12V 20AH Headlight 12V 35W 35Wx2 Front position light 12V W Front turn light 12V 10W Tail Brake light 12V 5W 21W Rear turn light 12V 10W Neutral Indicator 12V 3Wx1 Reverse Indicator 12V 3Wx1 High Beam Indicator Light 12V 3Wx1 Park indicator light 12V 3W Differential gear lock indicator 12V 3W 5 x2 x2 x2 x1 x1 10 3 Fuses Main fuse...

Page 152: ...y device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Exhaust system Muffler Exha...

Page 153: ...e done in accordance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MONTH SERVICE DEALER NAME AND ADDRESS REMARKS 150 km 1000 km 2000 km 3000 km 4000 km 5000 km 6000 km 7000 km 8000 km 9000 km 10000km 12 1 ...

Page 154: ...ELECTRIC WIRING DIAGRAM ELECTRIC WIRING DIAGRAM 13 1 ...

Page 155: ...S MANUAL FOLLOW ALL INSTRUC TIONS AND WARNINGS Without proper training or instruction At speeds too fast for your skills or the conditions On public roads a collision can occur with another vehicle With a passenger passengers affect balance and steering control Use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns Avoid paved surfaces pavement may seriousl...

Page 156: ...LX 500ATV USER S MANUAL 1st Edition September 2007 ...

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