Massimo 800ATV Owner'S Manual Download Page 101

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PERIODIC MAINTENANCE AND

ADJUSTMENT

Periodic inspection, adjustment and lubricat-

ion will keep your machine in the safest and

most efficient condition. Safety is an

obligation of the machine owner. The most

important points of machine inspection,

adjustment and lubrication are explained in

the following pages.

8-1

WARNING

Turn off the engine when performing

maintenance unless otherwise specified.

Have a dealer perform service if you are not

familiar with machine service.

Owner’s manual and tool kit

You are recommended to put this owner’s
manual in the vinyl bag and always carry it in
the storage box. Put the owner’s tool kit and
low-pressure tire gauge in the space beside
the battery.

1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge

The service information included in this
manual is intended to provide you, the owner,

MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO

Summary of Contents for 800ATV

Page 1: ...O MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASSI SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA ASSIMO MASSIMO MASSIMO MASSIMO MASS...

Page 2: ...ides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or mainte...

Page 3: ...DDEN BY ANYONE UNDER 16 YEARS OF AGE ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO...

Page 4: ...ust be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or clearer NOTE ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS...

Page 5: ...flameout switch firstly while make the radiator fan still work for at least 3 minutes then turn off the power switch to save the battery As long as the ATV key switch is on the oil pump of the EFI sys...

Page 6: ...pedal 4 16 Fuel tank cap 4 17 Seat 4 18 Storage box 4 18 Front and rear carrier 4 19 Front rear shock absorber adjustment 4 20 4 Auxiliary DC jack 4 21 Steering Lock 4 23 ASSIMO MASSIMO MASSIMO MASSIM...

Page 7: ...slope 6 8 ATV brake in 6 9 Engine brakie in 6 10 Braking system break in 6 11 Modifications 6 11 Loading 6 12 HOW TO RIDE YOUR ATV 7 1 7 Getting to know your ATV 7 1 Ride with care and good 6 judgment...

Page 8: ...tem examination 8 8 Engine oil and oil filter 8 8 Checking the engine oil level 8 9 Replacing the engine oil with or without oil filter cartridge replacement 8 10 Final gear oil 8 12 Differential gear...

Page 9: ...on 8 34 Wheel removal 8 34 Wheel installation 8 35 Battery 8 36 Battery maintenance 8 37 Fuse replacement 8 37 Replacing a headlight bulb 8 38 Headlight beam adjustment 8 40 Tail brake light bulb repl...

Page 10: ...O MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASSI SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA ASSIMO M...

Page 11: ...MO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASS SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA ASSIMO M...

Page 12: ...ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO M...

Page 13: ...MO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASS SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA ASSIMO MASSIMO MASSIMO MASSIMO M...

Page 14: ...O MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASS SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA ASSIMO MASSIMO MASSIMO MASSIMO MA...

Page 15: ...under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely z Never carry more than one p...

Page 16: ...h terrain Always be especially cautious on these kinds of terrain z Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at...

Page 17: ...ible z Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling use proper gear range and maintain a steady speed when climbing a hill If you stall or roll ba...

Page 18: ...lways use the size and type tires specified in this manual z Always maintain proper tire pressure as described in this manual z Never modify an ATV through improper installation or accessories z Never...

Page 19: ...oline is poisonous and can cause injuries If you swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin w...

Page 20: ...IMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASS...

Page 21: ...SSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASS SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA ASSIMO MASSIM...

Page 22: ...e identification number The vehicle identification number is stamped into the frame 1 Vehicle identification number ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSI...

Page 23: ...MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO...

Page 24: ...1 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO...

Page 25: ...lock switch is set to the position which means the differential comp in the working status While the switch is set to other positions this indicator would be lighted up which means the differential co...

Page 26: ...en the drive select lever is in the R position If the indicator flashes or the speedometer does not show the speed while the ATV is ridden ASK a dealer to check the speed sensor and circuit Park indic...

Page 27: ...is out Continuous usage while the light is on may cause damage to the engine Far light indicator When the far light is selected this indicator is lighted up Position indicator When the light switch i...

Page 28: ...the engine z a clock z an EFI fault code table which shows the code of the EFI faulted parts Odometer and trip meter modes Press the TRIP ODO button to select the mode ODO TRIP ODO A trip meter can re...

Page 29: ...meter which will flash on the clock If there are more than one fault codes they will be shown in rolling turn Press the clock button the time would be shown And after five seconds the fault code retur...

Page 30: ...m Set the switch to to turn on the high 4 7 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO...

Page 31: ...buzzer will sound Engine stop switch Make sure that the engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engin...

Page 32: ...h can provide ATV better performance in cross country running on muddy roads When riding in good road condition you can unlock the system to promote the reliability To shift 2WD 4WD and 2WD UNLOCK thi...

Page 33: ...ar bridge gears You are allowed to choose the two switches according to the road condition Only the rear bridge can be locked ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS...

Page 34: ...ould spark At this time the two rear wheels can change their speeds according to the requirement of the pulling force WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 2WD to UNLOCK or vice ve...

Page 35: ...z When 2WD is selected the ATV goes to the 2 wheel driving system z When the ATV adopts 2WD the indicator would disappear 4 12 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO M...

Page 36: ...W TO AVOID THE HAZARD Slow down the ATV at a safe speed Throttle lever Once the engine is running movement of the throttle lever will increase the engine speed Regulate the speed of the machine by var...

Page 37: ...the throttle from fully opening even when the throttle lever is pushed to the maximum Turn the adjusting screw to limit the maximum engine power available and decrease the maximum speed of the ATV Af...

Page 38: ...ke lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 Front brake lever ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM...

Page 39: ...brake 1 Parking clamp 2 Parking handlebar Drive select lever The drive select lever is used to shift your machine into the low L high H neutral N reverse R positions See P6 3 P6 5 4 16 ASSIMO MASSIMO...

Page 40: ...SSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASS SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASSIM...

Page 41: ...e box make sure they are wrapped with proper plastic bags When cleaning the ATV avoid water inflowing into the box 4 18 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO M...

Page 42: ...ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO M...

Page 43: ...ting the shock absorber to be hard WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an ac...

Page 44: ...of the ATV The auxiliary DC jack can be used for suitable work lights radios etc The auxiliary DC jack can provide 8 5A 12V 4 21 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO...

Page 45: ...ary DC jack Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10A ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MA...

Page 46: ...is vehicle is equipped with steering lock which can guard against theft while parking 1 Steering lock 2 Steering stem 4 23 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM...

Page 47: ...ential Lock System Check whether the rear differential can lock and unlock normally or not P4 9 Throttle Check for proper throttle cable operation and free play P4 13 Wheels and tires Check tire press...

Page 48: ...equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and s...

Page 49: ...fluid level Check the brake fluid level Add fluid if necessary See pages P8 29 Recommended brake fluid DOT 4 Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or b...

Page 50: ...sure there is sufficient gasoline in the tank Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total 25 L 5 50 lmp gal 6 6 US gal Use unleaded gasoline only The use of leaded gasoline will c...

Page 51: ...gasoline if using the gasohol mixed oil the engine s performance will be reduced while the emission will be worse 1 Fuel level 2 Fuel tank filler tube 5 5 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM...

Page 52: ...order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than sp...

Page 53: ...the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add distilled water to bring the level up to maximum level mark Change the coola...

Page 54: ...out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely re...

Page 55: ...of throttle cable or may be due to the ECU failure As the ATV is equipped with EFI system idle speed adjustment should be done through a special computer which can modify the ECU procedure Check with...

Page 56: ...m the rim under severe riding conditions The following are minimums Front 62kPa 0 62 kgf cm2 9 psi Rear 62kPa 0 62 kgf cm2 9 psi 4 Use no more than the following pressures when seating the tire beads...

Page 57: ...et tire pressures to the following specifications Recommended pressure Minimum Maximum Front 69kpa 0 70kpf cm2 10psi 62kpa 0 63kpf cm2 9psi 76kpa 0 76kgf cm2 11psi Rear 69kpa 0 70kpf cm2 10psi 62kpa 0...

Page 58: ...MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASS SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO MASSIMO MASS...

Page 59: ...n riding in cold weather always make sure all control cables work smoothly before you begin riding Starting Procedure 1 Apply the rear brake lever 2 Turn the fuel cock to ON 3 Turn the gear shift to N...

Page 60: ...third throttle to have a 3km driving or let the engine driving 3minutes with 2000rpm Engine s turning off Turn the left handlebar switch to then the engine will be turned off Or turn the key to OFF wh...

Page 61: ...speed is below 1400rpm apply the brakes and then shift by moving the drive select lever along the shift guide 3 Open the throttle lever gradually NOTE Make sure that the drive select lever is complet...

Page 62: ...al and vice versa by moving the drive select lever along the shift guide 1 Drive Select Lever ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS...

Page 63: ...ious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly 2WD 4WD and 2WD UNLOCK shifting The switches...

Page 64: ...ing ATV on wet road at a high speed prompt braking may cause the ATV out of control So slow down and be cautious when riding ATV on wet road 6 Remember that wet brakes may reduce the stopping ability...

Page 65: ...ave select lever into H L and R position then turn the main switch off Operate left handle to make parking brake work and use the limit clamp the keep the left handle jammed parking brake can be maint...

Page 66: ...main switch off 4 Operate left handle to make parking brake work and use the limit clamp the keep the left handle jammed parking brake can be maintained in the braking effect 5 Put a big rock or wedg...

Page 67: ...oil seals and the driving systems So never run your engine with full throttle for the first three hours Only use the certain oil recommended in this manual Others may do harm to the engine ASSIMO MASS...

Page 68: ...ubstantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a dealer 0 10 h...

Page 69: ...uations could lead to an accident If you plan to modify the vehicle or drive the ATV with modifications please remember followed Never modify this ATV through improper installation or use of accessori...

Page 70: ...n cause an accident Make sure the load does not interfere with controls or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower y...

Page 71: ...ler Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying cargo or pulling a trailer ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASS...

Page 72: ...d understand the operation of the controls Pay particular attention to the safety information Please also read all caution and warning labels on your ATV Ride with care and good judgement Get training...

Page 73: ...does not know how to operate the ATV properly in different situations and on different types of terrain ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO...

Page 74: ...ft position as needed during operation It is not for carrying passengers ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIM...

Page 75: ...ses your chances of a severe head injury or death in the event of an accident ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO M...

Page 76: ...ohol or drugs Operator s performance capability is reduced by the influence of alcohol or drugs Never consume alcohol or drugs before or while driving this ATV WARNING ASSIMO MASSIMO MASSIMO MASSIMO M...

Page 77: ...s Manual on page 38 Always go at a speed that is proper for the terrain and your experience WARNING Always go at a speed that is proper for the terrain visibility and operating conditions and your exp...

Page 78: ...G LIMIT Vehicle loading limit 230kg Total weight of cargo rider passenger and accessories and trailer hitch vertical load Front carrier 25kg Rear carrier 30kg Storage box 3 0kg Trailer hitch Pulling l...

Page 79: ...which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards of your ATV during operation ASSIMO MASSIMO MASSIMO MASSIMO...

Page 80: ...in some situations ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO M...

Page 81: ...eration To prevent burns avoid touching the exhaust system Park the ATV in a place where pedestrians or children are not likely to touch it WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN...

Page 82: ...ay cause the ATV to upset WARNING 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 ASSIMO MASSIMO MASSIMO MASSIMO...

Page 83: ...skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASS...

Page 84: ...rge flat area off road to become familiar with your ATV Make sure that this area is free of ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSI...

Page 85: ...will engage and you will start to accelerate If the throttle is applied too abruptly the front wheels may lift off the ground resulting in a loss of directional control Avoid higher speeds until you...

Page 86: ...TV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds below...

Page 87: ...position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper r...

Page 88: ...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 whe...

Page 89: ...you are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room...

Page 90: ...e 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 sl...

Page 91: ...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 de scribed in the Owner s Manual Avoid...

Page 92: ...y or dismount the ATV immediately on the uphill side WARNING 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...

Page 93: ...n 4WD or 4WD LOCK all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will brake all wheels When descending hills using ei...

Page 94: ...ll Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible A...

Page 95: ...hat wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the linings Test your brakes after leaving the water...

Page 96: ...t water or muddy conditions 1 Air filter case check hose ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIM...

Page 97: ...o 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 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS...

Page 98: ...ying the brakes or accelerating is not recommended until you have corrected the slide With practice over a period of time skill at controlled sliding can be developed The 7 27 ASSIMO MASSIMO MASSIMO M...

Page 99: ...e putting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control See pages 7 15 7 17 2 If your ATV begins to tip while turning Lean more...

Page 100: ...is going to tip over dismount on the uphill side See pages 7 20 7 21 6 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let w...

Page 101: ...ys carry it in the storage box Put the owner s tool kit and low pressure tire gauge in the space beside the battery 1 Owner s manual 2 Owner s tool kit 3 Low pressure tire gauge The service informatio...

Page 102: ...ions could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be components de...

Page 103: ...er hose for cracks or damage z Replace if necessary Exhaust system z Check for leakage z Tighten if necessary z Replace gasket s if necessary Spark arrester z Clean Sensor z Clean To clean for each 50...

Page 104: ...k operation z Repair if damaged z Check toe in z Adjust if necessary Front and rear suspension z Check operation z Correct if necessary Upper and lower arm pivot and steering shaft z Lubricate every 6...

Page 105: ...uired z On the inner parts of the master cylinders and scalpers replace the oil seals every two years z Replace the brake hoses every four years or if cracked of damaged EFI System Different from the...

Page 106: ...SIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MAS...

Page 107: ...determined both by the throttle valve s opening angle and the inlet pipe pressure ECU can adjust the injection quantity according to the inner pressure and the opening angle of the throttle valve The...

Page 108: ...ould be shown in the speedometer or you can examine the system through EFI fault detector purchasing from your dealer This detector could provide the detailed fault information An additional owner s m...

Page 109: ...l filler cap 2 Dipstick NOTE The engine oil should be between the minimum and maximum level marks 1 Maximum level mark 2 Minimum level mark 8 9 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO M...

Page 110: ...lt to drain the oil from the crankcase 1 Engine oil drain bolt 4 Remove the oil filter cap with an oil filter wrench 1 Engine oil filter 2 Oil filter B 8 10 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASS...

Page 111: ...drain bolt and tighten it to the specified torque Tightening torque oil drain bolt 30 Nm 3 0m kgf 21 85ft lbf ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA...

Page 112: ...check the oil level and adjust it if necessary Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a dealer check and repair the ATV Replac...

Page 113: ...iller bolt and tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3m kgf 17ft lbf ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA...

Page 114: ...Differential gear oil filler bolt 23 Nm 2 3m kgf 17 ft lbf Replacing the differential gear oil 1 Place the ATV on a level surface 2 Place a container under the differential gear case to collect the us...

Page 115: ...ller bolt 23 Nm 2 3m kgf 17 ft lbf 6 Check for oil leakage If oil leakage is found check for the cause Cooling system 1 Place the ATV on a level surface 2 Check the coolant level in the coolant reserv...

Page 116: ...ter is added have a dealer check the antifreeze content of the coolant as soon as possible The radiator fan operation is completely automatic It is switched on or off according to the coolant temperat...

Page 117: ...on the footrest 1 Trough 3 Remove the radiator cap 1 the radiator cap ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO...

Page 118: ...full and then install the radiator cap Recommended antifreeze High quality ethylene glycol antifreeze Containing corrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Total a...

Page 119: ...for holes or tears If any damage is found have them replaced by a dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASS...

Page 120: ...ridden normally Do not attempt to diagnose such problems yourself Instead take the ATV to a dealer You should periodically remove and inspect the spark 8 20 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS...

Page 121: ...ue Spark plug 17 5 Nm 1 75m kgf 12 93 ft lbf NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Ha...

Page 122: ...ove the air filter case cover 1 Holder 2 Air filter case cover 4 Remove the air filter element 1 Air filter element ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSI...

Page 123: ...foam air filter oil to the air filter element The air filter element should be wet but not dripping 10 Pull the air filter element over its frame 11 Install the air filter element ASSIMO MASSIMO MASSI...

Page 124: ...ut the air filter element equipped This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will lower the per...

Page 125: ...ways let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA...

Page 126: ...djustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This 8 26 ASSIMO MASSIMO MAS...

Page 127: ...sting bolt until the throttle lever free play is 3 5 mm 3 Tighten the locknut 1 Locknut 2 Adjusting bolt a Throttle lever free play Front rear brake pad checking Check the brake pads for damage and we...

Page 128: ...e If the brake fluid level is low please firstly find the reason The rear brake fluid master cylinder reservoir is located near the brake pedal 1 Minimum level mark ASSIMO MASSIMO MASSIMO MASSIMO MASS...

Page 129: ...p spilled fluid immediately Have a dealer check the cause if the brake fluid level goes down Brake fluid replacement z Complete fluid replacement should be done only by trained service personnel z Hav...

Page 130: ...ke sure the brakes do not drag z Make sure the brakes are not spongy All air must be bled from the brake system Replacement of brake components requires professional knowledge These procedures should...

Page 131: ...ing the rear brake light switch The rear brake light switch which is activated by the brake pedal and rear brake lever is properly adjusted when the brake light comes on just before braking takes effe...

Page 132: ...be smoothly plugged or pulled after cleaning and adding the right amount of oil replace the cable RECOMMENDED SAE10W30 ENGINE OIL Lubricating the brake lever and brake pedal Use lithium grease to lubr...

Page 133: ...SIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASS SIMO MASSIMO M...

Page 134: ...emove the wheel 1 Nut 4 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASS...

Page 135: ...Wheel nut torque Front 75 Nm 7 5m kgf 55 42 ft lbf Rear 75 Nm 7 5m kgf 55 42 ft lbf ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MAS...

Page 136: ...from your skin eyes and clothes When you work nearby the battery wear a mask to protect your eyes Keep the children far away from the battery EXTERNAL Flush with water INTERNAL Drink large quantities...

Page 137: ...ion Then install a new fuse of the specified amperage Turn on the main switch If the fuse immediately blows again consult a dealer 1 Main fuse 2 Spare main fuse 3 ECU fuses 4 Four wheel drive fuse 5 D...

Page 138: ...llows 1 Remove the cover at the rear of the headlight by pulling it off 1 COVER 2 Remove the headlight bulb holder cover by pulling it off ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM...

Page 139: ...e bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner ASSIMO MASSIMO MASSIMO MASSIMO...

Page 140: ...to have a dealer make this adjustment 2 Remove the bulb holder together with the bulb by turning it counterclockwise 8 40 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO...

Page 141: ...MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO...

Page 142: ...ID THE HAZARD Do not smoke when checking the fuel system Make sure there are no open flames or sparks in the area including pilot lights from water heaters or furnaces ASSIMO MASSIMO MASSIMO MASSIMO M...

Page 143: ...Brake system S N Troubles Solutions 1 Check whether the parking brake operating lever has been restored to the release position 1 Check if the brake discs on the front and rear wheels are deformed 1 L...

Page 144: ...the parts which install brake caliper are deformed 1 Check if the deviation of left and right brake power on the front and left brake is within the scale of rules 2 Check if the brake power of front...

Page 145: ...ed Check if the sensor is damaged Check if the meter board is damaged 4 Display abnomal of meter board Check if the surface of speed sensor is polluted by scrap iron Check if the shutdown switch is da...

Page 146: ...earing in the rear axle bearing seat is damaged Check if the moving bearing which connecting rear axle bearing seat and swinging arm is abrasion or loosen Check if the fastening nut on the rear axle a...

Page 147: ...maged Check if the gear inside the front and rear reduction gearbox or differential is excessive wear 6 Abnomal sound from front rear axle when moving Check if the dustproof rubber cover on the univer...

Page 148: ...air pipe is air leakage Check if the connecting joint of exhaust pipe and engine and muffler is air leakage 3 Engine shooting Check if the gasoline grade is lower Check if the voltage of the battery i...

Page 149: ...or bruned Check if the ignition signal of the magnetor is working normally Check if the air filter is blocked Check if the oil circuit is smooth Check if the exhaust system is blocked 6 Eninge could...

Page 150: ...of the dust is washed away An old toothbrush or small round brush which used to clean the glass bottle could be used to clean the place which could not catch easily Wash with clear water right away an...

Page 151: ...the oil on the cylinder wall Lubricate all the control cables Elevate the frame so that all the wheels off the ground Put a plastic bag on the exhaust pipe of muffler to prevent the moisture in If sto...

Page 152: ...IMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MASSIMO MASSIMO MASSIMO MASSIMO MASSIM IMO MASSIMO MASSIMO MASSIMO MASSIMO MASSI SIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS SSIMO...

Page 153: ...ication system 4 stroke Water cooled V type twin cylinder 800cm3 91 61 5mm 10 0 1 Electric starter Wet sump ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSI...

Page 154: ...use oils labeled ENERGY CONSERVING II or higher 1 9 L 1 67 Imp qt 2 01 US qt 2 0 L 1 76 Imp qt 2 11 US qt 10 2 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO M...

Page 155: ...le valve Type quantity Spark plug Type manufacturer Spark plug gap DR8EA NGK 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASS...

Page 156: ...front rear Tubeless AT25 8 12 AT25 10 12 ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO O MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MO MAS...

Page 157: ...system Generator system Battery type Battery capacity ECU A C magneto YTX20L BS 12 V 21 Ah Headlight type Krypton bulb ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MA...

Page 158: ...e Four wheel drive fuse Gear switch fuse Differential fuse Spare fuse 30A 15A 15A 10A 15A 10A 15A 15A ASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MASSIMO MAS...

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Massimo 800ATV, Owner'S Manual

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