Tractor Supply M150 Owner'S/Operator'S Manual Download | Manualshive

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67

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5. Front A-arm

pivot Shaft

Grease

Locate fitting on

pivot shaft and

grease

with

grease gun

Every 3 months

or50hours



6.Steering

Post Bushings

Grease

Locate fitting on

pivot shaft and

grease

with

grease gun

Every 3 months

or50hours



7.Front Wheel

bearings

Grease

Inspect

and

replace

bearings if

necessary

Semi-annually

8.Tie rods

Grease

Locate fittings

and grease

Semi-annually

15. MAINTENANCE

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Summary of Contents for M150

Page 1: ...ration Maintenance THIS VEHICLE IS NOT DESIGENED FOR USE ON RENTAL TRACKS OR RACING BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION AS WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER PORTIONS OF CEHICLE ...

Page 2: ...DAILY PRE RIDE INSPECTION 5 OPERATION WARNING 6 V I N 7 CONTROL AND FUCTIONS 8 STARTING THE ENGINE 9 VEHICLE BREAK IN PERIOD 10 RIDING GEAR 11 RIDING 12 CVT SYSTEM 13 BATTERY 14 EXHAUST SYSTEM 15 MAINTENANCE 16 TROUBLE SHOOTING 17 TOOLS 18 SPECIFICATION 19 WIRING DIAGRAM ...

Page 3: ... and follow all Warnings and Instructions in this material If you did not receive any of the material listed above please call your dealer and request to have them sent to you Important Safety Notice Never make any modifications to the engine drive system mechanical or electrical systems of your ATV Never install after market parts or accessories intended to increase the speed or power of your ATV...

Page 4: ... and completed a certified training course before operation Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never operating an ATV without wearing an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or...

Page 5: ...g on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper for crossing the side of a hill as described in this manual Avoid hills with excessi...

Page 6: ...the recommended maximum depth go slowly balance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads and the linings Always use ...

Page 7: ... OWNER S MANUAL KNOW YOUR VEHCLE BEFORE YOU BEGINNING RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibilities for your personal safety the safety of others and the protection of our environment NOTE Illustrations used in this manual are for general representation only Your model may differ ...

Page 8: ... to convey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the porential for personal injury Your safety is involved WARNING Indicates a potential hazard which could result in severe injury or death CAUTION Indicates a potential hazard which may result in minor personal injury or damage to the ATV CAUTION Indicates a sit...

Page 9: ...NOTE Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your dealer for a replacement ...

Page 10: ...10 3 SAFETY WARNING 1 6 ...

Page 11: ...11 3 SAFETY WARNING 2 3 ...

Page 12: ...12 3 SAFETY WARNING 4 5 ...

Page 13: ...13 3 SAFETY WARNING 7 8 ...

Page 14: ...t and fluid level 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop switch Tether switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element check for dirt clean or replace 9 Steering check for free op...

Page 15: ...ibed in the Owner s Manual For more information about the training course contact an authorized ATV dealer WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPERN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can ...

Page 16: ...IAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPERN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger ...

Page 17: ...ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPERN Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement ...

Page 18: ...rception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPERN Increases your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operating cond...

Page 19: ...ING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPERN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps 5 OPERATION WARNINGS ...

Page 20: ... the Owner s Manual WARNING POTENTIAL HAZARD Removing hand from handlebars or feet from footrests during operation WHAT CAN HAPPERN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels Which could injure you or cause an...

Page 21: ... 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 HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 5 OPERATION WARNINGS ...

Page 22: ...ious on these kinds of terrain WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPERN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the 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 w...

Page 23: ... Owner s Manual WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPERN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting large hills Never operate ATV on hills steeper than 15 5 OPERA...

Page 24: ...le to lean sharply to one side Go straight down the hill where possible WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPERN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD 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 t...

Page 25: ...l Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the front brake gradually When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the ATV around and remount following...

Page 26: ...s such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPERN You may lose control of the ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in or...

Page 27: ...t make sudden throttle changes Remember that 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 pads WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPERN Use of improper tires on this ATV or operation of this ATV with improper or unev...

Page 28: ...llation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized dealer WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo WHAT CAN HAPPERN Could cause changes in vehicle handling which cou...

Page 29: ... qualified service dealer check the complete machine including but not limited to brakes throttle and steering for possible damage WARNING Safe operation of this ride active vehicle requires good judgment and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death C...

Page 30: ...Your key can be duplicated only by obtaining a key blank and having it cut by mating it with your existing key Record Key Number The vehicle frame and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle were stolen these numbers are essential to the recovery and identific...

Page 31: ...e engine WARNING This ATV is not equipped with highway approved lighting This ATV is designed for off road use only and must not be ridden on streets or highways Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness NOTE The taillight is on whenever the main switch key is the on position Turn the key off to prevent battery drain ...

Page 32: ...Right Button Left Button Pushing the left button switches the display between the odometer and the tripmeter Right Button Holding in the right button and then turning the key to on switches the display between mph and km h ...

Page 33: ...sticking during riding and cause an accident Always check the lever for free movement and return before starting the engine and occasionally during riding Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded and engine speed returns to idle when the lever is released WARNING Washing or operating the scooter in freezing...

Page 34: ...d the possibility of sever injury Front Brakes The front brakes are located on the right handlebar and are operated by the right hand The front brakes are mechanical drum type brakes which are activated by one lever only Always test brake lever travel and brake shoes before riding When squeezed the level should feel firm Any sponginess would indicate a wear and tear of the brake shoes which must b...

Page 35: ...el which must be corrected before riding Contact your dealer for proper diagnosis and repairs WARNING Use caution when applying the rear brake Do not aggressively apply the rear brake the rear wheels may skid and slide sideways causing loss of control WARNING Never operate the ATV with a spongy feeling brake level Operating the ATV with a spongy brake level can result in loss of braking Loss of br...

Page 36: ...cylinder body Release the brake lever 3 To release the parking brake lock squeeze the brake lever It will return its released position Front Parking Brake 1 Squeeze the right hand brake lever two or three times and hold it 2 Push the park brake lock 1 into the hole on the lever body Release the brake lever 3 To release the parking brake lock squeeze the brake lever It will return its released posi...

Page 37: ...e downhill side of the wheels if leaving the ATV on a hill or park the ATV in a side hill position WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV An accident could result causing severe injury if the parking brake is left on while the ATV is operated Rear brake Brake Fluid Level The brake fluid in the master cylinder which is located on the left...

Page 38: ...djusting To adjust set up the mechanical brake use the following procedure 1 Loosen the jam nuts of the adjuster on the right hand of right and left brake cable 2 Turn the both adjusters keep the rock arm on the lever balance until 1 8 2to3mm free play is achieved at the brake lever NOTE While adjusting free play it is important you apply the lever back and forth 3 Tighten the jam nuts securely ag...

Page 39: ...llow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not over fill the tank Do not fill the tank neck If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of cons...

Page 40: ...three positions OFF For vehicle storage and whenever transporting ON For normal operation REA For reserve supply in the event of main supply exhaustion NOTE here is about a 9 mile 15km range on reserve gas Always refill the gas tank as soon as possible after having used reserve supply Always return valve to on position after refueling machine Fuel filter The filter should be replaced by your deale...

Page 41: ...s 3 Stop the engine remove dipstick 1 and wipe dry with a clean cloth 4 Put dipstick into the oil tank don t screw in it 5 Remove dipstick and check to see that the oil level is between the full and add marks 2 Add oil as indicated by the level on the dipstick Do not overfill CAUTION Use only SAE 15W 40 SG OIL Never substitute or mix oil brands Serious engine damage and voiding of warranty can res...

Page 42: ...nd axle will hurt your leg CAUTION You must allow your vehicle adequate warm up time before operating or engine damage could result 1 Turn the fuel tank valve to ON 2 Sit on the vehicle 3 Turn the engine stop switch to RUN 4 Turn the ignition key to on apply the brake lever and press the starter button 5 Do not press the throttle more than 20 while starting the engine 6 Activate the starter for a ...

Page 43: ...arts Please set a limit to half throttle during the break in periods 1 Locknut 2 Adjuster 1 Fill fuel tank 2 Check oil reservoir level indicated on dipstick Add oil if necessary 3 Drive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular check...

Page 44: ...ortant piece of protective gear for safe riding A helmet can prevent a severe head injury 2 Eye Protection A pair of goggles or helmet face shield offer the best protection for your eyes 3 Gloves off road style 4 Boots A pair of strong over the calf type boots with heels such as moto cross boots 5 Clothing To protect your body long sleeves and pants should always be worn Riding pants with kneepads...

Page 45: ...45 11 RIDING Shift display This ATV is divided into three gear forward gears neutral and reverse As shown 1 for the reverse 2 for neutral 3 for forward ...

Page 46: ...right with both feet on footrests and both hands on the handlebar 2 Starting the engine and allowing it to warm up 3 Check you surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with you right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly practice maneuvering and using the throttle and brak...

Page 47: ... of the turn must travel a greater distance than the inside wheels when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly WARNING Avoid turning at sharp angles as tip over and severe injury may result ...

Page 48: ...ng quick sharp turns which can cause skids 3 Correct a skid by turns the handlebars in the direction of the skid and shifting your body weight forward 4 Never apply brakes during a skid Complete loss of ATV control can result 5 Do not operate on excessively slippery surfaces 6 Always deduce speed and use additional caution WARNING Failure to exercise care when operating the ATV on slippery surface...

Page 49: ...e ATV could occur causing severe injury or death Whenever traveling uphill always travel straight uphill and 1 Avoid steep hills 15 maximum 2 Keep both feet on the footrests 3 Transfer you weight forword 4 Proceed at a steady rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV 11 RIDING ...

Page 50: ...upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately WARNING Improperly crossing hills or turning on hills can be dangerous Loss of vehicle control or overturning of the ATV could occur causing seve...

Page 51: ...ly downhill 2 Transfer you weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing WARNING Do not travel at excessive speeds It is dangerous and can cause loss of vehicle control and tipping resulting in severe injury or death 11 RIDING ...

Page 52: ...full left while facing front of ATV 5 While holding brakes release parking brake lock and slowly allows ATV to roll around to your right until ATV is pointing across the hill or slightly downward 6 Lock the parking brake and remount ATV from the uphill side maintaining body weight uphill 7 Restart engine release parking brake and proceed slowly controlling speed with the service brake until ATV is...

Page 53: ...oiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal CAUTION Never operating the ATV through deep or fast flowing water NOTE After running the vehicle in water it is critical your machine is serviced as outlined in the maintenance chart see 15 maintenance The following areas need special attention engine oil t...

Page 54: ... valve to OFF Remove the spark plug Loosen the carburetor drain screw 1 Turn the engine over several times with electric start Dry the spark plug and reinstall or replace with a new plug Tighten the carburetor drain screw 1 Turn the fuel valve to ON Attempt to start the engine If necessary repeat the drying procedure Take the machine to your dealer for service as soon as possible whether you succe...

Page 55: ... logs rocks and low hanging branches WARNING Not all obstacles are visible Travel with caution on trails Severe injury or death can vehicle comes in contact with a hidden obstacle CAUTION Opening the throttle more than required may cause excessive fuel to build in the exhaust resulting in engine popping and or engine damage 11 RIDING Parking on an incline ...

Page 56: ...kes 3 Shut off fuel supply 4 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown above 5 Do not leave the ATV on a hill depending on the parking brake for more than five minutes 12 CVT SYSTEM CVT System ...

Page 57: ... so may reduce its strength so that a failure may occur at high speeds Any modification will cause the system to be out of balance creating vibration and additional loads on components Routing maintenance is the responsibility of the owner Always follow recommended maintenance procedures See you dealer The CVT housing must be securely in place during operation Failure to comply with this warning c...

Page 58: ...oil Call physician immediately Eyes Flush with water for 15minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN MF Battery This battery is maintenance free type it is not necessary to replenishing the battery ...

Page 59: ...the order specified Red positive cable first black negative cable last An exploding battery can cause serious injury or death Battery terminals and connections should be kept free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the termi...

Page 60: ...e reusing take the battery to your dealer for testing and recharging When installing a new battery make certain it is fully charged prior to it is initial use Using a new battery that has not been fully charged can damage the battery resulting in a shorter life of the battery CAUTION Your ATV is equipped with a 8Ah Battery This may no be sufficient to provide power for optional equipment When inst...

Page 61: ... must be periodically purged of accumulated carbon as follows 1 Remove the arrestor screw located on the bottom of the muffler pull out the arrestor the mesh 2 Clean the arrestor or replace it WARNING When cleaning the spark arrestor you must follow the safe guards listed below to avoid serious injury Do not perform this operation immediately after the engine has been run because the exhaust syste...

Page 62: ... following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour 16km h Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for rep...

Page 63: ...ct Replace if necessary Transmission Oil Level 100 hrs Yearly Inspect yearly or 100hrs change annually Battery 20 hrs Monthly Check clean Terminals D Brake pad shoe wear 10 hrs Monthly Inspect periodically Engine Cylinder Head and Cylinder Base Fasteners 25 hrs 3 months Inspect re torque required at first service only General Lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc Eng...

Page 64: ...6 months tighten fasteners Rear Suspension 50 hrs 6 months Inspect tighten fasteners Spark Plug 100 hrs 12 months Inspect replace if necessary D Ignition Timing 100 hrs 12 months Inspect and adjust as needed D Fuel System 100 hrs 12 months Check for leaks at tank cap lines fuel valve filter and carburetor Replace lines every one year D Fuel Filter 100 hrs 12 months Replace annually Chain Before an...

Page 65: ...arance 100 hrs 12 months Inspect adjust D Brake fluid 200 hrs 24 months Change every two years Idle Speed As Required As Required Adjust D Toe adjustment As Required As Required Periodic inspection adjust when parts are replaced Headlight Aim if equipped As Required As Required Adjust if necessary 15 MAINTENANCE Lubrication Recommendations Item Lube Rec Method Frequency ...

Page 66: ...See 7 CONTROL As require change every two years or 200 hours 3 Transmissio n oil SEA 80W 90GL5 See 15 MAI NTENANCE TRAN S MISSION LUB Change annually or at 100 hours 4 Chain lubricant Graphite based Spray on graphite based chain lubricant before and after each use 1 15 MAINTENANCE Lubrication Recommendations Item Lube Rec Method Frequency ...

Page 67: ...ery 3 months or50hours 6 Steering Post Bushings Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or50hours 7 Front Wheel bearings Grease Inspect and replace bearings if necessary Semi annually 8 Tie rods Grease Locate fittings and grease Semi annually 15 MAINTENANCE ...

Page 68: ...68 ...

Page 69: ... Monthly or 20 hours 11 Throttle Cable Grease M Grease inspect and replace it if necessary Monthly or 20 hours NOTE 1 More often under severe use such as wet or dusty conditions 2 Grease Light weight lithium soap grease 3 Grease M molybdenum disulfide MoS2 grease water resistant 4 When suspension action becomes stiff or after washing 5 Hours are based on 10 mph 16Km h average ...

Page 70: ...dic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or person Remark First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs ...

Page 71: ...djustment Your ATV has handlebars which can be adjusted for your personal fit 1 Remove the handlebar cover 2 Loosen the four bolts 3 Adjust handlebar to desired height Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block to 10 12 ft Ibs 14 16Nm NOTE Tighten bolts so there is an equal gap at the front and rear of th...

Page 72: ...ation Front M10X1 25 33 37Ft Lbs 45 50N m Rear M10X1 25 33 37Ft Lbs 45 50N m NOTE All nuts that have a cotter pin installed must be serviced by an authorized Dealer Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations Service work must be performed by an authorized dealer Tapered nuts install with tapered side against wheel ...

Page 73: ...73 15 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension Rear Spring Adjustment ...

Page 74: ...ent in solvent squeeze it several times and wrap it in a piece of dry cloth and squeeze again to remove the remaining solvent Never twist the element NOTE It is inappropriate to use low flash point solvents such as gasoline to clean the air filter element 5 Apply some drops of engine oil to the element and squeeze it 6 Reinstall the element and the filter cover ...

Page 75: ... Do not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact your dealer He she has the training and tools to make these adjustment Toe Alignment Check The recommended toe alignment is 1 8 to 1 4 3to6mm toe out 1 Set the handlebars in a Straight ahead position and Hold them in this position 2 Measure A and B A minus B should be 1 16 to ...

Page 76: ...ften they need checking depends upon the type of driving that has been done Keep fluid level in the master cylinder reservoirs as described see 7 Control and functions Normal functioning of the diaphragm is to extend into the reservoir as fluid lever drops If the fluid lever is low and the diaphragm is not extended a leak is indicated and the diaphragm should be replaced Always fill the reservoir ...

Page 77: ...e lever only see 7 Control and functions Brake shoes The standard thickness of lining is 5 32 4mm Shoes should be changed when friction material lining is worn to 2 5mm a Replace the brake shoes as a set if either is worn to the limit Brake drum The standard brake drum inside diameter is 110mm the limit is 110 5mm Measure the brake drum inside diameter a Out of specification replace the hub ...

Page 78: ...tor can be adjusted as follows 1 Warm up the engine by running the vehicle approximately five minutes 2 With the parking brake applied 3 Adjust the carburetor idle screw in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM 4 The standard idle RPM is 1700 10 ...

Page 79: ...lay is achieved at thumb lever NOTE While adjusting freeplay it is important you flip the throttle lever back and forth 3 Tighten locknut and slide boots over cable adjuster Spark Plugs Inspect Insulator Abnormal color Replace Normal color is a medium To light tan color Electrode Wear damage Replace Clean Spark plug with spark plug cleaner or wire brush Measure Spark plug gap Out of specification ...

Page 80: ...NING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury Remove the spark plug by rotating counterclockwise Reverse the procedure for spark plug installation Torque to 17ft Ibs 23N m ...

Page 81: ... 10 F 12 AND RIDING BETWEEN 10 F 12 AND 30 F 0 when most trips are slow speed and less than 5 mph 8km h Be sure to change the oil filter whenever changing oil CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as severe burns may result 1 Place vehicle on a level surface lock the parking brake 2 Run engine two or three minutes until warm Stop engine 3 Clean area around drai...

Page 82: ... be changed annually The correct transmission lubricant to use is SEA 80W 90GL5 Lubricant Transmission Oil Changing Procedure 1 Remove the screw 1 2 Remove the screw 2 and drain the oil Catch and discard used oil properly 3 Clean and reinstall the screw 2 torque to 12 16 ft lbs 17 23Nm 4 Add the correct amount of SAE SEA 80W 90GL5 Lubricant 750ml 5 Clean and reinstall the screw 1 torque to 12 16 f...

Page 83: ...charts below Improper tire inflation may affect ATV maneuverability Do not use improper tires The use of non standard size or type tires may affect ATV handling Make certain the wheels are installed properly If wheels are improperly installed it could affect vehicle handling and tire wear Wheel Removal Procedure 1 Stop the engine lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate th...

Page 84: ...d rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found in 15 MAINTENANCE Wheel Nut Torque Tire Inspection When replacing a tire always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3mm or less Please refer to your Owner s Manual for tire ...

Page 85: ...djustment 2 Inspect chain sprocket for wear 3 if sprockets are worn replace sprockets and chain as a set 4 Replace guards if damaged Adjustment 1 Loosen but do not remove the four mounting bolts 1 2 Turn the chain adjuster 2 to obtain 1 4 6mm to 3 8 10mm chain flex To tighten the chain turn the chain adjuster 2 clockwise To loosen the chain turn the chain adjuster 2 count clockwise and push the re...

Page 86: ...ink out and remove the chain Installation chain 1 Slide the pin portion of the master link 3 in to each end of chain to be connected 2 Slide the side plate 2 portion of the master link on to the pins 3 Slide the retaining clip 1 on to the pins until clip snaps securely in to place CAUTION The master link should be installed with the open end of the retaining clip 1 facing away from direction of ch...

Page 87: ...s clean Poor light while riding can result in an accident causing severe injury or death CAUTION Do not service while headlight is hot Serious burns may result Do not touch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot which will shorten the life of the lamp ...

Page 88: ...5W 2 Turn the rubber sleeve and remove it 3 Turn the lamp holder 4 Change the bulb 5 Fix the replacing bulb 12V 35W 35W into the iron light basis of the reflecting mirror and make sure the bulb s points fit the light basis s inside roles 6 Place the lamp holder and the rubber sleeve ...

Page 89: ...m can be adjusted up and down 1 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 51mm below the...

Page 90: ...nd a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your dealer for replacement Waxing Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the b...

Page 91: ...ransmission brake fluid change every two years or as required if fluid looks dark or contaminated Fog the Engine Spray a light oil into the cylinder through the spark plug hole Check and Lubricate Cables Grease Inspect all cables and lubricate Battery Maintenance Remove the battery and Apply dielectric Grease to the terminal bolts and terminals Charge the battery Storage Area Covers Set tire press...

Page 92: ...e following measures should be taken 1 Turn off the engine and remove the key 2 Turn the fuel valve to off 3 Be certain the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting until securely using suitable straps or rope ...

Page 93: ...her speed Insufficient warm up of ATV s exposed to low ambient temperatures Warm engine at least 5 min The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Stuck in mud or snow Shut off the engine and dismount pull the ATV out of the mud Battery Wane Possible Causes Solutions Starting a faulty engine...

Page 94: ...riorated fuel or fuel containing Clogged air cleaner Water or foreign material element Clogged pilot jet Improper air cleaner Clogged air passage setting Improperly set pilot air s crew Clogged pilot air passage Improperly sealed valve seat Improperly adjusted fuel level Clogged starter jet Sucked in air COMPRESSION SYSTEM Cylinder and cylinder head Valve system Loose spark plug Improperly adjuste...

Page 95: ...d primary Loose coupler connection secondary coil Improperly grounded Faulty high tension cord Broken wire harness Broken ignition coil body POOR IDLE SPEED PERFORMANCE Carburetor Air cleaner Loose or clogged pilot jet Clogged air cleaner element Damaged carburetor joint Ignition system Improperly tightened carburetor Fault spark plug Joint clamp hose Fault high tension cord Improperly adjusted id...

Page 96: ...ulty pick up coil Cylinder gasket broken Fuel system Carbon deposit build up Clogged fuel tank breather hole Improperly adjusted valve Clogged air cleaner element clearance Clogged jet Improperly contacted Improperly adjusted fuel level valve and valve seat Improper carburetor air vent hose Faulty valve timing setting Clutch Refer to CLUTCH SLIPPING DRAGGING section Engine oil Improperly oil level...

Page 97: ...r setting Improper fuel level adjustment Clogged air cleaner element Compression system Heavy carbon deposit build up Improperly adjusted valve timing Improperly adjusted valve clearance Engine oil Incorrect engine oil level Improper engine oil quality High viscosity Low engine oil quality Brakes Dragging brake Air cooling system Entanglements weed and seeds on cooling fan ...

Page 98: ...ary sliding sheave Seized POORSTARTING FAULTY BRAKE PERFORMANCE POOR BRAKING EFFECT V belt Worn front hub bearing Slipping oily V belt Worn brake pad or lining Primary sliding sheave Worn brake disc or drum Improper operation Air in brake fluid Damage Leaking brake fluid Compressing spring Faulty master cylinder kit Secondary sliding sheave Faulty caliper seal kit Improper operation Loose union bo...

Page 99: ...99 17 Tool ...

Page 100: ... height 800mm 31 5 inch Wheel Base 1110mm 43 7 inch Dry Weight 190kg 419 lbs Load Capacity Combined Rider Payload 109kg 240 lbs Drive System Drive System CVT Front Tire 21 7 10 Rear Tire 22 10 10 Tire Pressure front 35kPa 5PSI Tire Pressure rear 35kPa 5PSI Brake System Service Brake Front Brake Mechanics Drum Rear Brake Hydraulic Disc Parking Brake Front Brake Mechanics Lock Rear Brake Hydraulic L...

Page 101: ... Bore x Stroke 57mm 57 8 mm Displacement 147 5ml Carburetor CVKfor157 Starter System Electric starting Engine Cooling Air Cooled Lubrication System Wet Sump Ignitions CDI Spark Plug Type C7HSA Electrical Equipment Battery 12V 8Ah Head light 12V 35W 35W Brake Tail Light 12V LED ...

Page 102: ...102 19 WIRNING DIAGRAM ...

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