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15. EXHAUST SYSTEM

SYSTEM REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

CAUTION:

Exhaust system components are very hot during and after use of ATV.

Do not tough exhaust system components. Serious burns can result.

Be especially careful when traveling through tall grass. The potential for fire exists.

Spark Arrester

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1. Remove the arrester screw

①

located on the bottom of the muffler, pull out the

arrester (the mesh)

②

2. Clean the arrester or replace it.

WARNING

When cleaning the spark arrester, 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 system becomes very hot.

Keep combustible materials away from exhaust system. Fire may result.

Содержание K550ATV EEC 4x4

Страница 1: ...HICLE IS NOT DESIGNED 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...

Страница 2: ...RNINGS 15 6 V I N 29 7 CONTROL AND PARTS FUNCTIONS 30 8 STARTING THE ENGINE 42 9 VEHICLE BREAK IN PERIOD 43 10 RIDING GEAR 44 11 CARRYING LOADS 45 12 RIDING 47 13 CVT SYSTEM 58 14 BATTERY 61 15 EXHAUS...

Страница 3: ...ied with this product will help your ATV Make sure that you understand and follow all Warnings and Instructions in this material If you did not receive any of the material listed above please call you...

Страница 4: ...and follow all local state province and federal national riding laws and requirements Remember Respect your vehicle respect the environment and respect the property of others You are responsible for...

Страница 5: ...erly You should also wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never opera...

Страница 6: ...the turning technique described in this manual on level ground Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards when climbing a hill To...

Страница 7: ...n reverse Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of ac...

Страница 8: ...FORE YOU BEGIN RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with its responsibilities for your personal sa...

Страница 9: ...following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is involved WARNING Indicates a...

Страница 10: ...TE 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...

Страница 11: ...3 6 9...

Страница 12: ...8 11...

Страница 13: ...13 14...

Страница 14: ...15 16...

Страница 15: ...level includes auxiliary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brake light check operation of all indicator lights and switches 6 Engine stop switch check for pr...

Страница 16: ...or 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 WHA...

Страница 17: ...d 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 HAPPEN Increase...

Страница 18: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or...

Страница 19: ...in the Owner s Manual WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to...

Страница 20: ...HAPPEN 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 wh...

Страница 21: ...lly cautious on these kinds of terrain WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow pro...

Страница 22: ...d in the Owner s Manual WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hill...

Страница 23: ...the vehicle to lean sharply to one side Go straight down the hill when possible WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or ca...

Страница 24: ...l Apply the brakes Lock parking brake after you are stopped If the ATV begins rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the...

Страница 25: ...obstacles 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 HAP...

Страница 26: ...avoid water go slowly balance your weight carefully avoiding sudden turns or stops and do not make sudden throttle changes Remember that wet brakes may have reduced stopping ability Test your brakes...

Страница 27: ...tire pressure as described in the Owner s Manual WARNING POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this v...

Страница 28: ...or pulling a trailer Allow a greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer WARNING POTENTIAL HAZARD Riding on frozen lakes a...

Страница 29: ...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 increase...

Страница 30: ...place 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 mod...

Страница 31: ...es 1 Main Switch This key switch must be turned clockwise to the on position to start the engine 2 Hazard Light Switch When the switch is pushed to the four signal lights are on and the buzzer is soun...

Страница 32: ...nfiguration of these lights differs with individual models and not every model is equipped with all the lights The information will help you identify the lights on your machine and their function 1 Fu...

Страница 33: ...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 controll...

Страница 34: ...evere injury Front and Rear Brakes The front and rear brakes are located on the inside of the right floor board and are operated by the right foot The front and rear brakes are hydraulically activated...

Страница 35: ...ing brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the parking brake for more than five minutes Always block the do...

Страница 36: ...ATV has an auxiliary brake provided brake provided as a safety feature It is located on the left handlebar and is operated by the left hand It is intended as a backup to the main brake system especial...

Страница 37: ...tor Operation The transmission gear selector is located on the right side of the vehicle The transmission selector lever has four positions high forward reverse neutral and low forward NOTE To extend...

Страница 38: ...een the minimum and levels indicated on the recovery bottle The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator...

Страница 39: ...adiator Coolant Level Inspection NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry the level in the r...

Страница 40: ...is stored Do not overfill the tank Do not fill the tank neck If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let...

Страница 41: ...torage and whenever transporting ON For normal operation Always return valve to on position after refueling machine Fuel filter The filter should be replaced by your dealer every 100 hours of operatio...

Страница 42: ...between the high and low CAUTION Use only SAE 15W 40SG OIL Never substitute or mix oil brands Serious engine damage and voiding of warranty can result...

Страница 43: ...Turn the fuel tank valve to ON 3 Sit on the vehicle 4 Turn the engine stop switch to RUN 5 Turn the main switch on wait until the EPC indicator is off apply the brake lever and press the starter butt...

Страница 44: ...n build up and cause damage to close fitted engine parts Please set a limit to half throttle during the break in periods 1 Locknut 2 Adjuster 1 Fill the fuel tank 2 Check the oil reservoir level indic...

Страница 45: ...nt piece of protective gear for safe riding A helmet can prevent a severe head injury 2 Eye Protection A pair of goggles or a helmet face shield offers the best protection for your eyes 3 Gloves off r...

Страница 46: ...200 kg on level ground Maximum vertical hitch weight 25 lbs 11 kg Improper loading of the front rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam with c...

Страница 47: ...the loads must be reduced to maintain stable operating conditions LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and...

Страница 48: ...iving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly practice maneuvering and using the throttle and brakes on level surfaces Making turns Practice making turns at slow s...

Страница 49: ...tering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the ski...

Страница 50: ...ed Loss of vehicle control or overturning of the 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 f...

Страница 51: ...upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If the vehicle begins to tip quickly turn the front wheel down...

Страница 52: ...cle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs WARNING Do not trav...

Страница 53: ...l left while facing front of ATV 5 While holding the service brake release parking brake lock and slowly allow the ATV to roll around to your right until the ATV is pointing across the hill or slightl...

Страница 54: ...d 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 A...

Страница 55: ...l times with the electric start Dry the spark plug and reinstall or replace it with a new plug Turn the fuel valve to ON Attempt to start the engine If necessary repeat the drying procedure Take the m...

Страница 56: ...cle or a person behind you or the vehicle could tip over rearward on a steep incline causing severe injury or death Backing up 1 Avoid backing up on steep inclines 2 Always back slowly 3 When in rever...

Страница 57: ...pen the throttle enough to maintain a desired speed CAUTION Opening the throttle more than required may cause excessive fuel to build in the exhaust resulting in engine popping and or engine damage Pa...

Страница 58: ...gear 3 Set the parking brake 4 Shut off fuel supply 5 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the downhill side as shown above 6 Do not le...

Страница 59: ...ce is the responsibility of the owner Always follow recommended maintenance procedures See your dealer The CVT housing must be securely in place during operation Failure to comply with this warning ca...

Страница 60: ...on engine speed By switching to low range while operating at low ground speeds the air temperature in the clutch will be reduced Reducing the temperature inside the clutch cover extends the life of th...

Страница 61: ...when to use low range rather than high Low Range Basic operation at speeds less than 7 MPH 11 km h Heavy pulling Riding through rough terrain swamps mountains etc at low ground speeds High Range Basic...

Страница 62: ...milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15minutes and get prompt medical attention Batteries produce explosive gases Keep spa...

Страница 63: ...one cup water to prevent damage to the ATV Battery Installation and Connections WARNING To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable f...

Страница 64: ...operly routed NOTE When your ATV is placed in storage for one month or more the battery should be removed charged to proper level and stored in a cool dry place Before reusing take the battery to your...

Страница 65: ...Arrester The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the arrester screw located on the bottom of the muffler pull out the arrester the mesh 2 Clean the arre...

Страница 66: ...ation intervals of important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of appro...

Страница 67: ...ation daily apply dielectric grease to connector when replaced Tail Lamp Inspection Daily Daily Check operation daily apply dielectric grease to socket when replaced z Air Filter Main Element Weekly W...

Страница 68: ...Inspect strength seasonally Shift Linkage 50 hrs 6 months Inspect adjust D Drive Belt 50 hrs 6 months Inspect replace if necessary z Steering 50 hrs 6 months Inspect daily lubricate z Rear Axle 50 hr...

Страница 69: ...hrs 3 months Inspect clean Engine Mounts 25 hrs 3 months Inspect D Valve Clearance 100 hrs 12 months Inspect adjust D Shift Selector Box H L R N 200 hrs 24 months Change grease every two years D Brake...

Страница 70: ...etween fill lines See 7 CONTROL As required change every two years or 200 hours 3 Transmission Oil SAE90 See 16 MAINTENANCE Transmission Lube Change annually or at 100 hours 4 Rear Gear Case Oil SAE90...

Страница 71: ...gs Grease Inspect and replace bearings if necessary Semi annually 9 Tie Rods Grease Locate fittings and grease Semi annually 10 Shift Linkages Grease Locate fittings and grease Semi annually z 11 Ball...

Страница 72: ...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...

Страница 73: ...re based on 10 mph 16 Km h average Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Rema...

Страница 74: ...our 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 a...

Страница 75: ...Nm Rear M10x1 25 27 4 ft lbs 37 Nm 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 ret...

Страница 76: ...n Air Filter Service 1 Remove seat 2 Release clips and remove cover 3 Loosen clamp and remove filter 4 Remove fabric type pre filter from main filter Wash pre filter in soapy water and dry it 5 Reinst...

Страница 77: ...ie 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 adjustments Toe Alignment Check The recommended...

Страница 78: ...ating condition How often 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 parts functions Norma...

Страница 79: ...friction material is worn to 3 64 1 mm Inspect the brake disc spine and pad wear surface for excessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to be used as a backup...

Страница 80: ...mb lever NOTE While adjusting free play it is important you flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster Spark Plugs Inspect Insulator Abnor...

Страница 81: ...very 3 months whichever comes first Suggested break in oil change is at 20 hours or one month whichever comes first Severe use operation requires more frequent service Severe use includes continuous d...

Страница 82: ...Always check and change the front gear case oil at the intervals outlined in 16 Maintenance Maintain the oil level even with the bottom of the fill hole threads 1 The correct gear case lubricant to u...

Страница 83: ...5W 40SG 5 Reinstall the fill plug Torque to 14 ft lbs 19 Nm 6 Check for leaks Transmission Lubrication The transmission fill plug is located on the right side of the machine The transmission lubricant...

Страница 84: ...transmission drain plug located on the bottom left hand side and drain the oil Catch and discard used oil properly 4 Clean and reinstall the drain plug torque to 14 ft lbs 19 Nm 5 Add the correct amo...

Страница 85: ...s The correct gear case lubricant to use is SEA 90 Weight Gear Lube Oil Changing Procedure 1 Remove drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sea...

Страница 86: ...tion 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...

Страница 87: ...oward 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 16 MAINTENANCE Wheel Nut Torque Tire...

Страница 88: ...s a residue causing a hot spot which will shorten the life of the lamp Lamp Replacement Headlight Lamp Relpacement 1 Use bulb 12V 35W 2 Turn the M4x30 bolt and remove it 3 Dismantle the hoop 4 Remove...

Страница 89: ...l High Beam Headlight Adjustment The headlight beam can be adjusted up and down 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance f...

Страница 90: ...tten 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...

Страница 91: ...d to the proper level Do not use tap water which may contain minerals that reduce battery life Apply dielectric Grease to the terminal bolts and terminals Charge the battery Storage Area Covers Set ti...

Страница 92: ...life Insufficient warm up of ATV s exposed to low ambient temperatures Warm engine at least 5 min with the transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times...

Страница 93: ...his manual for inspection adjustment and replacement of parts Adjustment and replacement must be done by your dealer STARTING FAILURE HARD STARTING FUEL SYSTEM Fuel tank Air cleaner Empty Clogged air...

Страница 94: ...nection secondary coil Improperly grounded Faulty high tension cord Broken wire harness Broken ignition coil body POOR IDLE SPEED PERFORMANCE Air cleaner Clogged air cleaner element Ignition system Fa...

Страница 95: ...ulty ignition coil Valve system Improperly adjusted valve clearance OVER HEATING OR OVER COOLING OVER HEATING OVER COOLING Ignition system Cooling system Improperly spark plug gap Faulty thermostat Im...

Страница 96: ...Damage Worn improper operation Gears Primary secondary sheave Damage CLUTCH SLIPPING CVT SYSTEM Clutch weight spring Incorrect Primary Clutch Position Worn damaged Incorrect engine mount Clutch shoe s...

Страница 97: ...Improper operation Oily or greasy brake pad Oily or greasy brake disc Worn guide pin groove Worn guide pin Clutch shoe Worn bent...

Страница 98: ...inutes then repeat above procedures 6 The engine can work normally the EPC error indicator is off the appearance of these show the system is right 2 Send for repairs for following situations 1 The eng...

Страница 99: ...19 Tool...

Страница 100: ...ight 331kg Front Rack 18 kg Rear Rack 36 kg Load Capacity Combined Rider Payload 156 kg Tongue Weight 11 kg Tow Capacity 200 kg Drive System Drive System CVT Front Tire 25x8 12 Rear Tire 25x10 12 Tire...

Страница 101: ...Cooling Liquid Cooled Lubrication System Wet Sump Ignitions ECU Spark Plug Type DR8EA NGK Electrical Equipment Battery 12V 18AH Head Light 35W 35W Brake Tail Light 21W 5W Reverse Indicator 12V 0 5W H...

Страница 102: ...B O LBl G W G B G Pu W Bl G W Bl O LBl Pu G Pu G G W Bl Pu G G R B R Gr B 3 1 2 Negative Speed signal Positive Gr Y W Br W B Y G Gr B Y Y W G G Pu To ECU J1 16 LBl LBl Br W G W B W Bl Bl LBl O O LBl...

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