CFMoto ATV CF500 4x4. Service Manual - part 1

 

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CFMoto ATV CF500 4x4. Service Manual - part 1

 

 

Failure to follow the warnings contained in this manual can result in serious injury or death.
An ATV is not a toy and can be hazardous to operate. This vehicle handles differently from other vehicles,
such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like
turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Read and understand your owner s manual and all warnings before operating an ATV.
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under the age of 16.
As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the
protection of our environment. Read and understand your owner's manual, which includes valuable information
about all aspects of your vehicle, including safe operating procedures.
When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all
aspects of vehicle safety. You were also provided with printed materials that explain safe operating procedures.
You should review this information on a regular basis.
If you purchased a used ATV from a party other than a dealer, you can request this free safety training from any
authorized dealer.
Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's
manual. This preventive maintenance program is designed to ensure that all critical components on your
vehicle are thoroughly inspected at specific intervals.
The following signal words and symbols appear throughout this manual and on your ATV. Your safety is
involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
The safety alert warning indicates a potential hazard that may result in serious injury or death.
The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
A caution indicates a situation that may result in damage to the vehicle.
A note will alert you to important information or instructions.
Read this manual and all labels carefully, and follow the operating procedures described.
Never operate an ATV without proper instruction. Take a training course. Beginners should receive training
from a certified instructor. Contact an authorized ATV dealer to find out about the training courses nearest
you.
Never allow anyone under 16 years of age to operate this ATV.
Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and
has completed a certified safety training course.
Never operate an ATV without wearing an approved helmet that fits properly. Always 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 an ATV.
Never operate at excessive speeds. Travel at speeds appropriate for the terrain, visibility and operating
conditions, and your experience
Never attempt wheelies, jumps or other stunts.
Always inspect your ATV before each use to make sure it s in safe operating condition. Always follow the
inspection and maintenance procedures and schedules outlined in your owner s manual.
Always keep both hands on the handlebars and both feet on the foot-rests of the ATV during operation.
Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain
conditions.
Never operate on excessively rough, slippery, or loose terrain.
Always follow proper turning procedures as described in this manual. Practice turning at low speeds before
attempting to turn at faster speeds. Do not turn at excessive speeds.
Always have the ATV inspected by an authorized dealer if it s been involved in an accident.
Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting
larger hills.
Always follow proper procedures for climbing hills. Check the terrain carefully before ascending a hill.
Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the
throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.
Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully
before you start down a 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. Travel straight down
the hill when possible.
Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or
loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on
any hill until you ve mastered (on level ground) the turning technique outlined in this manual. Avoid
crossing the side of a steep hill when possible.
Always use proper procedures if you stall or roll backwards while climbing a hill . To avoid stalling ,
maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure
for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is
pointed straight uphill. Turn the ATV around and remount following the procedure described in this
manual.
Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles,
such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described
in this manual.
Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution
to reduce the chance of skidding or sliding out of control.
Avoid operating the ATV through deep or fast-flowing water . If it s unavoidable, travel slowly , balance
your weight carefully, avoid sudden movements, and 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 allow friction to dry out the pads.
Always check for obstacles or people behind the ATV before operating in reverse. When it s safe to proceed
in reverse, move slowly and avoid turning at sharp angles.
Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load capacity for your ATV. Cargo must be properly distributed and securely
attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a
greater distance for braking.
Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental
starting.
Child or pets shall not be carried on the brackets.
Never touch running parts, such as wheels, drive shaft, etc.
We are concerned with the safety of our customers and for the general public. Therefore , we strongly
recommend that consumers do not install on an ATV any equipment that may increase the speed or power of
the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the
original equipment of the vehicle create a substantial safety hazard and increase the risk of body injury.
The warranty on your ATV is terminated if any equipment has been added to the vehicle, or if any
modifications have been made to the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or
large racks, may change the handling characteristics of the vehicle. Use only approved accessories, and
familiarize yourself with their function and effect on the vehicle.
Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each
decal carefully. If a decal becomes illegible or comes off, contact your dealer to purchase a replacement.
Always wear clothing suited to the type of riding. ATV riding
requires special protective clothing for comfort and to reduce the
chance of injury.
Your helmet is the most important piece of protective gear for safe
riding. An approved helmet can prevent a severe head injury.
Do not depend on sunglasses for proper eye protection.
A pair of goggles or a helmet face shield offers the best protection
for your eyes. They should be kept clean and be shatterproof
design.
Off-road style gloves with knuckle pads are the best for comfort and protection.
The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey
with shoulder pads provide the best protection.
Top speed is normally limited when operating in 4WD-LOCK.
If conditions require more engine power when riding forward,
push and hold this switch to override the 4WD-LOCK speed
limiting function. (See page 49-52 for a detailed explanation
about the front gear lock switch and its function.)
Releasing the switch restores the speed limiting function.
While this switch is pushed, the override indicator light will
come on.
The headlight switch consists of three positions:
When the switch is at this position, headlight, the front pilot light , the rear pilot light and instrument
light are on.
When the switch is at this position, the front pilot light, the rear pilot light and instrument light are on.
When the switch is at this position, headlight, the front pilot light, the rear pilot light and instrument
light are off.
Press the switch to
, the left turning indicator and left turning light are on.
Press the switch to
, the right turning indicator and right turning light are on.
Press the button, the horn will sound.
Press
button, the high beam is on.
Press
button, the low beam is on.
Press this button, the engine can be started.
Do not use the headlights with the engine turned off for more than thirty minutes. The battery may discharge to the
point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it.
The front brake lever is located on the right handlebar.
Pull it toward the handlebar to apply the front brake.
The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar.
Push down on the pedal or pull the lever toward the handlebar to apply the rear brake.
Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident.
Never operate the ATV with a spongy-feeling brake lever.
Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever
should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.
Check the brake fluid level in the front brake master
cylinder and in the rear brake cup before each use of
the ATV. The front brake master cylinder is located on
the right handlebar. The rear brake cup is near the rear
brake pedal.
The front brake fluid level can be seen through an
indicator window on the side of the master cylinder.
When fluid lever is lower the
lower line, refill
with the same type of brake fluid.
An over-full master cylinder may cause brake drag or
brake lock-up, which could result in serious injury or
death. Maintain brake fluid at the recommended level.
Do not overfill.
When checking the fluid level, the ATV must
be on level ground with the handlebars straight.
If the fluid level is low, add DOT3 brake fluid
only.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs
moisture from the air. The moisture causes the drop of boiling temperature of the brake fluid, which can lead
to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid,
always discard any unused portion.
When parking, stop the engine and shift the gear selector
Lever into the park position.
Operating the ATV while the parking brake is engaged
could result in an accident and serious injury or death.
Always check to be sure the parking brake is disengaged
before operating.
The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling.
Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels on the
downhill side of the ATV to prevent rolling. Another option is to park the ATV in a sidehill position.
The choke assists in starting a cold engine. Refer to the engine starting procedure on page 60 for correct choke
and throttle settings during starting.
The fuel tank filler cap
is located directly below the handlebar.
Remove the fuel tank filler cap by turning it counterclockwise.
Install the fuel tank filler cap by turning it clockwise.
Gasoline is highly flammable and explosive under certain conditions.
Always exercise extreme caution whenever handling gasoline.
Always refuel with the engine stopped, and outdoors or in a well ventilated area.
Never fill a gas plastic container while it's in the racks. Static electricity between the rack and container
could cause a spark.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where
gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If gasoline spills 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. Engine exhaust fumes are poisonous and can
cause loss of consciousness or death in a short time.
The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other
reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
The transmission gear selector is located on the left side of the vehicle.
L: Low Gear
H: High Gear
N: Neutral
R: Reverse
P: Park
To shift into Reverse or Park, you must first apply the rear
brake lever or pedal to activate the lock-out mechanism.
When shifting out of Reverse or Park, it's necessary to apply
the rear brake lever or pedal.
Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission
damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.
Apply the rear brake before attempting to shift into reverse or park.
Whenever the ATV is left unattended, always place the transmission in the park position.
Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if
you experience any shifting problems.
To extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven
miles per hour for extended periods of time.
If towing the vehicle is necessary, shift the transmission into neutral for better mobility and to prevent damage
to the belt.
If the battery is weak and cannot start the engine, use the recoil
starter
will allow vehicle operation until repairs can be made.
The recoil starter is located on the left side of the machine.
The engine is equipped with automatic decompressor. This
makes recoil starting possible by allowing compression to
leak at cranking speeds. The decompressor senses when the
engine is spinning fast enough to start and restores compression
for starting.
1. Position the vehicle on a level surface, place the transmission in park.
2. Grasp the recoil starter rope handle tightly and pull slightly until the starter mechanism engages.
3. Pull the rope abruptly to start the engine.
Extending the starter rope too far will cause damage to the recoil assembly. Do not extend the starter rope so
far that it stops.
If the starter rope handle is not seated properly, water may enter the recoil housing and damage components.
Make sure the handle is fully seated on the recoil housing, especially when driving in wet areas.
This ATV is equipped with an on-command four-wheel drive
switch
2WD
/
4WD
and a front gear lock switch
LOCK
/
4WD
Select the appropriate drive according to terrain and the conditions.
Two-wheel drive (2WD): Power is supplied to the rear wheels
only.
Four-wheel drive (4WD): Power is supplied to the rear and
front wheels.
Four-wheel drive with the front gear locked (4WD-LOCK): Power is supplied to the rear and front wheels
when the front gear is locked ( DIFF.LOCK
). Unlike the 4WD mode, all wheels turn at the same speed.
To change from 2WD to 4WD, stop the ATV, and then set the
switch to
4WD . When the ATV is in 4WD, the 4WD
indicator
will come on in the dashboard display. To
change from 4WD to 2WD, stop the ATV, be sure the lever
is set to position
a
, and then set the switch to
2WD
To lock the front gear in 4WD, make sure the on-command
four-wheel-drive switch is set to
4WD
, stop the ATV,
move the lever to position
b
, and then set the switch to
LOCK . When the front gear is locked, the front gear lock
indicator
( DIFF.LOCK
) light will come on along with
the indicator
in the dashboard display.
To release the front gear lock, stop the ATV and set the switch to
4WD
When the switch is set to LOCK
, the front gear lock indicator light will flash until the front gear is
locked.
When the indicator light is flashing, turning the handlebar left and right will help the front gear lock to
engage.
Riding before the front gear lock is properly engaged (e.g., when the indicator light is flashing) will
cause the engine speed to be limited until engagement is complete.
When the ATV is in 4WD-LOCK, the maximum traveling speed is limited to 35 km/h (22 mph).
However, if conditions require full engine power to be available, push and hold the override switch to
disable the 4WD-LOCK speed limiter.
Once the engine is running, movement of the throttle lever will
increase the engine speed. Regulate the speed of the machine
by varying the throttle position. Because the throttle is spring-
loaded, the machine will decelerate, and the engine will return
to an idle any time the hand is removed from the throttle lever.
Before starting the engine, check the throttle to be sure it is
operating smoothly. Make sure it returns to the idle position as soon as the lever is released.
Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for
the cause. Correct the problem before riding the ATV. Consult your dealer if you can t find or solve the
problem yourself.
The speed limiter keeps the throttle from fully opening,
even when the throttle lever is pushed to the maximum.
Turning in the adjusting screw limits the maximum
engine power available and decreases the maximum
speed of the ATV.
Do not turn the adjusting screw out more than 12 mm (0.47 in). Always make sure the throttle lever free play
is adjusted to 3-5 mm (0.12-0.20 in).
Functions of the respective switch positions are as follows:
ON:
The engine can be started only at this position and the headlights and taillight come on when the light switch is
on. The key can not be removed in this position.
OFF:
All electrical circuits are switched off. The key can be removed in this position.
: This indicator comes on when the
2WD
/
4WD switch is
set to the
4WD position.
: The front lock indicator DIFF.LOCK in the four-wheel-drive
indicator comes on when the LOCK
4WD switch is set
to the LOCK-4WD position.
Due to the synchronizing mechanism in the front gear case, the four-
wheel drive indicator may not come on until the ATV starts moving.
This indicator light comes on when press the turning switch to
This indicator light comes on when the gear selector is in the L position.
This indicator light comes on when the gear selector is in the H position
This indicator light comes on when the gear selector is in the N position.
This indicator light comes on when the gear selector is in the R reverse position.
This indicator light comes on when the gear selector is in the P
(park) position.
This indicator light comes on when press the turning switch to
This indicator light comes on when press the override switch.
This indicator light comes on when press the headlight illumination switch to
If the indicator light flashes or the speedometer does not show the speed while riding, have your dealer
check the speed sensor circuit.
when the temperature indicator is in the white area of side C, it
means that the temperature is normal. The red area of side H
indicates that the temperature is high. In that case please stop
the engine until the coolant temperature goes down. In case the
temperature frequently goes high, check coolant capacity or
consult the local dealer.
The engine may overheat if the ATV is overloaded. If this
happens, reduce the load to specification.
After restarting, make sure that the temperature indicator is in the white area of side C. Continuous use
while the temperature indicator is in the red area of side H may cause damage to the engine.
shows the riding speed. Odometer : shows the total distance traveled.
indicates the remaining amount of the gasoline in the fuel tank. F indicates the total amount
of fuel is 19L. When the indicator reaches the first point of red mark, fuel should be refilled as soon as possible.
The red mark indicates that the remaining fuel is only about 4.0L.
The break-in period for your new ATV is defined as the first twenty hours of operation, or the time it takes to
use the first four full tanks of gasoline. No single action on your part is as important as following the
procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance
and longer life for the engine. Perform the following procedures carefully.
Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do
not operate at full throttle or high speeds for extended periods during the first three hours of use.
Use of any oils other than those recommended may cause serious engine damage. We recommend the use of
4 Synthetic Oil for your 4-cycle engine.
1. Fill the fuel tank with gasoline.
2. Check the oil level on the dipstick.
Add 4 Synthetic Oil if necessary to maintain the oil level between the minimum and maximum level marks.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and
handling.
4. Vary throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.
See page 58.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 25 hours or one month.
If a proper inspection is not done before each use, severe injury or death could result. Always inspect the
vehicle before each use to ensure it s in proper operating condition.
Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe
injury or death. Never run an engine in an enclosed area.
Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up
for several minutes before operating the vehicle.
1. Apply the rear brake pedal.
2. Turn the main switch to ON
3. Shift the gear selector into the neutral or park position.
When the gear selector is in the neutral or park position, if either indicator light does not come on, ask
your dealer to inspect its electric circuit.
The engine can be started in any gear if the rear brake pedal is applied. However, it is recommended to
shift into neutral or park before starting the engine.
4. Use the starter (choke) in reference to the figure:
o
Position
: Cold engine start ambient temperature below 5
(40
F).
o
o
Position
: Cold engine start ambient temperature at 0
(30
F)
30
(90
F) and warming up position.
Position
: Cold engine start ambient temperature Above
o
25
(80
F) and warm engine start position.
5. Completely close the throttle lever and start the engine by
pushing the start switch.
If the engine fails to start, release the start switch, then
push the start switch again. Pause a few seconds before
the next attempt. Each cranking should be as short as
possible to preserve battery energy. Do not crank the
engine more than 10 seconds on each attempt.
If the battery is discharged, pull the recoil starter to
start the engine.
6. If the engine is started with the starter (choke) in position
, the starter (choke) should be returned to
position
to warm up the engine. If the engine is started with the starter (choke) in position
, keep the
starter (choke) in this position to warm up the engine.
7. Continue warming up the engine until it idles smoothly and return the starter (choke) to position before
riding.
See the Break-In Period section prior to operating the engine for the first time.
To start a warm engine, refer to the Starting a cold engine section. The starter (choke) should not be used.
The throttle should be opened slightly.
Before shifting, you must stop the machine and return
the throttle lever to the closed position. Otherwise, the
transmission may be damaged.
Shifting: Neutral to High and High to Low
1. Bring the machine to a complete stop and return the
throttle lever to the closed position.
2. Apply the brakes, then shift by moving the gear selector along the shift guide.
Make sure that the gear selector is completely shifted into position.
3. Open the throttle lever gradually.
Shifting: Neutral to Reverse and Reverse to Park
The gear selector cannot be shifted into reverse (R) or
park(P) without applying the rear brake.
1. Bring the machine to a complete stop and return the
throttle lever to the closed position.
2. Apply the rear brake pedal.
3. Shift from neutral to reverse or from reverse to park and
vise versa by moving the gear selector along the shift guide.
When in reverse, the reverse indicator light should be on. If the light does not come on, ask your dealer to
inspect the reverse indicator light electrical circuit.
Due to the synchronizing mechanism in the engine, the light may not come on until the ATV starts moving.
4. Check behind for people or obstacles, then release the rear brake pedal.
5. Open the throttle lever gradually and continue to watch rear while moving backward.
When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to
proceed, go slowly.
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause
loss of control or brake instability. Always follow these precautions when hauling cargo:
Never exceed the stated load capacity for this vehicle.
Reduce speed and allow a greater distance for braking.
When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
In the rear rack should be as far forward and as low as possible. Carrying a high load raises the center of
gravity and creates a less stable operating condition. Reduce load weight when cargo is high. When
handling off-centered loads that cannot be centered, secure the load and operate with extra caution.
Unsecured loads may shift and create unstable operating conditions, which could result in loss of control
of the vehicle. Always be sure that the rear rack is lowered.
when operating with loads extending beyond the rack. Stability and maneuverability may be adversely
affected, causing the machine to overturn.
Carrying a load on only the front rack or the rear rack may cause an imbalanced condition and increases
the possibility of vehicle overturn. Balance loads proportionally between the front rack and the rear rack,
but do not exceed the stated load capacity.
Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may
require backing down- hill.
Always attach the tow load to the hitch point.
The vehicle should never exceed 10 mph (16 km/h) while towing a load on a level surface. Vehicle speed
should never exceed 5mph (8 km/h) when towing loads in rough terrain, while cornering, or while
ascending or descending a hill.
Do not obstruct the headlight when loading the front rack.
Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load
distribution warnings listed on the warning labels, and never exceed the specified weights.
Cargo weight should be mounted as low as possible. When operating over rough or hilly terrain, reduce speed
and cargo to maintain stable driving conditions.
1. Always load the cargo as far forward as possible.
2. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling, and
control may be affected.
3. Slow down.
1. Sit upright with both feet on the footrests and both hands on the handlebars.
2. Start the engine and allow it to warm up, apply the brakes, then shift the transmission into gear.
3. Check your surroundings and determine your path of travel.
4. Release the brakes.
5. Slowly depress the throttle with your 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 brakes on level surfaces.
To make a turn, steer in the direction of the turn, leaning your upper
body to the inside of the turn while supporting your weight on the
outer footrest. This technique alters the balance of traction between
the wheels, allowing the turn to be made smoothly. The same leaning
technique should be used for turning in reverse.
Practice making turns at slow speeds before attempting to turn at
faster speeds.
Turning at sharp angles or at excessive speeds can result in vehicle
overturn and lead to serious injury. Avoid turning at sharp angles.
Never make turns at high speeds.
Whenever riding on slippery surfaces such as wet trails or loose
gravel, or during freezing weather, follow these precautions:
1. Slow down when entering 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
skid and shifting your body weight forward.
4. Driving with AWD engaged can assist in controlling the vehicle in slippery areas.
Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning.
Always engage AWD when the wheels have traction or are at rest.
Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss
of control, accident, and serious injury or death.
Never apply the brakes during a skid.
Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.
Whenever traveling uphill, follow these precautions:
1. Always travel straight uphill.
2. Avoid steep hills (25
maximum).
3. Keep both feet on the footrests.
4. Shift your weight forward.
5. Proceed at a steady rate of speed and throttle opening.
6. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
If all forward speed is lost:
Keep your weight uphill.
Apply the front brake. When fully stopped, apply rear brake as well, then shift gear selector into park position.
If the ATV begins rolling backwards:
Keep your weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards.
Apply the front brake. When fully stopped, apply the rear brake as well, and then shift gear selector into park
position.
Dismount on uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount,
following the procedure described on page 73.
Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause
loss of control or overturn and result in serious injury or death.
Avoid climbing steep hills (25
maximum).
Use extreme caution when operating on hills, and follow
proper operating procedures outlined in the owner s manual.
Improperly crossing hills or turning on hills can result in
loss of control or vehicle overturn, resulting in severe
injury or death. Avoid crossing the side of a hill when
possible. Follow proper procedures as outlined in the owner s manual.
Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a
situation where sidehilling is necessary, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your 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 downhill, if possible, or dismount on the
uphill side immediately!
Whenever descending a hill, follow these precautions:
1. Proceed directly downhill.
2. Shift your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly to aid in slowing.
Familiarize yourself with operation of the auxiliary rear brake
lever.
Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when
traveling downhill.
Improper hill climbing procedures could cause loss of
control or overturn and result in serious injury or death.
Avoid climbing steep hills (25
maximum).
Use extreme caution when operating on hills, and follow
proper operating procedures outlined in the owner s manual.
If the vehicle stalls while climbing a hill, never back it down
the hill! One maneuver that can be used when it s necessary to
turn around while climbing a hill is the K-turn:
1. Stop and shift the gear selector lever to the parking position while keeping body weight uphill.
2. Shut off the engine.
3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
4. Staying uphill of the vehicle, turn the handlebars full left.
5. While holding the brake lever, shift the gear selector lever to the low gear position and slowly allow the
vehicle to roll around to your right until it s pointing across the hill or slightly downward.
6. Shift the gear selector lever to the parking position and remount the vehicle from the uphill side, keeping
body weight uphill.
7. Restart the engine, while holding the brake lever, shift the gear selector lever to low gear position.
8. Release the brake and proceed slowly, controlling speed with the brake, until the vehicle is on more level
ground.
Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests .
Follow these procedures when operating through water:
1. Determine water depths and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles if possible.
4. After crossing, dry the brakes by applying light pressure to
the lever until braking action is normal.
Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that
exceeds the recommended maximum depth , go slowly , balance your weight carefully , avoid
sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
After running the vehicle in water, it s critical to have it serviced as outlined in the maintenance chart. See page
120. The following areas need special attention: engine oil, transmission oil, front and rear gear cases and all
grease fittings.
If water has been ingested into the CVT, follow the procedure on page 104 for drying out the CVT.
If your vehicle becomes immersed, and it s impossible to take it to your dealer before starting it, follow the
steps described on page 120. Have the vehicle serviced by your dealer promptly.
Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform
the services outlined in the maintenance chart.
If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your
dealer for service before starting the engine.
Be alert! Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low
hanging branches.
Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles
are immediately visible. Travel with caution in unfamiliar terrain.
Follow these precautions when operating in reverse:
1. Always avoid backing downhill.
2. Back slowly.
3. When in reverse, apply the brakes lightly for stopping.
4. Avoid turning at sharp angles in reverse.
5. Never open the throttle suddenly while backing.
Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into
reverse, always check for obstacles or people behind the vehicle. When it s safe to proceed, back slowly.
Do not use the override switch unless additional power is required for vehicle movement. Use with caution.
Avoid backing on inclines, and avoid turning at sharp angles.
Your ATV is equipped with a reverse speed limiter. The override button should be used with
caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open
the throttle just enough to maintain a desired speed.
Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting
in engine popping and/or engine damage.
Avoid parking on an incline if possible. If it s unavoidable, follow these precautions:
1. Turn the engine off.
2. Place the gear selector to parking position.
3. Always block the rear wheels on the downhill side as illustrated.
To achieve maximum traction while riding in 2WD or 4WD, the two rear wheels are mounted solidly on one
axle and turn together at the same speed. Furthermore, when riding in 4WD-LOCK
( DIFF. LOCK
), the front wheels also turn together at the same speed. Therefore, unless the wheel on the
inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning
technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be
learned first at low speed.
Always follow proper procedures for turning as described in this Owner s Manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at speeds too fast for your skills or the
conditions. Operate at a slow speed and allow extra time and distance for maneuvers when in 4WD- LOCK
( DIFF. LOCK
).
As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so,
put your weight on the footboard to the outside of the turn (opposite your desired direction) and lean your
upper body into the turn. Use the throttle to maintain an even speed through the turn. This maneuver will let the
wheel on the inside of the turn slip slightly, allowing the ATV to make the turn properly.
This procedure should be practiced at slow speed many times in a large area with no obstacles. If an incorrect
technique is used, your ATV may continue to go straight. If the ATV doesn t turn, come to a stop and then
practice the procedure again. If the riding surface is slippery or loose, it may help to 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 riding procedures such as abrupt throttle changes,
excessive braking, incorrect body movements, or too much
speed for the sharpness of the turn may cause the ATV to tip.
If the ATV begins to tip over to the outside while negotiating
a turn, lean more to the inside. It may also be necessary to
gradually let off on the throttle and steer to the outside of the
turn to avoid tipping over.
Remember: Avoid higher speeds until you are thoroughly
familiar with the operation of your ATV.
Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your
dealer.
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance
chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine parts available from your dealer.
Service and adjustments are critical. If you re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle
speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced
more frequently.
Frequent immersion in mud, water or sand
Racing or race-style high RPM use
Prolonged low speed, heavy load operation
Extended idle
Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting
in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if
it continues to rise, discontinue use and determine the cause or see your dealer.
Perform these procedures more often for vehicles subjected to severe use.
Have an authorized dealer perform these services.
Improperly performing the procedures marked with a
could result in component failure and lead to
serious injury or death. Have an authorized dealer perform these services.
Perform all services at whichever maintenance interval is reached first.
Steering
Pre-Ride
Make adjustments as needed. See
Front suspension
Pre-Ride
Pre-Ride Checklist on page 58.
Rear suspension
Pre-Ride
Tires
Pre-Ride
Brake fluid level
Pre-Ride
Brake lever/pedal travel
Pre-Ride
Brake systems
Pre-Ride
Wheels/fasteners
Pre-Ride
Frame fasteners
Pre-Ride
Engine oil level
Pre-Ride
Air filter, pre-filter
Daily
Inspect; clean often
Air box sediment tube
Daily
Drain deposits when visible
Check level daily, change coolant
Coolant
Daily
every 2 years
Check operation; apply dielectric
Headlamp/tail lamp
Daily
grease if replacing
Air filter, main element
Weekly
Inspect; replace as needed
Drain water as needed, check often
Recoil housing
Weekly
if operating in wet conditions
Brake pad wear
10H
Monthly
60 (100)
Inspect periodically
Battery
20H
Monthly
125 (200)
Check terminals; clean; test
Front gear case oil
25H
Monthly
155 (250)
Inspect level; change yearly
Rear gear case oil
25H
Monthly
155 (250)
Inspect level; change yearly
Transmission oil
25H
Monthly
155 (250)
Inspect level; change yearly
Engine oil change
Perform a break-in oil change at
25 H
1 M
155 (250)
(break-in)
one month
Lubricate all fittings, pivots, cables,
General lubrication
50 H
3 M
310 (500)
etc.
Shift Linkage
28H
1 M
310 (500)
Inspect, lubricate, adjust
Steering
50H
3 M
310 (500)
Lubricate
Front suspension
50H
6 M
310 (500)
Lubricate
Rear suspension
50H
6 M
310 (500)
Lubricate
Drain bowl periodically and prior
Carburetor float bowl
50H
6 M
310 (500)
to storage
Throttle Cable/ ETC
Inspect; adjust; lubricate;replace if
50H
6 M
310 (500)
Switch
necessary
Inspect; adjust; lubricate;replace if
Choke cable
50H
6 M
310 (500)
necessary
Carburetor air intake
Inspect ducts for proper sealing/air
50 H
6 M
310 (500)
ducts/ flange
leaks
Drive belt
50H
6 M
310 (500)
Inspect; adjust; replace as needed
Inspect coolant strength seasonally;
Cooling system
50H
6 M
310 (500)
pressure test system yearly
Perform a break-in oil change at 25
Engine oil change
100H
6 M
620 (1000)
hours/one month
Oil filter change
100H
6 M
620 (1000)
Replace with oil change
Oil tank vent hose
100H
12 M
620 (1000)
Inspect routing, condition
Valve clearance
100H
12 M
620 (1000)
Inspect; adjust
Check for leaks at tank cap, lines,
Fuel system
100H
12 M
620 (1000)
fuel valve, filter, carburetor; replace
lines every two years
Fuel filter
100H
12 M
620 (1000)
Replace yearly
Radiator
100H
12 M
620 (1000)
Inspect; clean external surfaces
Cooling hoses
100H
12 M
620 (1000)
Inspect for leaks
Engine mounts
100H
12 M
620 (1000)
Inspect
Exhaust muffler/pipe
100H
12 M
620 (1000)
Inspect
Spark plug
100H
12 M
620 (1000)
Inspect; replace as needed
Ignition Timing
100H
12 M
620 (1000)
Inspect
Inspect for wear, routing, security;
Wiring
100H
12 M
620 (1000)
apply dielectric grease to connectors
subjected to water, mud, etc.
Clutches
100H
12 M
620 (1000)
Inspect; clean; replace worn parts
(drive and driven)
Wheel bearings
100 H
12 M
1000 (1600)
Inspect; replace as needed
Brake fluid
200 H
24 M
1240 (2000)
Change every two years
Spark arrestor
300 H
36 M
1860 (3000)
Clean out
Idle speed
Adjust as needed
Inspect periodically; adjust when
Toe adjustment
parts are replaced
Auxiliary brake
Inspect daily; adjust as needed
Headlight aim
Adjust as needed
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on
page 83. Items not listed in the chart should be lubricated at the General Lubrication interval.
More often under severe use, such as wet or dusty conditions
All Season Grease
Use U-Joint Lube every 500 miles, before long periods of storage, or after pressure washing or submerging
Engine
SAE15W-40/SF
Add to proper level on dip- stick.
Brakes
DOT3 or DOT4 fluid
Maintain level between fill lines. See page 42.
Front Gear case
SAE15W/40 SF or SAE80W/90 GL-4
See Page 93.
Rear Gear case
SAE15W/40 SF or SAE80W/90 GL-4
See page 92.
Locate fitting on back side of struts and grease
Ball Joint
Grease
with grease gun.
Always check and change the engine oil at the intervals
outlined in the Periodic Maintenance Chart beginning on
page 83. Always change the oil filter whenever changing oil.
1. Pull outward on the areas shown
2. Position the ATV on a level surface.
3. Start the engine and let it idle for 20-30 seconds. Stop the
engine.
4. Wait a few minutes until the oil settles.
5. Remove the engine oil filler cap
and wipe off the
dipstick with a clean rag.
6. Insert the dipstick in the oil filler hole and screwing it in,
then remove it again to check the oil level.
The engine oil should be between the upper and
lower limit marks.
7. If the engine oil is at or below the lower limit mark, add
sufficient oil of the recommended type to raise it to the
correct level.
8. Insert the dipstick into the oil filler hole, and then tighten
the oil filler cap.
9. Install the panel.
1. Start the engine, warm it up for several minutes, and then
turn it off.
2. Place an oil pan under the engine to collect the used oil,
and then remove the engine oil filler cap.
3. Remove the engine oil drain bolt to drain the oil from
the crankcase.
6. Remove the oil filter cartridge with an oil filter wrench.
An oil filter wrench is available at a nearby dealer.
7. Apply a light coat of engine oil to the O-ring of the new oil
filter cartridge.
Make sure the O-ring is seated properly.
8. Install the new oil filter cartridge with an oil filter wrench, and
then tighten it to the specified torque with a torque wrench.
Oil filter cartridge tightening torque: 17 N m (1.7
m kgf, 12 ft lbf)
10. Install the engine oil drain bolt, and then tighten it to the specified torque.
Engine oil drain bolt tightening torque: 30 N m (3.0 m kgf, 22 ft lbf)
11. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it.
Without oil filter cartridge replacement oil quantity: 1.8 L (1.58 Imp qt, 1.90 US qt)
With oil filter cartridge replacement oil quantity: 1.9 L (1.67 Imp qt, 2.01 US qt)
12. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage
is found, turn the engine off immediately and check for the cause.
13. Turn the engine off, and then check the oil level and correct it if necessary.
The rear gear case must be checked for oil leakage before
each ride. If any leakage is found, have your dealer check
and repair the ATV.
1. Place the machine on a level place.
2. Place a container under the rear gear case to collect the
used oil.
3. Remove the oil filler bolt and the drain bolt to drain the oil.
4. Install the drain bolt and tighten it to the specified torque.
Drain bolt (rear gear case) tightening torque: 23
N m (2.3 m kgf, 16 ft lbf)
5. Fill the rear gear case with oil.
Periodic oil change oil quantity:
0.25 L (0.22 Imp qt, 0.26 US qt)
Total amount oil quantity:
0.30 L (0.26 Imp qt, 0.32 US qt)
6. Install the filler bolt and tighten to the specified torque.
Filler bolt (rear gear case) tightening torque: 23 N m (2.3 m kgf, 16 ft lbf)
7. Check for oil leakage. If oil leakage is found, check for the cause.
Be sure no foreign material enters the rear gear case.
1. Place the machine on a level place.
2. Remove the oil filler bolt and check the oil level. It should be
up to the brim of the hole. If the level is low, add sufficient oil
to raise it to the specified level.
3. Install the oil filler bolt and tighten it to the specified torque.
Oil filler bolt tightening torque: 2
3 Nm (2.3 m kgf, 16 ft lbf)
1. Place the machine on a level place.
2. Place a container under the front gear case to catch the oil.
3. Remove the filler bolt and drain bolt to drain the oil.
4. Install the drain bolt and tighten it to the specified torque.
Drain bolt tightening torque:
10 N m (1.0 m kgf, 7.2 ft lbf)
5. Fill the front gear case with oil.
Periodic oil change oil quantity:
0.28 L (0.25 Imp qt, 0.3 US qt)
Total amount oil quantity:
0.33 L (0.29 Imp qt, 0.35 US qt)
6. Install the filler bolt and tighten it to the specified torque.
7. Check for oil leakage. If oil leakage is found, check for the cause.
Be sure no foreign material enters the front gear case.
1. Place the ATV on a level surface.
2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with
engine temperature.
The coolant should be between the upper and lower limit marks.
3. If the coolant is at or below the lower limit mark, remove
the reservoir cap, add coolant to the upper limit mark,
install the reservoir cap, and then install the panel.
Coolant reservoir capacity(up to the upper limit
mark):0.3 L (0.26 Imp qt, 0.32 US qt)
Hard water or salt water is harmful to the engine. You
may use soft water if you can not get distilled water.
If water is added, have your 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 temperature in the radiator.
1. Place the ATV on a level surface.
2. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object
as shown to prevent coolant from spilling on the footrest.)
3. Remove the radiator cap.
4. Remove the coolant reservoir cap.
5. Disconnect the hose on the coolant reservoir side, and then
drain the coolant from the coolant reservoir.
6. After draining the coolant, thoroughly flush the cooling
system with clean tap water.
7. Replace the coolant drain bolt washer if it is damaged, and
then tighten the coolant drain bolt to the specified torque.
Coolant drain bolt tightening torque:
10 N m (1.0 m kgf, 7 ft lbf)
10. Install the coolant reservoir hose.
11. Fill the recommended coolant into the radiator until it is
full.
Recommended antifreeze:
High quality ethylene glycol antifreeze containing
corrosion inhibitors for aluminum engines.
Antifreeze and water mixing ratio:1:1
Total amount:1.9 L (1.67 Imp qt, 2.00 US qt)
Coolant reservoir capacity
(up to the upper limit mark):
0.3 L (0.26 Imp qt, 0.32 US qt)
Hard water or salt water is harmful to the engine. You may
use soft water if you can not get distilled water.
12. Install the radiator cap.
13. Start the engine and let it idle for several minutes. Stop the
engine, and then check the coolant level in the radiator. If
it is low, add more coolant until it reaches the top of the
radiator.
14. Fill the coolant reservoir with coolant up to the upper limit.
15. Install the coolant reservoir cap and check for coolant
leakage.
If any leakage is found, have your dealer check
the cooling system.
16. Install the panels and the front rack.
Check the protective boots for holes or tears.
If any damage is found, have them replaced by your dealer.
Removal
1. Remove panel.
2. Remove the spark plug cap.
3. Use the spark plug wrench in the tool kit to remove the
spark plug as shown.
The spark plug is an important engine component and is easy
to inspect. The condition of the spark plug can indicate the
condition of the engine. The ideal color on the white
insulator around the center electrode is a medium-to-light tan
color for a ATV that is being ridden normally. Do not
attempt to diagnose such problems yourself. Instead, take the
ATV to your dealer. You should periodically remove and
inspect the spark plug because heat and deposits will cause
the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other
deposits are excessive, you should replace the spark plug with the specified plug.
Specified spark plug: DPR7EA-9 (NGK)
1. Measure the electrode gap with a wire thickness gauge and, if
necessary, adjust the gap to specification.
Spark plug gap:0.8
0.9 mm (0.031
0.035 in)
2. Clean the gasket surface. Wipe off any grime from the threads.
3. Install the spark plug and tighten it to the specified torque.
Spark plug tightening torque: 17.5 N m (1.75 m kgf, 12.5 ft lbf)
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. Have the spark plug tightened to the specified
torque as soon as possible.
4. Install the spark plug cap.
5. Install the panel.
There is a check hose at the bottom of the air filter case. If dust or water collects in this hose,
empty the hose and clean the air filter element and air filter case.
1. Remove the seat.
2. Remove the air filter case cover by unhooking the holders.
3. Remove the air filter element.
4. Remove the air filter element from its frame.
5. Wash the air filter element gently but thoroughly in solvent.
6. Squeeze the excess solvent out of the air filter element and
let it dry.
Do not twist the air filter element when squeezing it.
7. Inspect the air filter element and replace it if damaged.
8. Apply foam air filter oil or other quality foam air filter oil to the air
filter element. If foam air filter oil is not available, engine oil may
be used.
The air filter element should be wet but not dripping.
9. Pull the air filter element over its frame.
10. Install the air filter element.
11. Install the air filter case cover and be sure to connect the hose.
12. Install the seat.
The air filter element should be cleaned every 20
40 hours. It should be cleaned and lubricated
more often if the machine is operated in extremely dusty areas. Each time air filter element
maintenance is performed, check the air inlet to the air filter case for obstructions. Check the air
filter element rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all
fittings securely to avoid the possibility of unfiltered air entering the engine.
Never operate the engine with the air filter element removed. This will allow unfiltered air to enter, causing
rapid engine wear and possible engine damage. Additionally, operation without the air filter element will
affect carburetor jetting with subsequent poor performance and possible engine overheating.
Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
1. Remove the bolts.
2. Remove the tailpipe by pulling it out of the muffler.
3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester
portion of the tailpipe.
4. Insert the tailpipe into the muffler and align the bolt holes.
5. Install and tighten the bolts.
When cleaning the spark arrester: Always let the exhaust
system cool prior to touching exhaust components. Do
not start the engine when cleaning the exhaust system.
If dust or water collects in the V-belt cooling duct check
hose, remove the hose and clean it.
After riding in water deep enough to allow it to enter the
V-belt case, remove this bolt to drain the water from the
case.
If water drains from the V-belt case after
removing the bolt, have your dealer inspect
the ATV as the water may affect other engine
parts.
The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be
left to your dealer who has the professional knowledge and experience to do so. However, the idling speed may
be performed by the owner as a part of the usual maintenance routine.
The carburetor was set at the factory after many tests. If the settings are disturbed by someone without
sufficient technical knowledge, poor engine performance and damage may result.
A diagnostic tachometer must be used for this procedure.
1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000r/min. Occasionally rev the
engine to 4,000 to 5,000 r/min. The engine is warm when it
quickly responds to the throttle.
2. Remove panel.
3. Connect the tachometer to the spark plug lead, and then set
the idle to the specified idling speed by adjusting the throttle
stop screw. Turn the screw in direction
a
to increase the
engine speed, and in direction
b
to decrease the engine
speed.
Specified idle speed:1,200
1,400 r/min
4. Install the panel.
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 adjustment however, should be left to a professional
service technician.
Adjust the engine idling speed before adjusting
the throttle lever free play.
1. Loosen the locknut.
2. Turn the adjusting bolt until the throttle lever free play is
3
5 mm (0.12
0.20 in).
3. Tighten the locknut.
Check the brake pads for damage and wear.
If a brake pad thickness is less than 2 mm (0.08 in), have
your dealer replace the pads as a set.
The wheels need to be removed to check the
brake pads.
Inspect the brake pads for damage and wear.
If the thickness is less than 4 mm(0.16 in), have your dealer
replace the pads.
Insufficient brake fluid may let air enter the brake system,
possibly causing the brakes to become ineffective. Before riding,
check that the brake fluid is above the lower level and replenish when necessary. The front brake fluid master
cylinder reservoir is located the right of the handlebar. The rear brake fluid master cylinder reservoir is near the
rear brake pedal.
Observe these precautions:
1. When checking the fluid level, make sure the top of the master cylinder reservoir is level by turning the
handlebars.
2. Use only the designated quality brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and
poor brake performance.
Recommended brake fluid: DOT3 or DOT 4.
3. Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to
poor brake performance.
4. Be careful that water does not enter the master cylinder reservoir when refilling. Water will significantly
lower the boiling point of the fluid and may result in vapor lock.
5. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
6. Have your dealer check the cause if the brake fluid level goes down.
Complete fluid replacement should be done only by trained service personnel. Have your dealer replace the
following components during periodic maintenance or when they are damaged or leaking.
Replace the oil seals every two years.
Replace the brake hoses every four years.
The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have your dealer
check the brake system.
After servicing:
Make sure the brakes operate smoothly and that the
free play is correct.
Make sure the brakes do not drag.
Make sure the brakes are not spongy.
All air must be bled from the brake system.
Replacement of brake components requires professional knowledge. These procedures should be performed
by your dealer.
The rear brake lever free play
c
should be 0.5
2 mm
(0.02
0.08 in).
1. Loosen the locknut
2. Turn the adjusting bolt in direction
a
to increase
free play, and in direction
b
to decrease free play.
3. Tighten the locknut
If correct free play cannot be obtained, ask your dealer to
make that adjustment.
When adjusting the rear brake lever free play:
Be sure not to step on the brake pedal.
Make sure the brake pedal does not move.
Adjust the rear brake before inspecting the rear brake pads.
The top of the brake pedal should be positioned 72mm (2.8 in)
above the top of the footrest. If not, ask your dealer to adjust it.
After servicing:
Make sure the brakes operate smoothly and that the free
play is correct.
Make sure the brakes do not drag.
All air must be bled from the brake system.
Replacement of brake components requires professional knowledge. These procedures should be performed
by your dealer.
The rear brake light switch, which is activated by the brake
pedal and brake levers, is properly adjusted when the brake
light comes on just before braking takes effect. If necessary,
adjust the brake light switch as follows.
Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on
earlier, turn the adjusting nut in direction a . To make the brake light come on later, turn the adjusting nut in
direction
b
Inspect cables frequently. Replace damaged cables.
Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask your dealer to replace
them.
Recommended lubricant: SAE 10W30 motor oil
Lubricate the knuckle upper and lower pivots with a grease
gun.
Recommended lubricant:
Lithium-soap-based grease
1. Loosen the wheel nuts.
2. Elevate the ATV and place a suitable stand under the frame.
3. Remove the nuts from the wheel.
4. Remove the wheel.
1. Install the wheel and the nuts.
Tapered nuts are used for both the front and rear
wheels. Install the nut with its tapered side towards the wheel.
The arrow
mark on the tire must point toward the rotating direction of the wheel.
2. Lower the ATV so that the wheel is on the ground.
3. Tighten the wheel nuts to the specified torque.
Wheel nut torque: Front: 55 N m ( 5.5 m kgf, 40 ft lbf). Re ar: 55 N m (5.5 m kgf, 40 ft lb f)
This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or
add distilled water in the battery. If the battery seems to have discharged, consult your dealer.
Do not try to remove the sealing caps of the battery cells. You may damage the battery.
Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of
reach of children.
Antidote:
EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of
magnesia, beaten egg or vegetable oil. Get prompt medical attention.
EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries away from sparks,
flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.
1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place.
Completely recharge the battery before reinstallation.
A special battery charger (constant voltage/ampere or constant voltage) is required for recharging a sealed-
type battery. Using a conventional battery charger may shorten
the battery life.
2. Always make sure the connections are correct when putting the
battery back in the machine.
1. The main fuse case and the fuse box are located under the seat.
2. If a fuse is blown, turn off the main switch and install a new
fuse of the specified amperage. Then turn on the switches. If
the fuse immediately blows again, consult your dealer.
Always use a fuse of the specified rating.
Never use a material in place of the proper fuse.
To prevent accidental short-circuiting, turn off the main switch
when checking or replacing a fuse.
If a headlight bulb burns out, replace it as follows:
1. Remove the bolts and pulling headlight cover off.
2. Remove the rubber cover at the rear of the headlight by pulling
it off.
3. Remove the headlight lock spring.
4. Pull headlight bulb out from the headlight bulb holder.
Wait for the bulb to cool before touching or removing it.
5. Insert a new headlight bulb into the headlight bulb holder,
and then lock it by spring.
6. Install the bulb holder by turning it clock-wise.
7. Install the rubber cover at the rear of the headlight.
8. Install the headlight cover with the bolts.
It is advisable to have your dealer make this adjustment.
Turn the adjusting screws can raise or lower the beam.
If the tail/brake light bulb burns out, replace it as follows:
1. Remove the screws
, and then pull tail/brake light cover out.
2. Remove the tail/brake light bulb by pushing it in and turning it counter-clockwise.
3. Insert a new tail/brake light bulb, push it in, and the turning it clockwise.
4. Install the tail/brake light cover with the screws.
The spring preload can be adjusted to suit the rider s weight
and riding conditions.
When adjusting the rear shock absorbers, the
rear wheels need to be removed.
Adjust the spring preload as follows.
To increase the spring preload, turn the adjusting ring in
direction
a
To decrease the spring preload, turn the ad-justing ring in
direction
b
A special wrench can be obtained at a dealer to
make this adjustment.
Standard position: B
A- Minimum (soft)
E- Maximum (hard)
Always adjust the shock absorbers on the left and right
side to the same setting.
If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly
inspected. Take the vehicle to your dealer before starting the engine.
If it s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
1. Move the ATV to dry land or at the very least, to water below the footrests.
2. Remove the spark plug.
3. Check the air box and drain if water is present.
4. Loosen the carburetor drain screw.
5. Turn the engine over several times using the electric start.
6. Dry the spark plug and reinstall, or replace it with a new plug.
7. Tighten the carburetor drain screw.
9. Attempt to start the engine. If necessary, repeat the drying procedure.
10. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not.
If water has been ingested into the CVT, follow the procedure on page 104 for drying out the CVT.
Keeping your ATV clean will not only improve its appearance but it can also extend the life of various
components. With a few precautions, your ATV can be cleaned much like an automobile.
The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a
professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water
frequently and dry with a chamois to prevent water spots.
If warning and safety labels are damaged, contact your dealer for replacement.
Your ATV does not recommend the use of a high pressure type car wash system for washing the ATV. If a high
pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals,
body panels, brakes and warning labels.
Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while to
evaporate any water that may have entered the engine or exhaust system.
Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since
they can scratch the body finish.
Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when
using these products near plastic surfaces.
Starting the engine during the storage period will disturb the protective film created by fogging and damage
could occur. Never start the engine during the storage period.
Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt
and grime. Don t use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts. Use
dish soap type cleaners only. High pressure washers may force water past seals.
Fill the fuel tank. Add Carbon Clean Fuel Treatment or Fuel Stabilizer. Follow the instructions on the container
for the recommended amount. (Carbon clean will also reduce the possibility of bacterial growth in the fuel
system.) Allow 15-20 minutes of operation for the stabilizer to disperse through the fuel in the tank and
carburetor and then drain the carburetor bowl.
Warm the engine and change the oil and filter.
Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube.
Inspect and clean or replace the breather filter.
Inspect the following fluid levels and change if necessary: front gear case; transmission; brake fluid (change
every two years or as required if fluid looks dark or contaminated).
Remove the spark plug and add 2
3 tablespoons of 4 Synthetic 0W40 engine oil. To access the plug hole, use
a section of clear 1/4 hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.
Do this carefully! If you miss the plug hole, oil will drain from the spark plug cavity into the hole at
the front of the cylinder head, and appear to be an oil leak. Install the spark plug and pull the
engine over slowly with the recoil starter. Oil will be forced in and around the piston rings and ring
lands, coating the cylinder with a protective film of fresh oil.
If you choose not to use Fogging Oil, perform the following procedure.
1. Support the front end of the machine so the engine is level or tilted slightly rearward.
2. Remove the spark plug. Rotate the piston to BDC and pour approximately two ounces of oil into the cylinder.
3. Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug.
4. Turn the engine over several times to ensure coverage of piston rings, cylinder walls and crankshaft bearings.
5. Treat the fuel system with Carbon Clean.
6. If fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of
gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops.
Inspect all cables and lubricate with Cable Lubricant. Follow lubrication guidelines in the maintenance section
of the service or owner s manual to completely grease and lubricate the entire vehicle with All Season Grease.
Remove the battery from the vehicle and ensure that it's fully charged before placing it in storage.
Engine Anti-Freeze
Test engine coolant strength and change if necessary. Coolant should be replaced every two years.
Set the tire pressure and safely support the ATV with the tires 1
2
off the ground. Be sure the storage area is
well ventilated, and cover the machine with a ATV cover.
Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation,
and may promote corrosion and oxidation.
Follow these procedures when transporting the vehicle.
1. Turn off the engine and remove the key to prevent loss during transporting.
2. Always place the transmission in park.
3. Be sure the fuel cap, oil cap and seat are installed correctly.
4. Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope.
Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a like new
appearance for many years.
1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime. Never use abrasive
cleaners on plated or painted surfaces.
2. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish.
3. Routinely and liberally apply a weather resistant wax to each polished chrome wheel.
Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.
4. Chrome wheels exposed to road salt ( or salt in the air in coastal areas ) are more susceptible to corrosion if
not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.
If light rust is found on the chrome finish, use steel wool ( # 0000
OTT grade ) to remove it. Gently rub the
affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined
above.
Driving the ATV onto a pickup or tall
Shift transmission to low range during loading of the ATV to prevent belt
trailer in high range.
burning.
When starting out on an incline, use low range or dismount the ATV (after
Starting out going up a steep incline.
first applying the park brake) and perform the K-turn as described on page
73.
Drive at a higher speed or use low range more frequently. The use of low
Driving at low RPM or low ground speed
range is highly recommended for cooler CVT operating temperatures and
(at approximately 3-7 MPH).
longer component life.
Warm the engine at least 5 minutes. With the transmission in park, advance
Insufficient warm-up of ATVs exposed to
the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will
low ambient temperatures.
become more flexible and prevent belt burning.
Slow and easy clutch engagement.
Use the throttle quickly and effectively for efficient engagement.
Towing/pushing at lowRPM/low ground
Use low range only.
speed.
Utility use/plowing snow, dirt, etc.
Use low range only.
Shift the transmission to low range, and carefully use fast, aggressive
Stuck in mud or snow.
throttle application to engage clutch.
Excessive throttle
may cause loss of control and vehicle overturn.
Shift the transmission to low range, and carefully use fast, brief, aggressive
Climbing over large objects from a
throttle application to engage clutch.
Excessive throttle may
stopped position.
cause loss of control and vehicle overturn.
Shift the transmission to park. Using the throttle, vary the engine RPM
from idle to full throttle. Repeat several times as required. During this
Belt slippage from water or snow
procedure, the throttle should not be held at the full position for more than
ingestion into the CVT system.
10seconds. Clutch seals should be inspected for damage if repeated leaking
occurs.
Clutch malfunction.
Contact your dealer for inspection of clutch components.
Check for fouled plugs or foreign material in gas tank, fuel lines, or
Poor engine performance.
carburetor. Contact your dealer for service.
Contact your dealer for service if you're unable to identify solutions using the following charts.
Tripped circuit breaker
Reset the breaker
Low battery voltage
Recharge battery to 12.5 VDC
Loose battery connections
Check all connections and tighten
Loose solenoid connections
Check all connections and tighten
Out of fuel
Refuel
Clogged fuel valve or filter
Inspect and clean or replace
Water is present in fuel
Drain the fuel system and refuel
Fuel valve is out of use
Replace
Old or non-recommended fuel
Replace with new fuel
Fouled or defective spark plug(s)
Inspect plug(s), replace if necessary
No spark to spark plug
Inspect plug(s), verify stop switch is on
Crankcase filled with water or fuel
Immediately see your dealer
Overuse of choke
Inspect, clean and/or replace spark plugs
Clogged fuel filter
Replace the filter
Low battery voltage
Recharge battery to 12.5 VDC
Mechanical failure
See your dealer
Poor quality or low octane fuel
Replace with recommended fuel
Incorrect ignition timing
See your dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Weak spark from spark plugs
Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Old or non-recommended fuel
Replace with new fuel
Incorrectly installed spark plug wires
See your dealer
Incorrect ignition timing
See your dealer
Mechanical failure
See your dealer
Fouled or defective spark plugs
Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires
See your dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Loose ignition connections
Check all connections and tighten
Water present in fuel
Replace with new fuel
Low battery voltage
Recharge battery to 12.5 VDC
Kinked or plugged fuel vent line
Inspect and replace
Incorrect fuel
Replace with recommended fuel
Clogged air filter
Inspect and clean or replace
Reverse speed limiter malfunction
See your dealer
Electronic throttle control malfunction
See your dealer
Other mechanical failure
See your dealer
Low or contaminated fuel
Add or change fuel, clean the fuel system
Low octane fuel
Replace with recommended fuel
Clogged fuel filter
Replace filter
Incorrect jetting
See your dealer
Overuse of choke
Inspect, clean and/or replace spark plugs
Fuel is very high octane
Replace with lower octane fuel
Incorrect jetting
See your dealer
Out of fuel
refuel
Kinked or plugged fuel vent line
Inspect and replace
Water present in fuel
Replace with new fuel
Overuse of choke
Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs
Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires
See your dealer
Incorrect spark plug gap or heat range
Set gap to specs or replace plugs
Loose ignition connections
Check all connections and tighten
Low battery voltage
Recharge battery to 12.5 VDC
Incorrect fuel
Replace with recommended fuel
Clogged air filter
Inspect and clean or replace
Reverse speed limiter malfunction
See your dealer
Electronic throttle control malfunction
See your dealer
Other mechanical failure
See your dealer
Clean radiator screen and core if equipped
Overheated engine
Clean engine exterior
See your dealer

 

 

 

 

 

 

 

 

 

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