ATV300 USER`S MANUAL.MDI
Contents
1. 1 Add fresh fuel into fuel tank 40 2 Add one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug Ground the spark plug wire and run the engine over several times to coat the cylinder body with oil 3 Lubricate all control cables 4 Elevate the engine body to raise all wheels off the ground 5 Seal with plastic bag over the exhaust pipe outlet to prevent moisture from entering 6 If storing ATV in a humid or salt air atmosphere cover all exposed metal surfaces with a light plastic film of oil Do not apply oil to any plastic parts or the seat cover 7 Take out the battery and store it in a dry place The battery should be stored in the place where the ambient temperatrue should be 30C maximum and OC minimum MAIN DATA AND SPECIFICATIONS ltem specification Item specification Dimension Engine oil Overall length 1850mm_ Periodic oil change Overal width 1140mm With oil filter replacement Overall height 1190mm Total amount Seat height 900mm Wheel base 1170mm Minimum ground clearance 185mm Minimum turning radius 2300mm Main fuel tank capacity Reserve fuel tank capacity Carburetor Type Vacuum film piece type Basic weight Spark plug type DR8EA With oil and full fuel tank 190kg Spark plug gap 0 6 0 7mm Engine Air cooled 4 stroke single cylinder Clutch type Wet centrifugal automatic Displacement 290ml _ Transmission 74 x 68mm Primry reduction system Spur gear Primary reduction ratio 73 22 3 3182. ccccccceeeeeeeeeeeeeeeeees 39 GIOANNING vaere 39 JE s r 40 Main data and specification rrrrrnnnrennnnrre 41 Maintenance record cccssseeeceeseeeeseeeeeees 43 Electric wiring diagram rrnnnnvvnrnnnrvnrnnnrennnnr 44 SAFETY INFORMATION This operation manual includes important safty and maintenance information When resell ing the ATV TO THE NEXT BUYER the operation manual should be passed on together with it because the next user also need the manual Please read the manual carefully before driving the new lf failed to conform the requirements described in the manual it will be easy to cause injuries and deaths WARNING e Read this manual carefully and follow the operating procedures and methods described in this manual e Never operate an ATV without proper training or instruction e A child under 16 years old should never operate an ATV Never allow drive of an ATV by an individal person if he or she does not have the abilities to operate it safely eAlways avoid driving an ATV on any paved surfaces including sidewalks driveways park ing lots and streets e Never operate an ATV in any public street road or highway even a dirt or gravel one e Never drive an ATV without wearing an approved motorcycle helment that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants e Nevr consume alcohol or drugs before or while operating thi
3. Compression ratio 8 9 1 Secondary reduction system Shaft drive Starting system Electric starter or recoil starten Secondary reduction ratio 19 18 x 46 11 4 414 Lubrication system Pressure splash Transmisson type Constant mesh 5 speed forward speed reverse Operation left foot operation Bore x Stroke MAIN DATA AND SPECIFICATIONS Item specification Item specification Gear ratio 1st 2nd 3rd 4th Frame Frame type CasterA angle Trail Tire Type Size Front Size Rear Brake Front brake type Operation Rear brake type Operation Steel tube 4 20mm Vacuum AT22 x 7 10 AT22 x 10 10 Disc brake Left hand operation Disc brake Right foot operation Suspension Front Supporting rod Rear Rotary rod Shock absorber Front Spring Oil damper Rear Spring oil damper Wheel travel Front 135mm Rear 135mm Electrical Ignition system PEI Generator system A C Magneto Battery type voltage capacity 12N14 BS 12V 14AH Headlight 12v 55W Taillight 12V 21W 12V 3W x 1 12V 3W x 1 12V 3W x 1 Neutral indicator Reverse indicator Hight beam indicator light MAINTENANCE RECORD Maintenance times receipts of purchased componects and assembly will be required to be recorded which should be done according to the warranty The chart below only acts as maintenance record not as maintenance proof MAINTENACE INTERVAL DRIVING MILEAGE SERVICING DEALER NAME AND ADDERSS REMARKS TIME 1Month 3Months 6Months 12Months 1
4. Be sure the fuel tank cap is closed securely Do not refuel right after the engine has been running and is still very hot Enegine oil Make sure the engine oil is at the specified level Add oil as necessary See pape Recommended oil SAE20W40 SAE10W30 SAE5W30 Recommended engine oil classfication SE SF SG type or higher Engine oil capacity 1 3L Lubrication oil of gear case Make sure the lubrication oil of gear case is at the specified level Add oil as necessary see page for defails Recommended oil SAE80 API GL Hypoid gear oil Throttle lever Check to see that throttle lever operates correctly It must open smoothly and spring back to idle posi tion when released Repair as necessary for proper operation Fittings and Fastenerns Always check the tightness of chassis fittings and fasteners before a ride Refer to the Service Manual for correct tightening torque Lights Check the headlight and taillight to make sure they are in working condition Repair as necessary for proper operation S witches Check the Operation of the headlight switch engine stop switch and any other switches Repair as necessary for proper operation Battery The battery is an enclosed one and unneces sary to fill water see page Don t take off the closing bolt when charging When charging please obey the charging cur rent and time as shown on the following table Charge criteria Charge the battery with ten per cent
5. Total amout 1 8L 1 6mp qt 1 oil gallery bolt Spark plug inspection You should periodically remove and check the spark plug because heat and deposits will cause slow damage and erosion of the spark plug if elec trode erosion is excessive you should replace the spark plug with one of the propet tyoe D7RTC Before installing the new spark pulg measure the electrode gap with a feeler gauge and adjust to spectifcation 1 Spark plug gap Spark plug gap Le 0 5 0 7mm 4 When installing the spark pulg generally clean the gasket surface and use a new gasket Clean off any grime from the threads and tighten to specification Spark plug torque 17 5Nm 1 75m kg Air fillter cleaning There is a check hose at the bottom of the air filter case if there are 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 1 Air filter element 2 Foam cover 3 Remove the air filter element 4 Remove the foam cover from the air filter element 5 Tap the element lightly to remove most of the dust and dirt Blow out the remaining dirt with com pressed air lf the element is damaged replace it 6 Wash the foam cover gently thoroughly in water or solvent 30 7 Squeeze the excess water or solvent out of the foam cover and let it dry Do not twist the foam cover when squeezing it 8 Check the foam co
6. 1 Lift the wheel by placing a suitable support Steering vertical tube lubrication under the frames 2 Remove the nut on the wheel Use a grease gun to lubricate the pivots lt l ae R heel ly Revommended lubricant Lithium base grease NN 35 3 Tighten the wheel nut Wheel installation When installing the wheel reverse the removal 1 Tapered nut procedure Pay attention to the following points Wheel nut torque Front wheel 55Nm 5 5m kg Rear wheel 55Nm 5 5m kg Battery WARNING Avoid contact with skin eyes or clothing Always shield eyes when working near batteries keep out of reach of children Use and maintenance 1 Arrow mark 1 Don t remove electrolyte cover after enclosed battery being used Please obey the operation in struction on battery to use the battery 2 lf ATV is suspended from use for a month or much longer time remove the battery and store in a cool and dark place charge fully before reusing 3 If the battery is stored over the above men 1 The arrow mark on the tire must point to the rotation direction of the wheel 2 Tapered wheel nuts are used for both front and rear wheels Install tapered side of the nut to wards the wheel 36 tioned time check the voltage at least one month Charge the battery when the voltage is lower than 12V 1 Main fuse 2 Start relay Fuse replacement 1 The fuse case is put under the seat 2 lf the fuse is blown switch off the main switch
7. MAINTENANCE LUBRICATION INITAL EVERY Ga Spark plug Check condition Adjust gap and clean Replace if necessary FJES ETE Air filter Clean Replce if necessary Every 20 40 hours more often in wet or dusty areas Check idle speed Starter operation Adjust if necessary EEG I Cylinder head Check breather hose for cracks or damage Replace if breather system necessary Exhaust system Check for leakage Retighten if necessary Repace gasket if nec essary Check fuel hose for cracks or damage Replaceif necessar TEREE S Replace Warm engine before draining OMOR aosan oem OL for jo Final gear oil Check oil level oil leakage Replace HE GT GJE PERIODIC MAINTENANCE LUBRICATION TEM ROUTINE INITAL EVERY 6months 1Ye Check operation Adjust if necessary Check operation Adjust if necessary Check balance damage runout Replace if necessary Wheel bearings Check balance assembly for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary ne Steering system I Check operation Correct if necessary Check toe in Steering system Adjust if necessary Steering shaft Lubricate every 6months use Li grease Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary Engine oil 1 Engine oil level measurement a Place the machine on a flat surface wram up the engine for several minutes and turn off it wait more than 10 minutes for the oil to dra
8. of capacity of battery for 5 to 10hours or quickly charge the battery with 2A to 3A for 2 hours Tire The size and type in low pressure condition of hollow tire used for ATV300 are listed below 12 Front wheel AT22 X 7 10 AT22 x 10 10 warning Use of improper tires on this AT Vor operation of this ATV with improper tire pressure may increase your risk of accident Use of improper tires on this AT V or operation of this ATV with improper tire pressure may cause loss of control Pay attention to choose the Size and type of used tire according to the description in the above chart and make sure that the tire pressure is normal 2 The tires should be set to the recommended pressure Front 20KPa 0 20kgf cm 2 2 8pai Rear 25KPa 0 25kgf cm 2 3 6pai Check and adjust tire presssure when the tires are cold Tire Pressure below the minimum specified could cause the tire to dislodge from the rim under severe riding conditions the following are minimums Front 17KPa 0 17kgf cm Rear 22KPa 0 22kgf cm Higher pressures may cause the tires to burst Inflation could cause the tires to burst How to measure tire pressure Use the low pressure tire gauge Caution The low pressure tire gauge is included as standard equipment conduct two measurements if the tire pressure and use the second reading Dust or dirt in the gauge would cause the First reading to be incorrect Set pressure when tires are in cold and set tire pres
9. slow in driving in such way 4 Always check your ATV each time before you ues it to make sure the reliability of ATV Always fol low the inspection and maintenance procedures in the operation manual to protect you ATV 5 Always select the size and type of tires speci fied in the operation manual for this vehicle to keep the normal tire pressure 6 Speed limit valve This valve is used for beginners to limit the max speed of the ATV Rotate the bolt clockwise to incresase max speed and rotate it coutercloclwise to decrease max speed 7 Always keep your feet on the footboards dur ing operation otherwise your feet may contact the rear wheels Never attempt stunts such as wheelies or jumps WARNING Don t try to show off 19 8 Improper installstion of accessories or modi fication of this vehicle may cause changes in harding which in some situations could lead to an accident Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genunie our or equivalent components designed for using on this ATV and should be installed and used according to instructions our dealer lf you have questions cousult an authorized ATV dealer 9 Exhaust silencer The exhaust silencer is very hot during driving To avoid burn do not touch the exhaust cylinder Park the machine where pedestrians or children can not touch it 10 Know where you should ride This machin
10. switches 3 Engine stop switch Make sure that the engine stop switch is in the 3 position The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The engine will not start or run when the engine stop switch is turned to SG ap Start switch The starter motor cranks the engine when this switch is pushed See starting instructions prior to starting engine see page for details If the starter switch is pushed with the main switch 3 and the engine stop switch the starter motor will be activated but the engine will not start To start the engine be sure to set the engine stop switch at ea Lights swtich LIGHTS Turn the switch to for the low beam and taillight Turn te switch to for the hight beam 1 Neutral indicator light N and taillight 2 Reverse indicator light R Throttle lever F Once the engine is running movement of the 3 Hight beam indicator light throttle lever will increase the engine speed Adjust the speed of the machine by changing 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 1 Lights switch
11. 7 PUGCISCOCK paa 8 ee EE ceed Nes te eande ET 8 SEE NOX zirean nA 9 From CaLlriGh sauene 9 REF CANE sura 9 Rear shock absorber rrrrnnrrrnrrnnnnvevnrnnnnnrennr 9 Spring preload adjustment rrrrnnnnnrnvnnnnnnre 9 Pre operation checkes rrrnrrrnnnnnenrannnnnnnennn 10 Front and rear brakes ccccscccccsseeeeeeeeees 10 FUT EEE EEE 11 ENGINE Os 11 Lubrication oil of gear CASE rrrrrrnnrrerrrnnnen 11 TOUS EVE oaei 11 Fittings and Fasteners errernennannnennnnennennns 12 0 STE RNA AE 12 Content SWINGS iarann Tr 12 ATG ene E E E 12 TESS 12 How to measure tire pressure rrrnnrrnnnrrennnn 12 Tre wear IMi ieu R 13 OPE IO 14 Starting an engine rrrrrnrnnrnnnnrvnnrnnnnnvnnnrnnenee 14 Starting a cold engine rrrrnnnnrrrnrnnnnnrennrnnnnre 14 Starting A warm engine rrrnnnnennnnnnnnvnnnrnnnnee 14 FO Wal MING reri 14 Drive select lever operation and reverse driving ccccccsssceccesseeeseeseeeseees 15 SMUG EN 15 To start out and accelerate wrrrnrrrrrvnrnnnrrr 16 To decelerate cccccccccssssseeeeceseseeeseeeseeeess 16 Engine break in aenar 16 ACCESSOS eee 17 LOS keen 17 Ride with care ta cr02655 Sccscusensdabeereaasietcoidadecchades 18 Speed limit valve eaa 19 Exhaust silencer rrrrnrrrrnrnnnrvnrnnnrvnvnnnnvnvnnee 19 ARE da aE DE E A 20 Climbing Slope srrrnrnnrnnnrrnnnnnnnnvrnnnrrnnnnnnnnee 21 Riding COW MIM ar esseen nai 22 Crossing d
12. 8Months 24Months 36Months 42Months 48Months 54Months 60Months somons 44 UATNS00 6334 All rights reserved reprinting is prohibited
13. Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side Go straight down the hill where possible eAlways follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible e Avoid crossing the steep hills e Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling use proper gear and maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual I eAlways check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when oper ating over obstacles as described in this manual e Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremly slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control e Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual Remember that wet b
14. Brake levers and brake pedal Follow the inspection and maintenance proce Check for correct free play in the brake levers dures and scheclules described in the Operation and brake pedal If the free play is incorrect adjust it Manual Ser Pages Front and rear brakes Check operation of the levers and pedal They Always check the brakes at the start of every should move smoothly and there shoud be a firm side Do not ride the ATV if you find any problem with feeling when the brake is applied If not have the the brakes If a problem cannot be corrected by the machine inspected by a our dealer adjustment procedures Provided in this manual have 2 Brake operation 10 Test the brakes at slow speed after starting out to make sure they are working properly lf the brakes do not provide proper braking performance inspect the brakes for wear See page Fuel Make sure there is sufficient gasoline in the tank Recommended fuel unleaded fuel Fuel fank capacity 12L Unleaded fuel will give a longer spark pulg life and reduce maintenance cost If unleaded gasoline is not available the leaded regular gasoline can be used CAUTION Fuel can spill causing a fire and severe injury Fuel will exoand when it heats up if the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun So do not overfill the fuel tank Be cerful Not to spill fuel especially on the engine or exhaust pipe wipe up any spilled fuel immediately
15. CRIPTION AND MACHINE IDENTIFICATION 1 Front wheel 12 Clutch 2 Headlight 13 Throttle lever 3 Shift pedal 14 Fuel tank cap 4 Fuel cock 15 Main switch 5 Cushion 16 Parking brake 6 Taillight 17 Rear brake lever 7 Rear wheel 8 Spark arrester 9 Carturetor 10 Rear brake pedal 11 Bumper The machine you have purchased may differ slightly fron those shown in the figures of this manual for progress or other change Identification numbers record When ordering spare parts from a our dealer or for reference in case the vehicle is stolen Record vehicle identification number in the spaces provided for assistance 1 VEHICLE IDENTIFICATION NUMBER Vehicle identification number The vehicle identification number is stamped on crosstube of pedestal CONTROL FUNCTIONS Main switch Functions of the respective switch positions are as follows ON Engine can be started only at this position and the headlight and taillight come on when the light swithc is on OFF All electrical circuits are switched off The key can be removed in this position Indicator lights Reverse indicator light R This indicator light comes on when the trans mission is in reverse The light is blue in color Neutral indicator light N This indicator light comes on when the trans mission is in neutral High beam indicator light This light is yellow in color It comes on when the head light and high beam light is on Handlebar
16. G 21 There may be other vehicles and persons on the other side of slope If your ATV can not climb the slope turn round your ATV Make turning practice according to procedures in operation manual Do not make turn on slope Be more careful when making aturn on slope Be more careful when making a turn on slope and avoid to climb steep slope when possible when climbing the slope Do not drive on depression and slippery slope and drive according to procedures in operation manual Ensure the ATV not to slip when stop it on slope The shift should be proper and speed shuld be stable when climbing slope losing traction force you should transfer the gravity center forward and brake the machine Close the brake closing piece after stop ping the machine If the machine slips backward Transfer you gravity center backward Use front brake Do not use rear brake Close the brake closing piece after stopping the machine Riding downhill Move your gravity center backward when riding ATV downhill your and grisp steering bar and drive at low speed Note The brake performance is very important Whenever possible ride your ATV straight Tur ing may cause the ATV to tip over Avoid too high speed so that you have time to deal with accident CAUTION Practise the braking skill when decending the hill look over the terrain carefully before decending and transfer your body gravity center backward Ride in low speed when decending the h
17. LIGHTS B lever is released 2 Engine stop switch lt 3 ix Check the operation of the throttle lever before 3 Start switch 2 starting the engine If it does not work smoothly check for the cause Correct the problem before riding the ATV Consult a our dealer if you can t find or solve the probem yourself 1 Throttle lever 2 Front brake lever Speed limiter The speed limiter keeps the throttle from fully opening even when the throttle lever is pushed to the maximum Screwing in the adjusting screw lim its the maximum engine power available and de creases the maximum speed of the ATV 1 Locknut 2 Adjusting screw a 12mm 047in CAUTION Do not turn the speed adjusting screw out more than 12mm Always make sure the throttle lever free play is adjuted to 3 5mm Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake Rear brake pedal and lever The brake pedal is located on the right side of the machine and the brake lever is located on the left handlebar Pull the lever toward the handlebar or tread slow the pedal to apply the rear brake Parking brake When you have to start the engine or park the machine especially on a slope use the parking brake 1 Rear brake pedal Apply the rear brake lever and push down the lock plate to apply the parking brake squeeze the rear brake lever to release the parking brake CAUTION the ATV c
18. READ THIS MANUAL CAREFULLY It contains important safety information OWNER S MANUAL ATV300 Anyone under 16 should not be allowed to operate this vehicle Our company has passed the certification of ISO9001 Brief introduction The full name of ATV is All Terrain vehicles ATV300 is newly manufactured by our indus tries group co Ltd ATV300 embodies the experience and essence of world motorcycle technology It adpots single cylinder four stroke air cooled engine newly developed by our company and employs the devices of carburetor manual clutch four speed shifting and have reverse PEI ignition pressure splash lubrication system etc which are good in performance This ATV is novel and bright in design having moved streamlined model and luxury decoration design And it meet the national standard in noise and dirt drainage especially it embodies the great power reliability endurance being an ideal transportation facility for ATV funs The correct operation and maintenance are the prerequisites at your safety riding of the ATV and also can reduce the fault of the ATV and keep its best performance So please read this manual to understand its basic operation repair and maintenance methoels he informa tion contained herein all relates to the ATV of the current design and is subject to changes by Our company according to the demands of market and users without notice if you have any questions Please consult with our motorcyc
19. and replace with a new fuse of the same specifiction If the fuse immediately blows again consult a our Group dealer Specified fuse 20A CAUTION To prevent accidental short circuting switch off the main switch when checking or replacing a fuse Replacing the headlight bulb If the headlight bulb burns out replace the bulb as following steps 1 Remove the headlight cover 2 Remove the cover and rotate the bulb holder counterclockwise and remove the defective bulb 1 Headlight 1 Cover WARNING Wait for the bulb to cool before removing it 3 Install a new bulb to the bulb holder 4 Reinstalll the cover and headlight cover Adjust the headlight beam if necessary Spark arrester cleaning Select a well ventilated area free of combustible materials and make sure the exhaust and silencer are cool 1 Remove the bolt 2 Start the engine block the end of sillencer with a dowel which will increase the speed about twenty times by momentarily producing exhaust system back pressure 3 Stop the engine and cool the exhaust pipe 4 Install the bolt and tighten it 38 WORKING SOCKET ATTENTION 1 The power connected to the socket should be less than 100 watts 2 The plug should be plugged in the plugged in the socket firmly or the wire will be burned 3 Do keep the engine running if you want to use the plug in facilities for more than 10 minutes CLEANING AND STORAGE CLEANING General speaking thorough cleaning
20. d to the outside of the curve and lean your body inside Make the engine to maintain an even speed when passing the curve This maneuver will let the tire on the inside of the curve slip slightly The turning practice should be in flat area with out any obstacles Improper operation may make your ATV to go straight If the ATV doesn t turn stop it and practise again If the riding surface is loose and slippery move your weight forward Once you have learn this technique you can turn your ATV at higher speed The sudden acceleration brake incorrect body position and too high speed will cause the ATV to slip lf the ATV slips while passing a curve and the ATV machine leans inward you should release the throttle and move your body gravity center to out side of the curve to avoid tipping over Remember ride at higher speed only after you are thoroughly familiar with the operation of your ATV Climbing slope Don t ride on slope before you are very familiar with ATV operation skill otherwise it will cause accidents Neccessary practice is required when climbing the hill move your body gravity center forward and operation manual Climb the hill according to the method in manual Climb the hill according to the method in manual Check carefuly before climbing Do not drive on slippery and loose slope Transfer your body gravity center forward and avoid abrupt acceleration and shitt Drive in low speed when climbing the hill WARNIN
21. e is designed to drive on off road Riding on asphalt road may lose control Dont ride the ATV on asphalt road including sidewalks driveways parking lots and walk streets Prohibit to drive the machine on any driveway streets or highways Know the terrain where you ride Ride carefully in complicated terrain stay alert for holes rocks or roots or roots in the terrain other wise may cause the machine to tip over When riding in an area where you might not easy to be seen such as dune and hilly land must mount a caution flag on the machine to remind other vehicles Do not ride in areas of forbidding pass Do not ride on private property Operation course CAUTION Do not shift gears without releasing the throttle Otherwise may cause damage to the engine or drive gear When slowing down or stopping release the throttle and brake gradually As you brake shift to lower gear Ensure that the engine has sufficiently slowed Improper use of the brakes or shifting can cause the tires slidding to lose the control Must make the engine to slow down fully before engaging a lower gear Turning 20 Must make the turning practice in low speed before making a turn Turn your ATV according to procedures in op eration manual Practice should be done before turn ing in high speed The turning speed should not be too high As you approach a curve slow down and begin to turn the direction rod Then put you gravity center on the footboar
22. e the shift pedal 3 Open the throttle gradually once the machine has obtained adequate speed release the throttle lever 4 Shift into second gear and release the shift pedal 5 Open the throttle gradually Follow the same procedure When shifting to the next higher gear To clecelerate When slowing down or stopping release the throttle and apply the brakes smoothly and even As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lowe gear improper use of the brakes or control can cause the tires to lose traction reducing control and 16 increasing the possibillity of an accident Engine break in There is never a more important period in the left of your machine than the period between zero and 20 hours During this period prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided after every full throttle acceleration the engine should run at lower speed for a rest so as to rid itself of the temporary build up of heat If any abnormality is found during this period consult a our dealer 1 0 10 hours Avoid continuous operaton above half throttle A allow a cooling off period of five to ten minutes after every hour of operation Vary the speed of the ma chine from time to time Do not operate it at one set throttle position 2 10 20 hours Avoid prolonged operation above 3 4throttle re volving the machine can freely throug
23. epression cccceeeseeeeeeeeeeeeeeaes 22 Crossing through shallow water 6 22 Riding over rough terrain ccecceseeeeeeeeees 23 SIPPING Sitewide ea ec Gena 23 Periodic maintenance and adjustment 24 Operation manual and tool kit 24 Content Periodic maintenance Lubrication 25 ENE Oss 27 Spark plug inspection rrrrrrrrrrrnnnrrvrnrrnnnnr 29 Air filter cleaning cccccssseeeecccseeeeeeeeeeeeees 30 Carburetor adjustment rrrrrrnnnrrvrnrnnnnnrre 31 Idle speed adjustment rrnnrrnnnnnnvrnnnnrennnnnre 31 Valve clearance adjustment rrrrrnnnnnrvnnnnnn 31 Throttle lever adjustment cccseeeeeeeeeeees 31 Front and rear brake shoe inspection 32 Front brake lever free play adjustment 32 Rear brake adjustment ccccccseeeeeeeeeeeees 33 Clutch adjustment rrrrrnnnnnrrrvrnrrrnnnnnnnnvrnnnn 34 Cable inspection and lubrication 35 Brake and shift pedal brake lever lubrication Steering vertical tube lubrication 35 Wheel removal rrnnnnnrnnnnnnvnvnnnnrnvnnnnvnnnnnnennnn 35 Wheel installation cccccececesseeeesseeeeeeeees 36 FUSE rEplACEMEMN1 cccccccccsseecseeeeseeeeeeees 37 Replacing the headlight bulb errrrnnnnnrnns 37 Spark arrester cleaning rrrrrrrrnrnnnnrrnvnnnnnnre 38 Cleaning and storage
24. er 1 lossen the locknut 2 Rotate the adjusting bolt until the throttle lever free play is 3 5mm 0 12 0 20in 3 Tighten the locknut 1 Adjusting bolt 2 Locknut a 3 5mm 0 12 0 20in 91 Front and rear brake shoe inspection A wear indicator is mounted on each brake The wear of brake shoe could be checked under the con dition of disassembling brake If the indicator reaches the wear limit line ask a our Group dealer to replace the shose as a set 1 Wear indicator 2 Wear limit 1 Wear indicator 2 Wear limit 29D Front brake lever free play adjustment Inspect the front brake shoes before adjusting the brake The front brake lever free play should be ad justed to 5 7mm 0 2 03in If the free play is incorrect adjust as following steps 1 Loosen the locknut and fully turn in the ad justing bolt of the front brake lever 2 Make sure the cable joint of the balancer is straight when applying the brake If not rotate the ad justing nut at the front hubs until the cable joint be comes straight 1 Adjusting nut front hub 3 Retate the adjusting bolt at the front brake le ver to make the free play satisfy the requirement Specified free play 5 7mm 0 2 0 3in a 5 7mm 4 Tighten the locknut After maintaining pay attention to Make sure the brakes operate smoothly and the free play meet the requirement Make sure the brakes do not skid Replacement of brake components requires profe
25. h the gears during running of engine but do not use full throttle any time 3 After break in Avoid prolonged full throttle operation change speeds occasionally Parking When parking Stop the engine and shift into neutral Turn the fuel to OFF and apply the parking brake 1 Lock plate Avoid parking on hills or other inclines If you have to park on an incline put the machine in low gear apply the parking brake and block the front and rear wheels with rocks or other object Do not park the ATV on the hills that are so steep that you could not walk up them easily 1 Appling the brakes in low gear to stop the machine 2 Stop the engine With the rear brake lever and pedal applied apply the parking brake and slowly release the rear brake pedal Accecsories Pay attention to the following points A7 choose only accessories designed for you ATV Our dealer has a variety of genuine accessories Choose a genuine accessory WARNING 1 Accessories should be rigidly and securely installed 2 Do not install an accessory where it could in terfere with your ability to control the ATV Examples include a heavy or bulky object attached to the handle bars which could make steering difficult an acces sory that limits your abitiy to move around on the seat or one that limits you view Use extra caution when riding an ATV with accessories Loading Never exceed the weight limits shown An overloded ATV can be unstable You must u
26. ill turning speed should not be too high when making a turn and keep driving straight as far as possible Crossing depression When crossing depression balance your ATV 292 with body gravity center You should be familiar with basic skills before crossing depression Avoid to lose balance to cause accident Don t make a turn on a slope before grasping turning skill totally You should be careful and cau tious if making a turn on any slope When crossing procedure Always follow proper prouclures in operation manual Avoid slope with slippery or loose surface Lean your gravity center in the slope direction Crossing through shallow water The ATV can be used to cross shallow water of maximum distance of 35cm Check your path care fully before crossing and avoid of ride where there is sharp drop off Drive slowly and carefully Pay attention that wet brakes may reduce brake ability Check your brakes after leaving water lf necesary apply them to let friction dry out the linings several times Riding over rough terrain Be careful when riding on rough terrain when riding over terrain which may damage the ATV lay your feets on the foot pedals to avoid jumping and loss of control Don t try to ride over big obstacles such as rock and tree on the road Follow the proceduces in op eration manual when riding over obstacles Slipping The ATV may lose control when driving on loose 23 and slippery surface Moving you grav
27. in back into the crankcase before checking the oil level Q 1 Maximum level mark 2 Minimum level mark b The oil level should be between maximum and minmum marks If level is low add oil to raise it to proper level D7 1 Drain plug 2 O ring 3 Compression spring 4 Oil strainer 1 Oil filter cover 2 Oil filter 3 0 ring 2 Engine oil replacement and oil fitter element cleaning a Place the machine in a flat suface Warm up the engine for several minutes and turn off place a container under the engine Remove the dipstick and open the drain plug to drain the oil b Remove the oil fiter cover and oil filter clean the oil strainer and oil filter with solvent c Inspect the O ring and replace if damaged d Reinstall the oil filter O ring and oil filter cover Replace the oil strainer compression spring O ring and drain pulg Then tighten the drain plug and filter cover bolts to the specified torque Tightening torque Drain pulg engine 43Nm 4 3m kg Filer cover bolt 10Nm 1 0m kg e Add oil to the engine with oil and install the dipstick CAUTION Be sure no foreign material enters the crankcase f Warm up the engine for several minutes at idle soeed Check for oil leakage when warming up CAUTION If oil leakage is found turn off the engine promptly and check for the cause Recommended oil see page 11 Oil quantity Periodic oil change 1 5L 1 3mp qt With oil filter replacement 1 6L 1 4mp at
28. ity center for ward is helpful to control the slipping of front wheels when the rear wheel begin to slip steer direction properly Apply the brake only until you have stopped the slipping Practise safely control slipping at low speed on very slippery surefaces such as ice drive slowly to avoid loss of control The above introduction is only for reference Read it carefully and act according to circumstances PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safety and most efficient condition The points of machine inspection adjustment and lubrication are detailed in following NOTE Turn off the engine when maintaining unless specified Have a our dealer perform service if you are not familiar with maintenance Operation manual and tool kit You are recommended to put this operation manual in the vinyl bag and lay it under the seat as shown Put the tool kit and low pressure tire gauge in the storage case The maintaining information included in this manual is provided you with the necessary information for completing preventive maintenance and minor repairs by yourself he tools provided in the tool kit are suffi cient for this purpose except a torque wrench necesary to tighten nuts and bolts NOTE If you do not have a required torque wrench during maintenance take you machine to a our dealer to check the torque settings and adjust them as necessary 24 PERIODIC
29. le dealer We are welcome for you precious advice and suggestions Our company has established many service centers stations points with spe cially tranined technical personnel in operation and maintenance please contact with our mo torcycle dealer and service center stations points Our company consisitantly adheres to the principle of quality first users upmost reputation foremost and be ready to provide you with high quality service IMPORTANT INFORMATION FOR OPERATION WARNING Injury or death could be result from failure to follow WARNING instruc tions when you are operating inspecting or repairing the ATV CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the ATV NOTE ANOTE provides information can make your operation in the ATV easier or clearer Safety information ccccccccesssssseeeeeeeeeeeees Description and machine identification Control FUNCTIONS cccccececcecececcecececeeces Main switch NA CATO MOMUS merene en Handlebar switches cccccececcecececeeneceeeees Start Sveen LIGNE SWINCI OS wi toveddisdunisaivnindadtee ean Throttle lever Speed limiter Front brake lever cccccccccecececececececcecececs Rear brake pedal and lever rrrrrrnnnrennnnrre Parking brake Shift pedal Drive select l VEr ccccccecececeecececcscececeacs Recoil statrer Content Fueltank CAP aksene
30. of your ATV Will improve its runing performance and pro long the service life of many components 1 Before cleaning the ATV a Block off the exhaust pipe with plastic bag or strong rubber band to prevent water entry b Make sure the spark plug and all filler caps are properly installed 2 If the engine case is excessively dirty wash 39 with degreaser Do not use degreaser for wheel axles 3 Rinse the dirt and remove oil dirt on the soft hose CAUTION Excessive water pressure may cause water seepage and deterioation of wheel bearings brakes transmission seals and electrical equipment 4 When rinsing dirty material for many times use warm water and mild detergent type soap Use old toothbrush or bottle brush to wash hard to get at places 5 After cleaning ATV with clean water immedi ately dry all surfaces with a chamois clean towel or soft absorbent cloth 6 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 7 Apply automotive type wax to all chrome plated surfaces Avoid use combination cleaner waxes Af ter using abrasives to protect scratched surface let the engine idle for several minutes After washing the brakes let engine brake sev eral times at slow speeds to dry the linings B Storage Long term storage 60 days or more of your ATV will require some protective procedures to prevent ATV from damage After thoroughly cleaning the ATV adopt the following protective measures
31. ould start moving unexpectedly if the parking brake is out of function before starting the engine his could cause loss of control or a collision The barke could overheat if you ride the ATV without releasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely 1 Lock plate HOW TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure the parking brake have been released before you begin to ride Shift pedal This machine is equipped with a constant mesh 4 speed transmission The shift pedal is located on the left side of the engine Reverse is at the bottom position 4 3 2 1 N R 1 Shift pedal N Neutral The drive select lever is used for driving the ma chine either forward or in reverse Refer to page for drive select lever operation CAUTION Don t start the engine in non neutral or without setting the parking brake system Put the transmission in neutral and set the park ing brake before starting the engine Fuel tank cap Remove the fuel tank cap by turning it counter clockwise QD 1 Fuel tank cap Fuel cock RES The fuel cock supplies fuel from the fuel tank to This indicates reserve If you run out of fuel while the carburetor riding turn the lever to this position After refuelling OFF return the fuel cock lever to the ON position If the lever is in this position fuel will not flo
32. rakes may have reduced stopping ability Test your brakes after wiping water away If necessary apply them several times to let fricting dry out the linings e Always be sure there are no obstacles or people behind you when operating in reverse When it is safe to procceed in reverse go slowly Always use the size and type tires specified in this manual Always maintain proper tire procedure as described in this manual e Never modify an ATV through improper installation or use of accessories e Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached e Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer IV Allow greater distance for braking e Improper handing of gasoline can cause fire and can cause injuries and deaths and other serious accident So do not refuel right after the engine has been running and is still every hot Never refuel while smoking or while in the vicinity of sparks open flames or other sources of ignition when transporting the machine in another vehicle be sure it is kept upright and that the fuel cock is in the OFF position otherwise fuel may leak out of the carburetor or fuel tank e Starting or running the engine in a closed area will cause the breakdown And exhaust fumes are poisonousus and may cause loss of consciousness and death within a short time Always operate your machine in an area with adequate ventilation DES
33. s ATV e Never operate at speeds too fast always drive at low speed on dusty surface eAlways inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this maunal e Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation e Never operate on excessively rough slippery or loose terrain unless you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain e Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster soeeds Do not turn at excessive speed e Never drive the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills e Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before starting up any 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 eAlways follow proper procedures for going down hills and for braking on hills as described in this manual check the terrain carefully before starting down any hill Shift your weight backward Never go down a hill at high speed
34. se common sense and good judge ment when carring cargo or towing a trailer keep the following points in mind Maximum loading limit Vehicle Loading limit 150kg Make sure the load does not interfere with con trols or your sighting Ride more slowly than you would with a load The more weight you carry the slower you should go Although conditions is different it is not allowed to exceed 2nd gear whenever you are carrying heavier loads or when towing a trailer Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid riding on hills and rough road surface And choose terrain carefully Extra weight will affects the stability and operation of the ATV This machine could be used to carry cargo and passengers is prohibited 18 OPERATION 1 Get training if you are unexperienced Beginners should be trained at the guide of pro fessional person Drive with this ATV with low speeds first to familiar with its performance even if you are an experienced rider do not attemp to operate at maxi mum performace until you are totally familiar with ATV s performance 2 Dress Always wear a motorcycle helment when riding Also wear the following protective tools eye protection goggles or dust proof shield gloves boots long sleeved shirt or jacket pants 3 Do not operate after drinking alchohol or drugs containing sleeping pill composition because op erator would be
35. ssional knowledge These procedures should be done by our Group dealer Rear brake adjustment 1 Brake pedal a Fully loosen the adjusting nut on the brake cable b Rotate the adjusting nut on the brake rod untill free play is 20 30mm 1 Brake cable adjusting nut 2 Brake rod adjusting nut 33 20 30mm 2 Brake lever a Loosen the locknut and fully turn in the ad justing nut on the handlebar b Turn in the adjusting nut on brake cable to get a gap of 0 1mm between the lever and pin of pivot 34 After maintaining pay attention to Make sure the brakes operate smoothly and the free play is correct Make sure the brakes do not skid Replacement of brake components requires professional knowledge These procedures should be done by our Group dealer Clutch adjustment 1 Loosen the lock nut 2 Slowly rotate the adjusting bolt counterclock wise until resistance is felt then rotate it by1 8 turn clockwise i e 45 1 Locknut 2 Adjusting nut a 5 7mm cable inspection and lubrication The damage of outer covering of control cable can cause corrosion fray or kink of cable Operation of cables could be strictly executed which could cause an accident or injury Inspect cable frequently and replace damaged cables Lubricate the inner cables and the cable joints If the cables do not operate smoothly ask a our Group dealer to replace them Recommended lubricant Wheel removal SAE 10W30 Lubricant
36. start ergine Starting a warm engine The throttle should be opened slightly when starting a warm engine Prewarming To get maximum engine service life orewarm the engine before startting off Never accelerate forcefully with a cold engine 14 Drive select lever operation and reverse driving CAUTION Before shifting stop the machine and return the throttle lever to its closed position Otherwise the trans mission may be damaged NOTE When in reverse the reverse indicator light should be on lf the light does not come on ask a our dealer to inspect the machine 5 Check for people or obstacles behind you then release the rear brake pedal 6 Open the throttle lever gradually and continue to watch to the rear while backing WARNING When shifting into reverse make sure there are no obstacles or people behind you when it is safe to proceed go slowly Shifting This machine has a 4 speed forward and 1 speed reverse transmission with manual clutch 1 Shift pedal 15 CAUTION Do not coast for long periods with the engine off and do not tow the machine a long distance Even when gears are in neutral the transmission is only Properly lubricated when the engine is running Inadequate lubrication may damage the trarsmission To start and accelerate 1 Release the throttle lever CAUTION Always close the throttle while shifting gears Otherwise the engine and drive train may be damaged 2 Shift into first gear and releas
37. sures to the condition following specifications 1 Low pressure tire gauge 43 Recommended os Minimum Maiximum pressure 20Kpa 17Kpa 23Kpa 0 20kgf cm 0 17kgf cm 0 23kgf cm 25Kpa 22Kpa 23Kpa 0 25kgf cm 0 22kgf cm 0 28kgf cm Tire wear limit When the tire groove decreases to 3mm due to wear a 3mm 0 12in OPERATION WARNING Never operate ATV until you are familiar with all controls Read the operation Manual carefully If there is a controls or function you do not understand ask your our dealer WARNING Never ride the ATV in cold weather always make sure all control cables work smoothly before you begin ridding Please read the engine brake in section before you operate the engine at first time Starting a cold engine 1 set the parking brake 2 Turn the fuel lock to ON and the engine stop switch to t 4 Shift the transmission into neutral WARNING The engine can be started in any gear if the rear brake lever is applier However it is recommended to shift into neutral before starting the engine 5 use the starter choke in reference to the figure NOTE If the engine fails to start release the start switch then push the start switch again pause a several secords before the next attempt Each cranking should be as short as possible to preserve battery energy Do not crank the engine more than 10 secords for each starting If the battery is discharged pull the recoil starer to
38. ver if damaged replace it 9 reinstall the foam cover to the air filter element 10 Reinstall the removed air filter unit and parts removed CAUTION The carburetor was set at the our factory after many tests If the settings are disturbed by somenone without sufficient technical knowledge poor engine performance and damage may result CAUTION Never run the engine with the air filter element removed This will let unfiltered air enter causing rapid wear and possible damage of engine Additionally operation without the filter element will weak the performance of carburetor and cause overheating of engine Carburetor adjustment The idle speed may be performed by customer as a part of the routine maintenance Idle speed adjustment 1 Start the engine and warm it up for a few min utes at approximately 1 000 to 2 000 r min increase the speed of engine to 4000 to 5000r min 2 Set the specified idle speed by adjusting the throttle adjusting screw Turn the screw into increase engine speed and out to decrease engine speed Specified idle speed 1450 1550 r min 1 Throttle adjusting screw Valve clearance adjustment Incorrect valve clearance will result in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly but the adjustment should be done by a professional mainterance technician Throttle lever adjustment NOTE Adjust the engine idle speed before adjusting the throttle lev
39. w Always turn the lever to this position when the en gine is not running Seat To remove the seat pull the seat lock lever up ward and pull up the seat at the rear ON To install the seat insert the lobes on the frame If the lever is in this position fuel flows to the and push down the seat at the rear you should pay carburetor Normal riding is done with the lever in this position attention to make sure that the seat is securely fitted Re Rear shock absorber The spring preload can be adjusted to suit the rider s weight and riding conditions Spring preload adjustment To increase the spring preload turn the adjuster in direction O To decrease the spring preload rurn the adjuster in direction Standard position A Minimum Soft E Maxinum Hard PRE OPERATION CHECKS Before using this machine check the following points ROUTINE vere Brakes nec operation condition and free play eS it necessary Me ia Check oil level ngine ol Fill with oil if necessery Check fuel level Fuel tank Fill with fuel if necessary Check for leakage Wheels and tires Check tire pressure wear and damage Fittings and fasrteners Check all fittings and fasteners Check for proper operation Check the voltage the ATV inspected by a our deatler Throttle Check for proper throttle cable operation NN Inspect the ATV each time you use it to make sure the ATV is in safety operationg condition 1
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