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Kolpin 180cc Owners Manual

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1. ATV 180 Owner s Manual FOREWORD Thank you for choosing the Kolpin Powersports 180 as your all terrain vehicle ATV This user manual was prepared with the comfort and safety of the rider in mind It provides all the details necessary to safely operate and maintain your vehicle Carefully read the manual before operating your Kolpin Powersports 180cc If you have any questions regarding your ATV contact your local Kolpin Powersports dealer for assistance Keep the following information in mind while operating the ATV PROTECT YOUR SPORT Know all local and state riding laws Respect your vehicle Respect the environment and You will gain the respect of others You should strictly follow the maintenance program as outlined in this manual see page 95 This preventive maintenance program is designed to ensure that your ATV is inspected on a regular schedule that will keep it operating at peak performance Illustrations and photos in this manual are general representations of parts having similar functions Your model may differ so be sure to contact your dealer with questions TABLE OF CONTENTS SECTION Introductory Safety Message RIDER S SECTION Know Your Machine Overview Photo Engine Stop Switch Engine Start Switch Throttle Lever Kick Starter Brake Levers Ignition Switch Lights Pre Ride Check RIDING RULES FEATURES amp OPERATION Ignition Switch Engine Stop Switch Engine Start Lever Engine Throttle Horn
2. Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly press the throttle lever 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 5 MAKING TURNS Practice making turns at slow speeds Kolpin Powersports_ATVs are equipped with a solid rear axle that drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel and the inside tire must slip traction slightly during the turn To turn steer in the direction of the turn lean 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 rear wheels allowing the turn to be made smoothly AWARNING Avoid turning at sharp angles Tipover and severe injury may result 53 RIDING amp OPERATING INSTRUCTIONS cont 6 HAULING CARGO The Kolpin Powersports 180 was designed to haul loads within a limited weight range Never exceed the weight capacities listed in the specifications table on page 124 of this Owner s Manual Cargo weight should be evenly distributed on the front rack and 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain
3. obtaining insurance or whenever replacement parts are required If your vehicle is stolen these numbers are essential to the recovery and identification of your ATV 95 VEHICLE MAINTENANCE cont PERIODIC MAINTENANCE SCHEDULE e Periodic maintenance will help keep your ATV in the safest most reliable condition Inspection adjustment and lubrication intervals of important components are explained in the chart on the following pages e Maintenance intervals are based upon average riding conditions and an average ATV speed of approximately 10 mph ATVs subjected to severe use such as operation in wet dusty or salt water areas should be inspected and serviced more frequently If you are not familiar with safe service and adjustment procedures have your local Kolpin Powersports dealer perform these operations e Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine parts available from your local Kolpin Powersports dealer A CAUTION Due to the nature of the adjustments marked with a Ml in the following maintenance table it is recommended that an authorized overland dealer perform service 96 VEHICLE MAINTENANCE cont Adjustments marked with gt must be performed more often if ATV is under severe use such as dirty or wet conditions ara ITEM WHEN REMARKS vee a ee Pre ride Pre ride Check Operation See pg 108 Frame nuts b
4. 87764 173 000 66 e Adjust chain as figure shown e Inaccurate adjustment could cause damage to the chain and adjuster ADJUST CHAIN AS FIGURE SHOWN INACCURATE ADJUSTMENT WOULD CAUSE THE DAMAGE OF CHAIN AND ADJUSTER SCREW 87758 156 000 OPERATION WARNING DECALS e TO AVOID ACCIDENT OR SEVERE cont INJURY NEVER EXCEED 8 MPH 13 KM WHILE IN REVERSE GEAR e Do not operate this ATV on HILLS with a grad steeper than 25 degrees To prevent flipover when going up or down hilly terrain use brakes and throttle gradually e Operating in REVERSE even at low speeds can be dangerous as steering becomes difficult TO AVOID ACCIDENT OR SEVERE INJURY Avoid sudden braking or sharp turns to NEVER EXCEED 8 MPH 13KM WHILE IN REVERSE GEAR prevent flipover e When parking on grades leave the shifter in Forward as the PARKING BRAKE may relax when engaged for longer than 15 minutes 87754 156 000 e Do not operate this ATV on HILLS with a grade steeper than 25 degrees_ 25 To prevent flipover when going up or down hilly terrain use brakes and throttle gradually e Operating in REVERSE even at low speeds can be dangerous as steering becomes difficult Avoid sudden braking or sharp turns to prevent flipover e When parking on any grades leave the shifter in Forward as the PARKING BRAKE may relax when engaged for longer than 15 minutes 87749 173 000 67 OPERATION WARNING DECALS cont Shift p
5. Brakes Front Rear Auxiliary Parking Free Play Transmission Gear Shift Lever CVT System Engine Air Filter Engine Fuel amp Oil Systems PAGE SECTION 5 11 FEATURES amp OPERATION cont Seat Exhaust Pipe Muffler Heat Shields Battery Tool Set Kick Starter Adjusting the Throttle Cable Spark Plugs Drive Chain Gear Assembly Suspension Braking Light Section Table of Contents Riding Gear Starting the Engine ATV Break in Period Riding Making Turns Hauling Cargo Riding on Slippery Surfaces Traveling Uphill TABLE OF CONTENTS cont SECTION PAGE SECTION PAGE RIDING amp OPERATION 47 62 VEHICLE MAINTENANCE cont 95 126 INSTRUCTIONS cont Side Hill Riding 58 Brake Adjustment 108 110 Traveling Downhill 59 Throttle Cable Adjustment 111 Turning Around on a Hill 60 Spark Plug 112 Crossing Streams 61 ATV Storage long term 114 Trail Obstacles 62 Transmission Oil Change 115 Parking 62 Engine Oil Change 116 OPERATION WARNING DECALS amp 63 94 Tire Tire Pressure Wheel Installation 117 WARNINGS PRINTED IN MANUAL Operation Warning Decals 63 68 Drive Chain Inspection amp Adjustment 119 Operation Warnings Printed in Manual 69 94 Brake Light Lamp Replacement 121 VEHICLE MAINTENANCE 95 126 Cleaning your ATV 122 Vehicle Identification Numbers VIN 95 Transporting your ATV 123 Periodic Maintenance Schedule 96 99 Carburetor Adjustment 123 Lubrication Recommendations 100 Kolpin Powersport
6. Button and wait five seconds then press the Starter Button for another five seconds Repeat this procedure until engine starts If the engine is cold engage the manual choke After the engine starts vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Do not make any adjustments to the carburetor until the engine has warmed up at least five 5 minutes A CAUTION Don t press the Starter Button when the engine is running 51 RIDING amp OPERATING INSTRUCTIONS cont 3 ATV BREAK IN PERIOD The break in period for your Kolpin Powersports ATV is the time it takes for the ATV to use up the first full tank of gasoline This break in period 1s vital to the efficiency of performance and length of life of the engine A CAUTION Do not operate at full throttle or high speeds for extended periods during the first 3 hours of riding Excessive heat can build up and cause damage to close fitted engine parts 1 Drive slowly at first Operate in an open area to familiarize yourself with the ATV s operation and handling 2 Vary the throttle position 3 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined on the pre ride checklist found on page 18 32 RIDING amp OPERATING INSTRUCTIONS cont 4 RIDING 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 3
7. carefully avoid sudden movements maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes NOTE If the ATV is run through water it is critical that it is serviced as outlined in the maintenance chart beginning on page 97 of this manual These areas need special attention engine oil gear lube and all grease fittings 61 RIDING amp OPERATING INSTRUCTIONS cont 12 TRAIL OBSTACLES KEEP ALERT Look ahead and learn to read the trail as you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches AWARNING Not all obstacles are visible Travel with caution on trails Severe injury or death can result if your ATV comes in contact with hidden obstacles 13 PARKING 1 Turn the ignition key to the OFF position 2 Set the parking brake NOTE Avoid parking on an incline If you must park on an incline always block the rear wheels on the downhill side with a rock or other heavy object that is large enough to prevent the ATV from rolling back 62 OPERATION WARNING DECALS AND WARNINGS PRINTED IN MANUAL UNDERSTANDING WARNINGS Failure to follow the WARNINGS in this manual can result in SEVERE INJURY OR DEATH SAFETY ALERTS WARNINGS identify special instructions or procedures which if not correctly followed could result in personal injury or loss of life Read all WARNINGS in this
8. engine air filter should be changed every 100 hours of operation or annually service more often if run in dusty or wet conditions The air filter is located under the rear body It 1s recommended that you have your local dealer perform this procedure l E aA AE a E a Remove the seat battery bolts fender bolts holding rear body to floorboards and frame unplug taillight and remove rear body from frame to access the engine air filter Loosen the screws on the air filter cover and remove cover screen and air filter Clean the air filter screen with mild sudsy water rinse and allow to air dry Install the NEW air filter and replace the air filter screen Re assemble the air filter body and cover reattach to the carburetor with screw Re attach the rear body battery fender bolts seat and plug in taillight Check to make sure the taillight and brake light work Air Filter Air Filter Screen 105 VEHICLE MAINTENANCE cont THROTTLE STOP SYSTEM The Adjustable Throttle Stop System throttle limiting screw allows you to limit the speed of the vehicle according to the rider s skill and experience The throttle stop system controls how far the throttle opens To adjust loosen the jam nut turn the screw inward to reduce speed and outward to increase speed Tighten the jam nut after adjusting Jam Nut Adjustment Screw 106 VEHICLE MAINTENANCE cont STEERING INSPECTION The steering assembly of the A
9. is running the key cannot be taken out e You should use this key to stop the engine by turning it to the OFF position e DO NOT turn the ignition switch to OFF while riding Ignition switch should not be turned off unless the vehicle is completely stopped Ignition Switch 21 FEATURES AND OPERATION cont 2 ENGINE STOP SWITCH The B will not start or run when the Engine Stop Switch is in Engine Stop Switch either position It provides the operator with a quick way to shutdown the engine in case of stuck throttle or other emergency e When you push the Engine Stop Switch left or right to position the engine cuts off 3 ENGINE START LEVER e Set the parking brake See page 27 Remember to release the park brake before driving forward e Turn the ignition key to the ON position e Make sure the Engine Stop Switch is in the position Engine Start Lever e Push the grey Engine Start button to 2 A CAUTION Engine damage could occur if the ATV is driven without the park brake released 22 FEATURES AND OPERATION cont 4 ENGINE THROTTLE AWARNING Do not start or operate an ATV with a sticky or improperly operating throttle A sticky or improperly operating throttle could cause an accident resulting in severe injury or death Always contact your dealer for service repairs whenever throttle problems arise Failure to check or maintain proper operation of the throttle system can result in
10. kick start push you heel downward to crank the engine Kick Starter e Once the engine is running fold the kick start lever back into place 42 FEATURES AND OPERATION cont Tighten Loosen 16 ADJUSTING THE THROTTLE CABLE e Check to be sure the throttle lever moves smoothly and returns on its own if it does not then adjust the free play of throttle To adjust free ga 9 play loosen the nut and adjust to the proper position The normal free play of throttle is g g inch 5 mm 10 mm To measure free play measure the rotation of the throttle lever from rest position to the position the throttle is affected e Make sure the throttle doesn t stick e The lever should come right back to where it was before you pushed it If it comes back slowly or stays open you have a sticky throttle e If you have a sticky throttle do NOT start the engine You could get Throttle Adjuster hurt Have an overland dealer fix the throttle 17 SPARK PLUG e Foul black deposit on the spark plug electrodes and or improper gap size may result in spark plug misfire The proper gap for the electrode is 024 028 inch 0 6 0 7 mm The standard type of spark plug is NGK C7HSA or NGK CR7HSA Walis 43 FEATURES AND OPERATION cont 18 DRIVE CHAIN Chain e After periods of extended operation the drive chain will stretch and loosen The normal chain slack should be gt 1 inch 13 25 mm Check the drive chain and a
11. manual carefully ALWAYS follow their instructions NOTE Warning decals have been placed on the vehicle for the protection of the operator s Read and follow the instructions on each decal carefully If any decal becomes illegible or comes off contact your Kolpin Powersports dealer for replacement The part number is printed on the decal 63 OPERATION WARNING DECALS pmproper ATV use can result in SEVERE INJURY OR DEATH Always use an approved helmet and protective gear Never use with drugs or alcohol Never use on public roads Never carry passengers NEVER OPERATE on public roads a collision can occur e with a passenger passengers affect balance and steering and increase risk of losing control e at speeds too fast for your skills or the conditions e without proper training or instruction ALWAYS e avoid paved surfaces pavement may seriously affect handling and control e use proper riding techniques to avoid vehicle overturns on hills rough terrain and in turns LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 64 A one USE NEVER USE NEVER CARRY ITH DRUGS ON PUBLIC PASSENGERS oR ALCOHOL ROADS HELMET AND PROTECTIVE GEAR NEVER operate on public roads a collision can occur with a passenger passengers affect balance and steering and increase risk of losing control at speeds too fast for your skills or the conditions without proper
12. more information on how to use the kick starter Brake Levers Squeeze these levers towards the handle bar to slow down or stop your ATV The right hand lever controls the front brakes The left hand lever or the auxiliary foot pedal controls the rear brake To slow down or stop squeeze both brake handles at the same time A CAUTION Always apply both brakes at the same time or you may lose control of your ATV resulting in serious injury or death Always take your thumb off the throttle control when you pull the brake lever 16 Rear Brake Lever Front Brake Lever Auxiliary Foot Pedal RIDER S SECTION KNOW YOUR MACHINE cont 8 Ignition Switch e The key must be turned to the ON position before you push the starter button or use kick starter e You should use this key to turn the engine OFF Headlight Position 9 Lights Your ATV is equipped with high and low beam headlights The light will not function unless the engine is running e Turn the key to the headlight position to turn on headlights e Select High Low beam by pressing toggle switch on left handlebar 2 3 Let s review the two 2 ways to stop your ATV High Low Beams 1 Sliding the Engine Stop Switch left or right to the di position 2 Turning the ignition key to OFF RIDER S SECTION PRE RIDE CHECK Before the ATV is started you must always perform a PRE RIDE CHECK AWARNING This ATV must be inspected eac
13. premature wear and drive chain failure A CAUTION The adjuster stud must be held secure when tightening jam nuts or the stud may break 120 VEHICLE MAINTENANCE cont DRIVE CHAIN INSPECTION AND ADJUSTMENT cont The normal chain slack should be kept between Ye Tin 13 mm 25 mm A CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result Adjustment Procedure 1 Loosen 4 rear housing mount bolts 2 Tighten chain adjust to reduce slack to recommended setting y Lin 13 mm 25 mm 3 Tighten jam nuts on chain adjuster 4 Tighten the four rear housing mount bolts Chain Adjuster 121 VEHICLE MAINTENANCE cont BRAKELIGHT LAMP REPLACEMENT If the brake light does not work the bulb may need to be replaced 1 Krom the rear of the brake light remove two screws holding lens cover in place and remove lens cover 2 Remove bulb and replace it with the recommended bulb 1157 or 12V P21 S5W 3 Test the brake light to see if it is working 4 Reinstall the lens cover removed in Step 1 122 VEHICLE MAINTENANCE cont CLEANING YOUR ATV 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 Washing Do not use a high pressure type car wash system Many exp
14. resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during operation It is not for carrying passengers val OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN z The ATV tires are designed for off road use Paved surfaces may seriously affect handing and control of the ATV and may cause loss of control of the vehicle resulting in severe injury or death HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever possible If you must ride on a paved surface go slowly and do not make sudden turns or stops 72 OPERATION WARNINGS cont WARNING POTENTIAL HAZARD Ne Operating this ATV on public streets roads Se SA or highways Sa WHAT CAN HAPPEN 7Y You can collide with another vehicle resulting in J T severe injury or death HOW TO AVOID HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways 73 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Operating this ATV Without wearing an approved helmet eye protection And protective clothing WHAT CAN HAPPEN Operating without an Approved helmet increases your chances
15. the oil drain completely 4 Clean and inspect oil drain plug gasket oil cap sealing O ring and oil filter screen for damager Replace if damaged Install the drain plug and torque to 12 ft Ibs Fill with API classification SF SG SAE 15W 40 Oil 28 32 oz Start engine and check for leaks Shut off engine and check the oil level with the dipstick Do not screw it in when making this check Add oil if necessary to fill up to the safe range indicated on the dipstick ADU Oil Drain Bolt 116 VEHICLE MAINTENANCE cont BRAKE OIL ENSURE Check the brake oil tank If the brake oil to reduce under the limit You must to fill the brake oil until upper limit Be careful the brake oil when to topple into the oil tank to avoid the oil to sprinkle Under limit 117 VEHICLE MAINTENANCE cont TIRE TIRE PRESSURE TIRE INSTALLATION AWARNING ATV tires can become distorted by over inflation Ballooning stretching of rubber and fiber cords Once a tire has been over inflated it will not return to its original size Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death Follow the safeguards listed below to prevent this type of situation Important Safeguards Maintain proper tire pressure according to the chart on the following page Always use orig
16. to be rebuilt by your Kolpin Powersports dealer e Engine repair cost resulting from damage caused by running the engine with low oil levels is not covered under warranty 35 FEATURES AND OPERATION cont 12 SEAT e To remove the seat reach under the rear of the cab and pull back on the seat latch e To replace the seat set it in place and push down on the rear of the Seat e Always make sure the seat is locked in place before riding A CAUTION Do not attempt to release the seat latch unless the machine has not been run for at least an hour The exhaust gets very hot when the machine is run and can Seat Latch Hook cause Serious burns Seat Latch e The battery and tool set are located under the seat attached to the rear fender by a rubber strap 36 FEATURES amp OPERATION cont 13 EXHAUST PIPE MUFFLER HEAT SHIELDS Heat Shields A CAUTION The exhaust pipe muffler and heat shields are very hot after operation DO NOT touch them until they have cooled A CAUTION The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time 37 14 BATTERY TOOL SET The battery and tool set are located under the seat attached to the rear fender by a rubber strap Tool Set The tool set includes a spark plug tool a scre
17. to reduce the chance of skidding or sliding out of control 87 OPERATION WARNINGS cont POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Never attempt to ride over large obstacles such as large rocks or fallen trees If you cannot avoid obstacles use extreme caution when riding over obstacles 88 OPERATION WARNINGS cont POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator break through the ice HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water 89 OPERATION WARNINGS cont A WARNING Operating this ATV through deep or fast following water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth go slowly balance your weight carefully avoiding sudden movement maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remember that wet brakes have reduced stopping ability Test your brakes after leavi
18. training or instruction ALWAYS avoid paved surfaces pavement may seriously affect handling and control use proper riding techniques to avoid vehicle overturms on hills and rough terrain and in turns LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 87752 131 00E OPERATION WARNING DECALS cont NO ONE UNDER 16 year of age Operation of this ATV by anyone under the age of 16 increases the risk of severe injury or death Never permit children under age 16 to operate this ATV Operation of this ATV by anyone under the age of 16 increases the risk of severe injury of death Never permit children under age 16 to operate this ATV 87751 173 000 65 NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 87753 131 00E OPERATION WARNING DECALS cont Improper tire pressure or overloading can cause loss of control resulting in SEVERE INJURY or DEATH MAXIMUM WEIGHT CAPACITY Gross vehicle weight including machine driver and cargo is 680 Ibs TIRE PRESSURE PSI FRONT 5 REAR 3 Improper tire pressure or overloading can cause loss of control resulting in SEVERE INJURY or DEATH e MAXIMUM WEIGHT CAPACITY Gross vehicle weight including machine driver and cargo is 680 Ibs e TIRE PRESSURE PSI FRONT 5 REAR 3
19. with clean rags e Coat the terminals with dielectric grease or petroleum jelly e Becareful not to allow cleaning solution or tap water into the battery 40 FEATURES amp OPERATION cont 14 BATTERY TOOL SET cont BATTERY cont Battery Fluid Battery Removal Your Kolpin Powersports ATV is equipped with an Absorbed Glass Matte AGM no maintenance battery e DO NOT remove battery top e DO NOT attempt to add water Battery Removal e Disconnect hold down straps holding the electrical box and battery in position e Disconnect the Black cable first e Disconnect the Red cable next e Lift the battery out of the ATV Battery is sealed and should not leak NOTE If the ATV will not be operated for 3 months or more the Battery battery should be removed charged to proper level and stored in a cool dry place Before reusing take the battery to your dealer for testing and recharging 4 FEATURES amp OPERATION cont 15 KICK STARTER If the battery is too weak to start the engine you can start the engine with the kick starter The kick starter will allow the ATV to operate until repairs can be made e Be certain the ATV is on a level surface and the parking brake is set See page 27 e Fold out the kick start lever located on the left hand side of the ATV e Turn the S key to ON and make sure the Engine Stop Switch is in the position e Placing your left foot on the
20. 1 3 ATV Break in Period 52 4 Riding 53 5 Making Turns 53 6 Hauling Cargo 54 7 Riding on Slippery Surfaces 56 8 Traveling Uphill 57 9 Side Hill Riding 58 10 Traveling Downhill 59 11 Turning Around on a Hill 60 12 Crossing Streams 61 13 Trail Obstacles 62 14 Parking 62 47 RIDING amp OPERATING INSTRUCTIONS cont gt gt PAY ATTENTION WHEN YOU SEE THE SYMBOLS BELOW 44 A CAUTION This is the safety alert symbol When you see this symbol in this manual be alert to the potential for personal injury AWARNING This symbol indicates a potential hazard that could result in severe injury or death When you see this symbol on your machine or in this manual it means PAY ATTENTION If you don t you could get hurt very badly or even killed Your safety is involved 48 RIDING amp OPERATING INSTRUCTIONS cont AWARNING Never run an engine in an enclosed area Carbon monoxide exhaust gas is poisonous and can cause severe injury or death Always start engines outdoors A CAUTION Engine damage could result if you do not allow your ATV adequate warm up time before operating A CAUTION Remember to perform the Pre ride Check before riding ATV 49 RIDING amp OPERATING INSTRUCTIONS cont 1 RIDING GEAR ATV riding requires special protective clothing and equipment to help reduce chances of injury Helmet Your helmet is the most important piece of protective gear for safe riding A hel
21. Ee SAE 85 W 140 See page 115 Change annually or at 200 hrs Drive Chain SAE 85W 140 or chain Lubricate as As required lube often as required Before each ride in wet conditions Front A Arm Grease Locate fittings Every 3 mos or 50 hrs and grease 100 VEHICLE MAINTENANCE cont PERIODIC MAINTENANCE RECORD Use the following chart to record periodic maintenance work Interval Performed or Person FirstShrs FT 101 VEHICLE MAINTENANCE cont PERIODIC MAINTENANCE RECORD Maintenance Servicing Date Servicing Dealer Remarks Interval Performed or Person 102 VEHICLE MAINTENANCE cont The following items should be checked occasionally for tightness AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Front Spindle Nuts 42 45 ft lbs 58 62 Nm Rear Spindle Nuts 78 81 ft Ibs 108 112 Nm NOTE an authorized dealer must service all nuts that have a cotter pin installed FRONT WHEEL HUB TIGHTENING Front wheel bearing tightness and spindle nut retention are critical component operations Your authorized Kolpin Powersports dealer must perform Service work 103 VEHICLE MAINTENANCE cont REAR SPRING ADJUSTMENT The rear shock absorber spring is adjusted by rotating the adjuster clockwise to one of five 5 positions to increase spring rate or counter clockwise to decrease spring rate Rear Shock Absorber Spring Adjuster 104 VEHICLE MAINTENANCE cont ENGINE AIR FILTER The
22. TV should be checked periodically for loose nuts and bolts Before riding the ATV have your dealer tighten any loose nuts and bolts you find CAMBER AND CASTER Not adjustable See your dealer TOE ALIGNMENT SEE YOUR LOCAL Kolpin Powersports dealer AWARNING Do not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact your local dealer They have the training and tools to make adjustments 107 VEHICLE MAINTENANCE cont BRAKE ADJUSTMENT Front Brakes Each front brake has a cable connected to the right hand brake lever Check the front brakes by turning the adjustment knob until free play is in acceptable range The acceptable range for the front brake levers free play is 3 3 34 in 10 20 mm Front Brake Adjustment Sec Knobs Use the adjustment knobs to change free play Check free play by measuring the travel of the free end of the front brake levers from their rest position to the position where you first feel tension on the cables The free play should fall between g 34 in 10 mm 20 mm 108 VEHICLE MAINTENANCE cont BRAKE ADJUSTMENT cont Rear Brakes The rear brake is operated by using the left hand brake lever The adjustment nut for the rear brake 1s beneath the brake light at the back of the ATV To adjust free play turn the adjustment nut until you reach the proper free play setting Check free play by measuring t
23. ation These changes include 1 Carburetor re jetting to compensate for altitude and or temperature changes 2 Transmission converter modification to adjust for loss of horsepower in high altitude operation 3 On models with air screw adjustments can be made to compensate for temperature and or altitude changes NOTE Contact your dealer for all altitude adjustments They have the training and special tools necessary to perform all modifications for you 124 Overland ATV 180 Specifications D rum MAX LOAD 319 Ibs 145 kg FRONT RACK MAX LOAD 33 Ibs 15kg REAR RACK MAX LOAD 66 lbs 30 kg FUEL Unleaded Gasoline FUEL CAPABILITY 2 11 Gallons 8 liters 125 TROUBLESHOOTING Procedures The following information is provided to help you identify probable questions you may have about the operation of your ATV See your dealer with any additional questions you may have ENGINE CRANKS BUT FAILS TO START No Spark to Clogged Fuel Contact Your filter Dealer 126 TROUBLESHOOTING cont ENGINE STOPS OR LOSES POWER Fouled Overheated Replenish Fuel Air Filter Clean Oil Cooler Clogged Screen Fuel Vent Line Kinked Exhaust Clean Engine Or Plugged Restricted Exterior Contact your Contact Your 127
24. attern FORWARD NEUTRAL REVERSE 68 OPERATION WARNINGS PRINTED IN THIS MANUAL POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident with severe injury or death is greatly increased if the operator does know not how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete a certified training course They should regularly practice the skills learned in the course and operating techniques described in the Owner s Manual For more information about the training course contact your authorized ATV dealer 69 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child Even though a child may be within the age group for which some ATVs are recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and could be involved in a serious accident HOW TO AVOID THE HAZARD Follow the age guideline printed on your vehicle 70 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly reduces yours ability to balance and control this ATV Could cause an accident
25. c sleeves pull the sleeves back to expose the adjustment nut Check free play by measuring the travel of the free end of throttle lever from its rest position to the position when you first feel tension on the cable Plastic Sleeve Adjustment Nut Plastic Sleeve 111 VEHICLE MAINTENANCE cont SPARK PLUGS The proper spark plug for the Kolpin Powersports 180 is the NGK C7HSA or NGK CR7HSA The spark plug gap should be between 024 028 inch 0 6 0 7 mm An incorrect spark plug gap can cause the spark plug to foul The spark plug and its condition is an indicator of how the engine is operating The firing end of the spark plug should be checked after the engine has warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 1 Normal The insulator tip is gray tan or light brown There will be a few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should NOT be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor adjustments 2 Wet fouled The insulator tip is black A damp oily film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes are excessive oil due to low compression or incorrect carburetor adjustments 112 Spark Pl
26. cteristics of your ATV Any accessories to be added to your ATV must be approved by your local Kolpin Powersports dealer before installation 11 RIDER S SECTION KNOW YOUR MACHINE Owners Review the information in this manual with any person who may be operating this ATV It is up to you to instruct other riders in the proper and safe way to operate an ATV Set boundaries and adhere to them keeping everyone s safety foremost in your mind Never allow your child to operate this ATV Riders Before you ride your new Kolpin Powersports ATV you need to know information about how the ATV operates and most important of all you need to know how to keep safe while operating the ATV Remember YOUR SAFETY IS THE MOST IMPORTANT THING You must learn what will keep you safe and also keep your friends and other people around you safe while you are riding Pay attention when you see this symbol A CAUTION This is the safety alert symbol When you see this symbol on your machine or in this manual is means PAY ATTENTION If you don t you could get hurt very badly or even killed Your safety 1s involved 12 OVERVIEW OF Kolpin Powersports 180 Fuel Gauge a Brake ever Neutral Indicator Reverse Indicator Rear Brake Lever a amp A n A Throttle A Lever Light Switch Engine Stop Switch Engine Start Switch Horn Ignition Switch 13 RIDER S SECTION KNOW YOUR MACHINE cont Before you start the engine for t
27. djust if necessary before each use Keep the drive chain properly lubricated e The chain adjuster can adjust the slack Loosen the fixed bolts and adjust the slack to the proper setting After adjusting the chain don t forget to tighten the nuts 19 GEAR ASSEMBLY After the break in procedure page 52 please change the gear oil in the transmission see page 115 SAE 8SW 140 gear oil 7 oz is Chain recommended on this vehicle The gear oil change process is described Adjuster on page 115 of this manual 44 FEATURES AND OPERATION cont 20 SUSPENSION Front Adjuster Front Suspension Ring e The front R L side suspensions can be adjusted to any of five 5 pre load positions so they can be matched to load and riding conditions e Always be sure to adjust both front left and front right shock absorbers to the same position Failure to do so could result in severe injury or death Rear Rear S Adjuster ear Suspension Ring e The rear suspension can be adjusted to any of five 5 pre load positions Adjust to the proper setting for load and riding conditions Shown in the softest spring setting 45 FEATURES AND OPERATION cont 21 BRAKE LIGHT e The brake light operates when the rear brake lever left is pulled e The bulb type for the braking light is 1157 or 12V P21 SW Rear Brake Light 46 RIDING amp OPERATING INSTRUCTIONS OUTLINE PAGE 1 Riding Gear 50 2 Starting the Engine 5
28. e sure the area around you and your ATV is safe gt Never ride alone Always drive within the sight of another rider gt Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the running boards gt Don t ride your ATV on roads or over railroad tracks Your ATV makes noise that will keep you from hearing cars trucks or trains that may be coming towards you Don t ride at night gt Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them gt Never ride on frozen water The ice could cause an accident resulting in severe injury or death All ice can be dangerous gt Always be alert and pay attention to where you are driving Pay attention to other drivers and be even more careful around them because you don t know what they re going to do gt Never follow another ATV too closely Always allow lots of time and space to stop your ATV AWARNING You must always follow the safe riding rules found on this page If you do not an accident could occur resulting in severe injury or death 20 FEATURES AND OPERATION 1 IGNITION SWITCH e The Ignition Switch is operated with a key and must be turned to the ON position before you start the engine e For Headlight turn the key from the ON position to the headlight position The headlight will not function unless the engine is running Headlight Position e Once the engine
29. ensive repair bills can result from the damage caused by the high pressure wash to wheel bearings transmission seals body panels brakes and warning labels 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 NOTE If warning labels are damaged contact your Kolpin Powersports dealer for replacement Waxing Your ATV can be waxed with any non abrasive past wax Avoid the use of harsh cleaners since they can scratch the body finish 123 VEHICLE MAINTENANCE cont TRANSPORTING Whenever the ATV is to be transported the following measures should be taken 1 Turn the fuel valve OFF if so equipped 2 Be certain the fuel cap and seat are installed correctly 3 Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope 4 Always lock the parking brake CARBURETOR ADJUSTMENTS If the ATV is to be operated at various altitudes and temperatures certain adjustments can be made to improve its operation Above 6 000 feet 1 800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1 000 feet 304 9 m increase in elevation This power cannot be regained but changes to the carburetor and drive system can be made to allow efficient oper
30. est position to their position when you first feel tension on the cables The free play should fall between 34 in 10 20 mm e For the front R L brakes the adjusters are located on the brake lever Turn the adjuster to obtain the proper position e For the rear brake you can adjust the brake adjuster wing nut to the proper free play and brake setting Rear Brake Adjuster 25 FEATURES AND OPERATION cont 6 BRAKES cont Auxiliary Brake Your ATV has an auxiliary brake for an added safety feature It is located on the inside of the right floorboard beneath the oil plug and is operated by the right foot Use the auxiliary brakes as a backup to the main brake system Auxiliary Brake 26 FEATURES AND OPERATION cont 7 PARKING BRAKE The parking brake is a safety device to lock the rear brake and limit ATV movement Setting the Parking Brake e Squeeze the left hand brake lever e Press the parking brake lock to hold the brake lever in place Releasing the Parking Brake e Squeeze the brake lever and the park lever will release automatically A CAUTION Always check to be sure that the parking brake has been released before operating the ATV An accident could result causing severe injury if the parking brake is left on while the ATV is operated 27 Parking Brake Lock FEATURES AND OPERATION cont 7 PARKING BRAKE cont IMPORTANT SAFEGUARDS Always lock the
31. h time before riding to insure it is in proper working order If proper inspection is not performed severe injury or death could result M Make sure the throttle doesn t stick Check this by pushing the lever toward the handlebar and then let it go Ifit comes right back to where it was before you pushed it then it s okay If it comes back slowly or stays forward you have a sticky throttle This means that something is wrong or broken A CAUTION If you have a sticky throttle do not start the engine You could get hurt if you ride when you have a sticky throttle Have an adult or your local Kolpin Powersports dealer fix the throttle M Make sure the brakes don t stick Check the brake levers by squeezing them toward the handlebar and then letting go The brake levers should come right back to where they were before you squeezed them If they go back slowly or stay on your brakes are sticking A CAUTION If you have sticky brakes do not start the engine You could get hurt if you ride when you have sticky brakes Have an adult or your Kolpin Powersports dealer fix the sticky brakes RIDER S SECTION PRE RIDE CHECK cont NNNNANNNANANRARAN N AA Make sure the seat is locked back in place Check the gas level Before adding gasoline to your ATV read the instructions and warnings on page 33 of this Owners Manual Check the engine oil level when the engine is cold The engine is very hot after it has been running It cou
32. he first time you need to learn about the controls on your new ATV 1 Engine Stop Switch The switch has to be in the position before you can start the engine When the engine is running you can stop it by sliding the Engine Stop Switch left or right to the Engine Start Switch Horn The Engine Start Switch Horn switch is the grey switch just below the Engine Stop Switch The Engine Start Switch is used to start the engine by pushing the switch to the osition di position Engine Start Switch Horn Engine Stop Switch RIDER S SECTION KNOW YOUR MACHINE cont 3 as Throttle Lever The throttle lever is located on the right side handlebar It makes your ATV go forward when you press it with your thumb You must always make sure the throttle control does not stick before you operate your ATV Read more about it on page 43 Transmission Neutral Indicator Green The Neutral Indicator green will light when the ATV is in Neutral The ATV cannot move forward nor will it reverse when the ATV is in Neutral Transmission Reverse Indicator Orange The Reverse Indicator orange will light when the ATV is in Reverse The ATV will move in reverse only 15 Throttle Lever RIDER S SECTION KNOW YOUR MACHINE cont 6 Kick Starter If your battery is too weak to start your ATV you can push on the kick starter with your left foot to start the engine Review page 42 for
33. he travel of the free end of the rear brake lever from its rest position to its position when you first feel tension on the cable The free play and should fall between 3 g 34 in 10 mm 20 mm To adjust the rear brake turn the adjustment nut until the proper free play is attained The free play range for the rear brake is g inch 10 mm 20 mm Rear Brake Adjustment Nut 109 VEHICLE MAINTENANCE cont BRAKE ADJUSTMENT cont Auxiliary Brake Adjustment The Kolpin Powersports 180 a rear auxiliary foot brake located at the right side of the engine assembly and is operated by the operator s right foot To adjust follow the steps below 1 Make adjustments to rear brake lever as described on page 109 2 Remove the four 4 bolts securing the right floorboard to frame and slide outward enough to access adjustment on brake cable 3 Loosen the lock nut and turn adjustment nut clockwise until proper pedal height is obtained then tighten lock nut 4 Reinstall floorboard and bolts Adjustment Cable Lock Nut Auxiliary Foot Brake 110 VEHICLE MAINTENANCE cont THROTTLE CABLE ADJUSTMENT e Check the throttle for smooth operation before every riding session e Periodically check the throttle free play It should be kept between Nie g in 1 5mm 3 2mm e If adjustment is required turn the adjustment nut until the free play reaches the acceptable limit adjustment nut 1s protected by plasti
34. inal size and type tire Make certain the wheels are installed properly Always replace tires when tread depth is worn to s in 3 cm or less 118 VEHICLE MAINTENANCE cont TIRE TIRE PRESSURE WHEEL INSTALLATION cont ATV Model Tire Size PSI Wheel Nut Torque Front Rear Front Rear Kolpin Powersports 21x7 10 21x10 8 5 3 28 ft lbs 180cc WHEEL INSTALLATION 1 Lock the parking brake place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart below Specification Front Rear Wheel Bolts 22 29 ft lbs 30 40 Nm Front Spindle Nut 42 45 ft lbs 58 62 Nm Rear Spindle Nut 78 81 ft Ibs 108 112 Nm 119 VEHICLE MAINTENANCE cont TIRE TIRE PRESSURE TIRE INSTALLATION cont WHEEL REMOVAL PROCEDURE Stop the engine and lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the footrest frame Remove the wheel nuts and remove the wheel po le DRIVE CHAIN INSPECTION AND ADJUSTMENT Regularly lubricate the drive chain with SAE 85W 140 oil or chain amp cable lube A CAUTION Never wash the chain with a high pressure washer or gasoline Damage could result causing
35. ing technique on level ground Practice turning at low speeds on level ground before attempting to turn at faster speeds Do not turn at excessive speeds Avoid crossing the side of a steep hill 1f possible 85 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN Could allow ATV to overturn causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the front brake slowly by squeezing the RH lever When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual 86 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also regain traction unexpectedly both of which may allow the ATV to overturn causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in order
36. it down the hill Stop and lock the parking brake while maintaining body weight uphill Shut off engine Dismount on left or uphill side of ATV Staying uphill turn handlebars full left while facing front of ATV While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward Lock the parking brake and remount ATV from the uphill side keep body weight uphill Restart engine release parking brake and proceed slowly controlling speed with the brakes until ATV is on reasonably level ground eee a SD AWARNING Avoid climbing steep hills Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death 60 RIDING amp OPERATING INSTRUCTIONS cont 11 CROSSING STREAMS Your Kolpin Powersports ATV can operate through water up to depths just below the footrests Before operating through streams l 2 3 4 Determine water depths and currents Choose a crossing where both banks have gradual inclines Proceed slowly avoiding rocks and obstacles if possible Remember that wet brakes do not always operate normally After crossing dry the brakes by applying light pressure to the levers until braking action is normal Do not operate your ATV through deep or fast moving water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight
37. ld burn you Check the tires check condition and pressures Brakelight check for proper operation Engine Stop Switch check for proper function Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins Drive chain check the drive chain slack Air cleaner check for dirt If the filter is dirty or clogged clean or replace it Steering check to be sure the steering operates freely Look for any unusual looseness in any area Check free play and operation of brakes levers Check throttle lever making sure you do not have sticky throttle lever see pg 43 Loose parts inspect ATV for any damaged parts or loose nuts bolts or fasteners Operator s helmet goggles and proper clothing long pants long sleeves or jacket This last check is done with the engine running You must check to make certain that the two ways to stop your ATV are working the way they should 1 Sliding the Engine Stop Switch left or write to the position 2 Turning the Ignition Key to OFF 19 RIDER S SECTION RIDING RULES Now you are ready to ride your new ATV Remember that safety while you ride is the most important thing Let s ride gt Your ATV is made for one person Never carry a passenger A passenger will make the ATV harder to drive You may lose control and hurt yourself and your passenger gt Make sure you know where you are going to ride when your ATV is started Mak
38. ld result in severe injury or death When you see this symbol on your machine or in this manual is means PAY ATTENTION If you don t you could get hurt very badly or even killed Your safety is involved A CAUTION Failure to follow the warnings contained in this manual can result in SERIOUS INJURY OR DEATH ATTENTION OPERATOR This vehicle is designed and manufactured for off road use only Carrying passengers is prohibited Always wear a helmet while operating ATVs gt Read the Owner s Manual and all warning labels on the ATV carefully Follow the operating procedures described e Training Kolpin Powersports strongly suggests new owners call the ATV Safety Institute ASI a division of SVIA to enroll in safety training or visit their website www ATVSAFETY org e Never operate an ATV without first reviewing this manual watching the instructional video and taking a certified ATV Safety Training course e Youth ATVs are designed and intended for use by children in the following age groups e ATVs with engine sizes less than 50cc should be used only by persons ages 6 and older e ATVs with engine sizes 51cc up to and including 90cc should be used only by persons age 12 and older e ATVs with engine sizes greater than 90 cc should be used only by those persons age 16 and older e No children under the age of 16 should operate any ATV designed and sold for an adult e Do not allow children to ride this ATV Always inspect you
39. met can prevent severe head injury Make sure your helmet meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label Eye Protection Do not depend on sunglasses for eye protection A pair of goggles or helmet face shield offers the best protection for your eyes They should be shatterproof and should be kept clean Check for one of these marks to be sure your choice of eye protection is of shatterproof design z2 1 or VESC8 Gloves Off road gloves with knuckle pads are the best for comfort and protection Clothing To protect your body long sleeves and pants should always be worn Riding pants with kneepads a jersey a chest protector and elbow pads provide the best protection Itis also suggested that your footwear should be ankle or higher boots 50 RIDING amp OPERATING INSTRUCTIONS cont 2 l STARTING THE ENGINE Procedure for Starting a Cold Engine Set the parking brake Push the Engine Stop Switch to Turn the ignition key to ON Press the Engine Starter Button B 2 NOTE The rear brake lever must be engaged or the engine will not start Do not press the throttle when starting the engine Push the Starter Button for a maximum or five seconds releasing the Starter Button when the vehicle starts If engine does not start release the Starter
40. ng water If necessary apply them several times to let friction dry out the pads 90 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Operating this ATV with incorrect size tires or with uneven tire pressure WHAT CAN HAPPEN Use incorrect size tires on this ATV or operation of this ATV with uneven tire pressure may cause loss of control and increases the risk of an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle Always maintain proper tire pressure as described in the Owner s Manual 91 OPERATION WARNINGS cont POTENTIAL HAZARD Overloading this ATV WHAT CAN HAPPEN Could cause changes in vehicle handling that could lead to an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed Allow greater distance for braking 92 OPERATION WARNINGS cont A WARNING After a rollover or an accident have a qualified service dealer check the entire vehicle including but not limited to brakes throttle and steering for possible damage A WARNING Safe operation of this rider active vehicle requires good judgment and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of
41. of severe Head injury or death in event of an accident Operating without eye protection can result in severe Injury in event of an accident HOW TO AVOID THE HAZARD Always wear an Approved helmet that fits properly You should Also wear eye protection goggles or face shield Gloves long sleeved shirt or jacket and long pants 74 OPERATION WARNINGS cont POTENTIAL mA WARNIN G Operating this ATV after consumption of alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and protection Could cause an accident resulting in severe injury or death HOW TO AVOID THE HAZARD NEVER consume alcohol or drugs before or while driving this ATV 75 OPERATION WARNINGS cont A WARNING Operating this ATV at excessive speeds WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can cause an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always travel at a proper speed for the terrain visibility operating conditions and your experience 76 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of rolling the vehicle and or causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to sho
42. olts Pre ride Pre ride Look for loose fasteners fasteners i Engine Oil Check when refueling Brake pad wear 10 Monthly Inspect periodically replace as necessary hrs 100 miles 97 VEHICLE MAINTENANCE cont ee pe eee ITEM WHEN REMARKS see ee Bowl ee ae Inspect adjust lubricate replace if necessary pre ride inspection item Steering 50 hrs 6 mos Inspect daily lubricate Rear Axle 50 hrs 6 mos Inspect bearings Lube Front Suspension 50 hrs 6 mos Inspect lubricate tighten fasteners Rear Suspension 50 hrs 6 mos Inspect tighten fasteners ee a Inspect daily adjust and lubricate if needed Cd iia drive amp 100 hrs 12 mos Inspect clean driven gt Engine Oil 100 hrs Change oil clean filter 98 VEHICLE MAINTENANCE cont ica ITEM WHEN REMARKS ae O ae Mounts a hrs mos L C ee Plug hrs itna mos Inspect aaan if necessary PE Ignition Timing 100 hrs Inspect and adjust as needed Fuel System 100 hrs 12 mos Check for leaks at tank cap lines fuel valve filter and carburetor Replace lines every two years PE Fuel Filter 100 hrs Replace annually os i wheel ka wae hrs mos Inspect replace 1f necessary Oc a Required m Peete fege SE es an Wn Required replaced 99 VEHICLE MAINTENANCE cont LUBRICATION RECOMMENDATIONS LUBRICATION ITEM RECCOMMENDATION METHOD FREQUENCY Engine Oil SF SG SAE 15W 40 See page 116 Change every 6 mos or 100 hrs
43. overturns and loss of control which could result in severe injury or death 93 OPERATION WARNINGS cont POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of non OEM accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of non OEM accessories All parts and accessories added to this vehicle should be designed for use on this ATV and should be installed and used according to instructions WARNING Do not ride this vehicle without battery properly installed Riding Kolpin Powersports 180cc without battery properly installed may cause short circuit and result in shorting out electrical system causing a fire resulting in severe injury or death If you have questions consult an authorized dealer 94 VEHICLE MAINTENANCE VEHICLE IDENTIFICATION NUMBERS Record these numbers from your ATV in the spaces provided 1 Engine Serial Number Left side of engine crankcase 2 Frame VIN found on the front of frame below steering post Remove the spare Key and store in a safe place Your key can be duplicated only by obtaining a key blank from Kolpin Powersports and having it cut by using your existing Key The Engine Serial Number and Frame VIN are important for model identification when registering your vehicle
44. parking brake before starting the engine Once the engine has warmed enough for operation release the parking brake and gently apply the throttle to go forward Always lock the parking brake whenever the ATV is left unattended TRANSMISSION GEAR SHIFT LEVER The transmission gear shift lever is located on the right side of the ATV The gear shift lever has three 3 positions Forward Neutral and Reverse 28 To Change Gears Stop ATV and hold the rear break lever keeping the engine idling Move the lever to the desired gear DO NOT attempt to shift gears with engine speed above idle or while the vehicle is moving Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjust is important to assure proper transmission function Should you experience any shifting problem see you local Kolpin Powersports dealer Shift Patterns F N a FEATURES AND OPERATION cont 8 TRANSMISSION GEAR SHIFT LEVER cont Be sure the ATV is in the Neutral position before you start the engine If you cannot change gears do not force gear shift lever into gear Instead try to change to the Neutral position first press the throttle and then try to change gears The white back up lights will be illuminated when the transmission is shifted fully into Reverse Do not attempt to shift the transmission while the vehicle is moving or while ope
45. perated in salt water areas it must be rinsed with fresh water to prevent corrosion that can be caused by seawater 31 Fuel Tank FEATURES AND OPERATION cont 11 ENGINE FUEL SYSTEM Fuel Tank e The fuel tank filler cap is located directly behind the handlebar below the dash e The capacity of fuel tank is 2 1 gallons 8 liters e Use unleaded gasoline with an octane rating of 92 or higher Fuel Gauge e When the fuel gauge needle is on the red line refuel e Be sure to tighten fuel cap after refueling AWA R N N e Fuel e DO NOT refuel when engine is hot Gauge e Be sure to tighten fuel cap after refueling 32 FEATURES AND OPERATION cont 11 ENGINE FUEL SYSTEM cont AWARNING Gasoline is highly flammable and explosive under certain conditions Never store ATV near products with a pilot light such as gas hot water heater or Stoves Always exercise extreme caution when you handle gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area 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 you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Never start the engine o
46. r ATV before you ride to make sure it is in safe operating condition Follow the inspection and maintenance procedures and schedules as described in this manual Always wear an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never exceed your riding capabilities Never consume alcohol drugs or any medications that affect alertness before or while operating this ATV Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation Never carry a passenger on an ATV Always go slowly be extra careful when operating on unfamiliar terrain Be alert for changes in terrain weather and ATV operating conditions Never operate on excessively rough slippery or loose terrain Avoid operating ATV on paved surfaces including sidewalks driveways parking lots and streets Avoid operating ATV on any public street road or highway even dirt or gravel ones Avoid excessive speeds sharp turns and uneven terrain Travel at speeds proper for the terrain visibility and operating conditions and your experience Never ride during low light conditions Never attempt wheelies jumps or other stunts Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Never operate the ATV on hills too s
47. r let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Shut off fuel valve Gf so equipped whenever the ATV is stored or parked 33 FEATURES AND OPERATION cont Re ee Fuel Valve 11 ENGINE FUEL SYSTEM cont Fuel Valve In line Fuel Fil The Kolpin Powersports 180 has an auto vacuum operated fuel gas ue EIEI valve When the engine is running it opens the auto vacuum fuel valve when the engine is shut down the auto vacuum fuel valve closes Fuel Filter e The Kolpin Powersports 180 ATV is equipped with an in line fuel filter e This filter should be replaced by your dealer after every 100 hours of operation or annually e Do not attempt to clean the fuel filter 34 FEATURES AND OPERATION cont 11 ENGINE FUEL SYSTEM cont Engine Oil Check e Remove the oil plug dipstick e Wipe off the dipstick and insert back into opening do not screw in e Pull the oil plug dipstick back out and check the oil level If the oil level is low add oil SAE SF SG 15W 40 Oil Plug Dipstick AWARNING e In order to maintain the excellent performance of your ATV engine check the engine oil level before every use To avoid serious engine damage always refill oil reservoir when the oil level is low Running the engine with low oil levels will cause the engine to overheat and seize If the engine seizes it will have
48. rating on hilly terrain Always place the transmission in gear with the parking brake locked whenever the vehicle 1s left unattended For your safety apply the rear brake lever when you shift to Reverse It you do not the engine will stop immediately To restart the engine shift back to Neutral and use normal start procedure 29 9 THE CVT SYSTEM The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Do not modify any component of the CVT system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components Routine maintenance is the responsibility of the owner Always follow recommended maintenance procedures See your Kolpin Powersports dealer for questions or maintenance The CVT housing must be securely in place during operation FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SEVERE INJURY OR DEATH 30 FEATURES AND OPERATION cont 10 ENGINE AIR FILTER e The engine air filter should be changed by dealer every 100 hours of operation or annually e For more information see page 105 A CAUTION If your ATV is stored o
49. rely attached Reduce speed and follow instructions outlined in this manual Allow greater distance for braking e DRIVE SAFELY amp RESPONSIVELY FOR MORE INFORMATION ABOUT ATV SAFETY 10 AWARNING The following information identifies a potential safety hazard that could result in severe injury or death Additional Important Information The safety of our customers and the general public is the first priority at Kolpin Powersports It is strongly recommended that consumers not install any non Original Equipment Manufacturer OEM supplied equipment intended to increase speed or power on any Kolpin Powersports ATV Do not make any other modifications intended for these purposes Any modifications to the original equipment of the ATV substantially increase the risk of serious injury or death Because these modifications may create a substantial safety hazard Kolpin Powersports hereby informs you that the warranty on your ATV is terminated if any non OEM equipment has been added or modifications have been made to the original ATV which increase s speed or power It is also advised that ATV owners strictly follow the recommended maintenance program described in this manual The preventive maintenance program is designed to insure that all critical components on the ATV are inspected by your dealer on a regular schedule hourly intervals BE FURTHER ADVISED the addition of certain accessories may change the handling chara
50. rests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismount of the ATV oP ee 57 RIDING amp OPERATING INSTRUCTIONS cont 8 SIDE HILL RIDING Avoid traveling across the side of a hill In the event you do enter into a situation where side hill riding is unavoidable 1 Slow down 2 Lean into the hill transferring your upper body weight up hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction IF THE VEHICLE BEGINS TO TIP QUICKLY TURN THE FRONT WHEEL DOWNHILL IF POSSIBLE OR DISMOUNT ON THE UPHILL SIDE IMMEDIATELY AWARNING Improperly crossing hills or turning on hills can be dangerous Loss of vehicle control or overturning of the ATV could result causing severe injury or death 58 RIDING amp OPERATING INSTRUCTIONS cont 9 TRAVELING DOWNHILL When descending a hill 1 Drive directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Slightly apply the front and rear brakes at the same time to help in slowing AWARNING Do not travel at excessive speeds It is dangerous and can cause loss of vehicle control and tipping resulting in severe injury or death 59 RIDING amp OPERATING INSTRUCTIONS cont 10 TURNING AROUND ON A HILL If your ATV stalls while climbing a hill NEVER back
51. rrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 83 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner s Manual Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that could cause the vehicle to lean sharply to one side Go straight down the hill where possible 84 OPERATION WARNINGS cont A WARNING 4 4 4 POTENTIAL HAZARD Improperly crossing hills or turning on hills N WHAT CAN HAPPEN Could cause loss of control or ATV to roll or cause an accident resulting in severe injury or death HOW TO AVOID THE HAZARD 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 turn
52. rturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS 55 RIDING amp OPERATING INSTRUCTIONS cont 7 RIDING ON SLIPPERY SURFACES A CAUTION Whenever riding on slippery surfaces such as wet trails or loose gravel or during cold freezing weather special attention must be paid to prevent vehicle turnover 1 Slow down when entering slippery areas Remain alert reading the trail and avoiding quick sharp turns that can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 Never apply brakes during a skid Complete loss of ATV control can result 5 Whenever possible avoid excessively slippery surfaces 6 Always reduce speed and use additional caution AWARNING e Failure to exercise care when operating the ATV on slippery surfaces can be dangerous e Loss of tire traction and vehicle control can result in an accident including an overturn resulting in severe injury or death 56 RIDING amp OPERATING INSTRUCTIONS cont 8 TRAVELING UPHILL AWARNING Do not operate this ATV on hilly terrain If you cannot avoid operating in hilly terrain use extreme caution Braking and handling are greatly affected Loss of vehicle control or overturning of the ATV could result causing sever injury or death If you HAVE to travel uphill always travel straight uphill and Avoid steep hills 25 maximum Keep both feet on the foot
53. s 180 Specifications 124 Periodic Maintenance Record 101 Troubleshooting 125 Axle Wheel amp Torque Specifications 103 Rear Spring Adjustment 104 Engine Air Filter 105 Throttle Stop System 106 Steering Inspection 107 1 INTRODUCTORY SAFETY MESSAGE TO OWNERS PARENTS amp ADULTS MUST READ BEFORE OPERATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE An ATV handles differently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles YOU MUST TAKE PROPER PRECAUTIONS You should read the owner s manual and warning labels Review this information on a regular basis Riders differ in skills physical abilities and judgment Some riders may not be able to operate an ATV safely Never allow anyone to operate an ATV without first reading the Owner s Manual watching the instructional video and attending a certified ATV Safety Training course Never allow others to use your ATV if he or she does not have the abilities to operate it safely MAKE CERTAIN THE OPERATOR S UNDERSTAND ALL WARNINGS AND THE OWNER S MANUAL BEFORE OPERATION gt gt PAY ATTENTION WHEN YOU SEE THE SYMBOLS BELOW 44 A CAUTION This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury AWARNING This symbol indicates a potential hazard that cou
54. severe injury or death HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing conditions when operating the ATV 80 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Could cause damage to terrain or loss of vehicle control or rolling the vehicle or causing an accident resulting in severe injury or death HOW TO AVOID HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on rough terrain 81 OPERATION WARNINGS cont POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Driver could lose control of the ATV rolling the vehicle or causing an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for turning Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed 82 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Climbing hills improperly Could cause loss of control or cause ATV to overturn or cause an accident resulting in severe Injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills Always check the te
55. stable driving conditions Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death Always heed the warnings listed on this page and the following page e REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO e CARGO WEIGHT DISTRIBUTION should be WE on the front rack and T on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle tip over 54 RIDING amp OPERATING INSTRUCTIONS cont 6 HAULING CARGO cont ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating conditions OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads which cannot be centered securely fasten load and operate with extra caution EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides Stability and maneuverability may be adversely affected causing the machine to ove
56. teep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of any hill at high speed Always follows proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle that would cause the vehicle to lean sharply Go straight down the hill wherever possible Always follows 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 Always use proper procedures as described in this manual if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you lose all forward speed Keep weight uphill Apply the brakes Lock the parking brake after you are stopped Dismount on uphill side or
57. the air out This will keep tires from getting flat spots Drain and refill the transmission oil with 7 oz SAE 85W 140 see page 115 Drain and refill the engine oil with 28 to 32 oz of SAE 15W 40 API classification SF SG motor oil see page 116 114 e Lubricate chain and cables with SAE 85W 140 oil or chain amp cable oil VEHICLE MAINTENANCE cont TRANMSSION OIL CHANGE Change the gear oil after the first 30 hours of operation The recommended gear oil is SAE 85W 140 Run ATV for at least five 5 minutes or until warm Turn off unit and remove the ignition key Place a suitable container for draining oil beneath the rear of engine Remove the transmission drain plug located under rear of sprocket shaft Let drain complete Remove fill plug located on left rear of engine case Inspect drain and fill plug gasket for damage Replace with new gasket if damaged Replace drain plug torque to 95 in lbs Fill transmission through the oil fill plug with 7 oz or 200 cc SAE 85W 140 gear oil Replace oil fill plug and start the engine Check for leaks Se er ea Transmission Oil Fill Plug Transmission Oil Drain Plug 115 VEHICLE MAINTENANCE cont ENGINE OIL CHANGE 1 Run unit for at least five 5 minutes or until warm Turn Ignition Key to OFF and remove the key 2 Place suitable container for draining oil beneath the engine 3 Remove the engine drain plug oil filter cap spring and oil filter screen Let
58. the throttle lever sticking during riding and cause an accident Always check the lever for free Accelerate movement and return before starting the engine Check occasionally during riding e The throttle lever is located on the right side handlebar e Pressing the throttle lever forward controls engine speed and vehicle movements e The throttle lever is spring loaded The engine speed returns to idle when the lever is released Throttle Lever 23 FEATURES AND OPERATION cont 5 HORN SWITCH To sound the horn turn on the ignition switch and pull the horn switch grey Engine On Horn switch Horn Button To sound the horn turn on the ignition switch and pull the horn switch grey Engine On Horn switch 6 BRAKES Right Brake e The left hand brake activates the rear brakes the right hand brake Front activates the front brakes e To activate the rear brakes squeeze the left hand lever toward the handlebar e To activate the front brakes squeeze the right hand lever toward the handlebar Left Brake AWARNING Always apply both brakes at the same time or loss of control of ATV can occur resulting in serious injury or death 24 FEATURES AND OPERATION cont 6 BRAKES cont Brake Lever Free Play e Check the free play of front and rear brake levers e Use the adjustment knobs to change free play Check the free play by measuring the travel of the front and rear brake levers from their r
59. to either side of pointed straight uphill Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees If you cannot avoid large obstacles use extreme caution when proceeding The proper procedure for operating over obstacles is described later in this manual Always be careful of skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely 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 Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the height of the bottom of the footrest go slowly balance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remember that your brakes may be wet e Wet brakes have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads e Always use size and type tires specified in this manual Always maintain proper tire pressure as described in this manual See page 97 e Never modify an ATV through improper installation of and or use of accessories e Never exceed the stated load capacity for an ATV Cargo should be properly distributed and secu
60. ug Removal and Replacement 1 The spark plug can be removed by using the special wrench provided in the tool pouch Remove the spark plug cap and then the spark plug by rotating counter clockwise AWARNING NEVER attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you and cause severe injury 2 Reverse the procedure for spark plug installation Torque to 17 ft Ibs 3 NOTE Failure to use the recommend spark plug type could cause engine damage Recommended type is NGK C7HSA or NGKCR7HSA 113 VEHICLE MAINTENANCE cont ATV STORAGE long term When your ATV is to be stored for a period of more than 60 days certain preparations should be made for the engine and fuel system to prevent rust and or corrosion of engine parts Supplies Needed l 2 o 7 Vinyl amp rubber protectant 4 SAE 85W 140 transmission oil Fuel Stabilizer 5 SAE 15W 40 engine oil Fogging Oil 6 Chain and cable lube Brake oil Clean wash and dry ATV Apply vinyl and rubber protectant to all vinyl and plastic surfaces Add fuel stabilizer to the tank and let run for at least five 5 minutes to get additives through the entire fuel system Remove and clean air filter Before replacing air filter start engine and lubricate engine with fogging oil Replace air filter Remove battery leads and charge battery with a storage charger Place unit on stand so tires are not touching the ground and let all
61. w off 77 OPERATION WARNINGS cont POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increased possibility of an accident or equipment damage Could cause an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 78 OPERATION WARNINGS cont AWARNING Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot will reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels which could injure you or cause an accident resulting in severe injury or death HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation 79 OPERATION WARNINGS cont A WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV rolling or driver losing control of the vehicle and causing an accident resulting in
62. wdriver and a tire gauge Battery Installation To avoid the possibility of explosion always connect battery cables in the order specified Red first Black last An exploding battery can cause serious injury or death e Your ATV has an Absorbed Glass Matte AGM battery e The proper battery for this ATV is YTOLBS e To install the battery set the battery in its holder e Connect the red wire to the terminal and the black wire to the terminal e Attach the hold down strap 38 FEATURES amp OPERATION cont 14 BATTERY TOOL SET cont BATTERY cont Never remove battery tops I Never attempt to add water Never reverse leads this could cause an EXPLOSION Never operate this ATV without the battery cables connected and tightened Loose or disconnected battery cables will spark and could cause the unit to catch on fire Never use a car to jumpstart Damage to the system will result and could cause an EXPLOSION Failure to pay attention to this warning could result in severe personal injury or death 39 FEATURES amp OPERATION cont 14 BATTERY TOOL SET cont BATTERY cont Care of Terminals e Battery terminals and connections should be kept free of corrosion e If cleaning is necessary remove the corrosion with a stiff wire brush e Wash with a solution of 1 tablespoon baking soda and 1 cup water e Rinse well with tap water and dry off

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