Coleman 800ATV-2 Owner's Manual
POWERSPORTS
OWNER’S MANUAL
(888)-405-8725 Coleman Powersports
364 S. Smith Rd. Tempe, AZ. 85281
No one under the
age of 16 should
operate this ATV
800ATV - 2
Owner Manual
Owner Manual
INTRODUCTION
Operator’s manual will provide you information regarding safe operation, operational instructions,
maintenance and care. Fully understanding this manual and following all of the instructions will
provide the knowledge needed to have a safe and enjoyable ATV experience.
If you have any questions regarding the operation or maintenance of your ATV, please
contact Coleman Powersports toll free 888-405-8725.
IMPORTANT SAFETY MESSAGES
● READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE
SURE YOU UNDERSTAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
● NEVER OPERATE THE ATV WITHOUT PROPER TRAINING OR INSTRUCTION.
● THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
Congratulations on your purchase of the Coleman Powersports 800ATV-2. This Owner’s /
Owner Manual
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. Particularly important information is noted in this manual using the
following symbols:
The Safety Alert Symbol means ATTENTION!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or
death to the ATV operator, a bystander or a person inspecting or
repairing the ATV.
A CAUTION indicates special precautions that must be taken to avoid
damage to the ATV.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
Owner Manual
IMPORTANT NOTICE
Turning speed must be less than 19mph (30 km/h).
This ATV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe
to operate this ATV on any public street, road or highway.
This ATV complies with all applicable OFF - ROAD noise level and spark arrester laws and
regulations in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
When the temperature is below -4°F (-20℃), please park the ATV in the place where the
temperature is higher than -4°F (-20℃). After the ATV has warmed up, the ATV can be started.
Please see page 6-2 on the warming up process.
When the temperature is higher than 100°F (38℃), and you park the ATV after operating
at high speeds, keep the engine running for 3 minutes at idle and make sure that the radiator
fan continues for 3 minutes to prevent the coolant from boiling. Then turn off the power switch.
Your ATV may have a 3 minute automatic continuous fan after ignition shut down.
When you park the ATV and turn off the engine, please turn the ignition switch fully to shut off
the instrument panel display. With the EFI system used in this ATV, the electric fuel pump
located in the fuel tank can work when the panel display is on. If the fuel pump runs for a long
time it will result in the battery discharging and the electric starter may not work.
Owner Manual
Coleman Powersports Limited
Warranty
Location of the Warning and
Specification Labels
1-1
Safety Information
2-1
Description and Vehicle
Identification
3-1
Identification Number Records
3-2
Vehicle Identification Number
3-2
Control Functions
4-1
Main Switch
4-1
Indicator and Warning Lights
4-2
Speedometer Unit
4-4
Odometer and Trip Meter Modes
4-4
Clock time adjustment
4-5
Fault Code indicator
4-7
Fuel Fuel level indicator
4-7
Left Handlebar Switches
4-8
Throttle Lever
4-13
Speed Limiter
4-15
Foot brake pedal – all wheel
brakes
4-15
Parking brake – Park position
lever
4-16
Gear shift lever
4-17
Fuel Tank Cap
4-17
Seat
4-18
FRONT SUNDRY BOX
4-19
REAR SUNDRY BOX
4-19
Front & Rear Carrier
4-19
Auxiliary DC Jack
4-22
Steering Lock
4-24
Pre Operation Checks
5-1
Brake System
5-3
Fuel
5-4
Engine Oil
5-6
Differential Gear Oil
5-7
Coolant
5-7
1
2 3 4
5
Owner Manual
Throttle Lever
5-8
Fittings and Fasteners
5-9
Lights
5-9
Switches
5-9
Idling
5-9
Ignition and Emergency Switches
5-9
Tires
5-10
How to Measure Tire Pressure
5-11
Tire Wear Limit Indicator
5-12
Operation
6-1
Starting Procedure
6-1
Starting a Warm Engine
6-2
Warming the engine
6-2
Engine shut down
6-2
Recommended procedure for
turning off the engine
6-2
Drive Select Lever Operation
and Reverse Driving
6-3
Neutral to Reverse Low
6-4
Shifting between 2WD and 4WD
6-5
Braking
Parking brake
Engine break-in
ATV break-in
Braking system break-in
Modifications
Loading
6-6
6-7
6-9
6-10
6-11
6-11
6-12
Your Vehicle
7-1
Driving Your Vehicle
7-1
Ride with care and good Judgment
7-1
Apparel
7-4
Speed Limiter
7-8
Loading and Accessories
7-8
During Operation
7-9
Modifications
7-11
Exhaust System
7-12
Pay attention to the road
conditions
7-13
Turning Your ATV
7-17
Climbing Uphill
7-19
6
7
Owner Manual
Riding Downhill
7-23
Crossing Through Shallow Wate
r
7-25
Riding Over Rough Terrain
7-28
Sliding and Skidding
7-29
Periodic Maintenance and
Adjustment
8-1
Periodic Maintenance and Adjustment
8-1
Periodic Maintenance Chart for
the Emission Control System
8-2
General Maintenance and
Lubrication Chart
8-3
EFI System
8-5
Engine Oil and Oil Filter
8-8
Final Gear Oil
8-12
Differential Gear Oil
8-13
Cooling System
8-15
Coolant Replacement
8-16
Axle Boots
8-19
Spark Plug Inspection
8-19
Air Filter Element Cleaning
8-21
Spark Arrester Cleaning
8-25
V-belt Cooling Duct Check Hose
8-26
V-belt Case Drain Plug
8-26
Valve Clearance Adjustment
8-27
Throttle Lever Adjustment
8-27
Front/Rear Brake Pad Inspection
8-28
Brake Fluid Replacement
8-28
Front Brake Lever Free Play
8-30
Adjusting the Parking Brake
Lever
8-31
Adjusting the Brake Pedal
8-32
Adjusting the Rear Brake Light
Switch
8-32
Inspecting / Lubricating Cables
8-33
Lubricating the Brake Lever and
Brake Pedal
8-33
Rear Knuckle Upper and Lower
Pivot Lubrication
8-34
Wheel Removal
8-35
8
Owner Manual
Wheel Installation
8-35
Battery
8-36
Battery Maintenance
8-37
Fuse Replacement
8-38
Replacing A Headlight Bulb
8-39
Replacing a taillight
8-41
ATV common fault inspection
and solution charts
8-42
Electric power steering system
Introduction
Advantages of EPS system:
Important information for safety:
Introduction of EPS system
What is EPS system
Typical parts of EPS system
Construction of EPS
Operation and use of
EPS
system
EPS system operation
Function of EPS system
EPS system’s inspection,
maintenance, repair：
Malfunction assortment：
9-1
9-1
9-1
9-2
9-3
9-3
9-4
9-4
9-10
9-10
9-12
9-15
9-16
To drive ATV at every time, need
to do daily inspection of EPS system
Solutions for common fault：
Maintenance and repair’s
supplemental description:
EPS
system periodic maintenance
EPS system parameter table
EPS system basic technical
parameters
EPS system working conditions
Motor assy basic parameters
9-17
9-20
9-26
9-26
9-27
9-27
9-27
9-27
Cleaning and Storage
10-1
Cleaning
10-1
Storage
10-2
Specifications
11-1
Fault codes for the Electronic
Fuel Injection System
12-1
USA EPA Emissions Limited
Warranty
13-1
10
11
12
13
9
Owner Manual
Coleman Powersports Limited Warranty
Coleman Powersports LIMITED WARRANTY
This Warranty is NOT the Emissions Control Warranty. Please note this is a general Limited Warranty for this
product. It IS NOT an Emissions Control Warranty. Please see the Emissions Control Warranty in this manual.
The Warranty:
Coleman Powersports Inc offers the following warranty to the initial purchaser of this new Coleman Powersports
product. The initial purchaser is defined as the first person to purchase a new Coleman Powersports product from
an Authorized Retailer of Coleman Powersports products.
The limited warranty period for this product is 1 year from the date of purchase shown on the original sales receipt.
What is a Defect?
The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 1 year
from the date of purchase shown on the sales receipt. During this period of time Coleman Powersports will, at its
option, either repair or replace any original Coleman Powersports part which is covered by this warranty and is
proven to be defective in workmanship or material.
To qualify for this warranty the part:
1. Must have been purchase from Coleman Powersports or from an authorized Coleman Powersports Retailer.
2. This warranty does not apply to any vehicle which is used in competition or used in a manner not consistent
with the normal and proper intended use for the vehicle. This vehicle is not intended for rental or commercial use.
Coleman PowersportsLimited Warranty
Who Can Perform Repairs Under this Warranty?
Repairs under this warranty should be performed by an authorized Coleman Powersports retailer or comparable
servicing dealer.
How to get service under this warranty:
To get warranty service, call Coleman Powersports at 888-405-8725 for the location of your local servicing retailer /
dealer. Please do not return the product to the retailer where the product was purchased unless instructed to do
so by Coleman Powersports. The retailer of this product does not make any warranty of its own and has no
authority to implement this warranty on behalf of Coleman Powersports without the approval of Coleman
Powersports. A COPY OF YOUR SALES RECEIPT IS REQUIRED FOR WARRANTY SERVICE.
What this Warranty Does Not Cover:
This warranty does not cover the following
1. Damage due to lack or improper maintenance as described in this manual.
2. Damage which is caused by normal use and not caused by a defect in materials or workmanship.
3. Use of the product which is not consistent with the intended use as described in the operating instructions.
4. Any expendable maintenance item which need replacement or service as part of normal maintenance, unless
such items have defects in material or workmanship which cause failure or premature wear.
5. Any product which has been altered or modified in a manner not consistent with the original design of the
product or in a manner not approved by Coleman Powersports.
6. Tires
7. Damage or failures due to abuse, neglect, or misuse of the product.
Coleman Powersports Limited Warranty
Limitations of this Warranty:
This warranty does not cover and Coleman Powersports disclaims any responsibility for:
1. Loss of time or loss of use of the product.
2. Transportation costs to and from the authorized center.
3. Other loss or damage to other equipment or personal items.
Length of Implied Warranties:
Any implied warranties are limited to the duration set forth in this warranty. Coleman Powersports does not make
any claim as to the merchantability or fitness for a particular purpose which would extend longer than the duration
of this written warranty.
Check your State Laws as some State Laws do not allow limitations as to the duration of an implied warranty.
Some States may also not allow limitation or exclusions based on incidental or consequential damages.
Location of the Warning and Safety Labels 1-1
LOCATION OF THE WARNING AND SPECIFICATION LABELS
1-2 Location of the Warning and Safety Labels
Read and understand all of the labels on
your ATV. They contain important
information for safe and proper operation
of your ATV.
Never remove any labels from your ATV. If
a label becomes difficult to read or comes
off, a replacement label is available from
your dealer.
①
②
③
Location of the Warning and Safety Labels 1-3
④
⑤
1-4 Location of the Warning and Safety Labels
⑥
⑦
Location of the Warning and Safety Labels 1-5
⑧
⑨
⑩
⑪
⑫
2-1 Safety Information
An ATV is a special vehicle, which is different from other vehicles such as motorcycles and cars.
A collision or rollover can occur quickly, even during routine maneuvers such as turning and
riding on hills or over obstacles if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and follow the operating procedures described.
Never operate an ATV without proper training or instruction. Take a Training Course.
Beginners should receive training from a certified instructor.
Always follow the age recommendation:
A child under 16 years old should never operate an ATV with an engine size greater than
90cc.
Never allow a child under age 16 to operate an ATV without adult supervision, and never
allow continued use of an ATV by a child if he or she does not have the abilities to operate
it safely.
Never carry more than one passenger on an ATV unless it is designed for two people.
Never operate an ATV without wearing an approved motorcycle helmet that fits properly.
You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved
SAFETY INFORMATION
Safety Information 2-2
shirt or jacket, and long pants.
Never use alcohol or drugs before or while operating an ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that
is proper for the terrain, visibility and operating conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time when you use it to make sure it is in safe operating
condition. Always follow the inspection and maintenance procedures and schedules
described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV
during operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating an ATV.
Never 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 these kinds of terrain.
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 speed.
Never operate the ATV on hills too steep for the ATV. Don’t operate an ATV beyond your
capabilities. Practice on shallow inclines before attempting larger steeper hills.
2-3 Safety Information
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. Never go over
the top of a hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described
in this manual. Check the terrain carefully before you start to go down any hill. Shift your
weight rearward. Never go down a hill at a high speed. Avoid going down a hill at an angle
that would cause the vehicle to lean sharply to one side. Go straight down a hill where
possible. Brake carefully when necessary, braking when going downhill may cause the
ATV to roll rear end over.
Always 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. Avoid crossing the face of a steep hill if
possible.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid
stalling, use the proper gear range 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.
Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and
Safety Information 2-4
remount, following the procedure described in this manual.
Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles, such as large rocks or fallen trees. Always follow proper procedures when
operating over obstacles as described in this manual.
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 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. NEVER ride your ATV on an icy road.
Never operate an ATV in fast flowing water or in water deeper than that recommended in
this manual. Remember wet brakes will reduce brake performance. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry the linings.
Always be sure there are no obstacles or people behind you when you operate in
reverse. When it is safe to proceed in reverse, go slowly.
Always use the size and type tires specified in this manual.
Always maintain proper tire pressure as described in this manual.
Never modify an ATV through improper installation or accessories.
Never exceed the stated load limit for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo
or pulling a trailer. Allow longer distances for stopping when braking.
2-5 Safety Information
WARNING
Improper handling of gasoline may cause fire
and you could be burned.
Remember: Always turn off the engine when
refueling. Do not refuel right after the engine
has been stopped which is still very hot.
Do not spill gasoline on the engine or exhaust
pipe/muffler when refueling.
No smoking while refueling.
Never refuel in the vicinity of sparks, open
flames, or other sources of ignition such as
the pilot lights of water heaters and clothes
dryers.
When transporting the ATV in another vehicle,
be sure it is in an upright position. Otherwise,
fuel may leak out of the fuel tank.
Gasoline is poisonous and can cause injuries.
If you swallow gasoline or inhale gasoline
fumes, or get gasoline in your eyes, see your
doctor immediately. If gasoline spills on your
skin, wash with soap and water. If gasoline
spills on your clothing, change your clothes.
Safety Information 2-6
WARNING
POTENTIAL HAZARD
Starting or running the engine in a closed area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may cause
loss of consciousness and death within a short
time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with good
ventilation.
3-1 Description and Vehicle Identification
DESCRIPTION AND MACHINE IDENTIFICATION
1. headlights 2. radiator part 3. shock absorber comp 4. meter 5. left handle bar 6. air filter 7. front seat 8. rear seat
9. back rest 10. carrier 11 . rear bumper 12. front bumper 13. front carrier 14. front sundry box 15. ignition switch 16. auxiliary dc plug
17. steering bar part 18. gearshift bracket 19. range gear shift lever 20. fuel tank cap 21. rear shock absorber comp
22. rear sundry box 23. rear turning light 24. taillight comp
Description and Vehicle Identification 3-2
NOTE:
The ATV you have purchased may differ
slightly from those shown in the figures of
this manual.
Identification number records
Record the key identification number,
vehicle identification number and model
label information in the spaces provided for
assistance when ordering spare parts from
a dealer or for reference in case the
vehicle is stolen.
2.VEHICLE IDENTIFICATION NUMBER:
3. MODEL LABEL INFORMATION:
○
●
Vehicle identification number
The vehicle identification number is
stamped into the frame.
1. Vehicle identification number
1. KEY NUMBER:
3-3 Description and Vehicle Identification
NOTE:
The vehicle identification number is used
to identify your machine.
Model label
The model label is affixed at the location
shown in the illustration. Record the
information on this label in the space
provided. This information will be needed
to order replacement parts from your
dealer.
1. Model label
Control Functions 4-1
CONTROL FUNCTIONS
Ignition switch
Switch functions in respective positions are as
follows:
1. Ignition switch
2. “OFF”
3. “ON”
ON:
The engine can be started only in this position
and the headlights and taillights can be turned
on when the light switch is on.
OFF:
All electrical circuits are switched off. The key
can be removed in this position.
4-2 Control Functions
Indicator and Warning Lights
1. Low gear indicator “L”
2. High gear indicator “H”
3. Neutral indicator “N”
4. Reverse indicator “R”
5. Engine indicator light ”P”
6. Mechanical parking brake indicator light “ ”
7. Parking lights indicator
8. High beam indicator
9. Emergency flashers indicator
10. Coolant temperature gauge
11. Engine Oil-Pressure
12. Battery Charge indicator
Low-gear range indicator “L”
This indicator light comes on when the drive
select lever is in the “L” position.
High-gear range indicator “H”
This indicator light comes on when the drive
select lever is in the “H” position.
Neutral indicator“N”
This indicator comes on when the drive
select lever is in the “N” position.
Reverse indicator“R”
This indicator comes on when the drive
select lever is in the “R”position.
Park indicator “P”
Control Functions 4-3
When the parking brake lever (left lever) is
fully applied and held in place this indicator
light comes on. Some models may be
equipped with a latch to lock the left lever in
the Park position.
Coolant temperature warning indicator
“ ”
When the coolant temperature reaches a
specified level, this light comes on indicating
the coolant temperature is too hot. If the light
comes on during operation, stop the engine
as soon as possible when it is safe to do so
and allow the engine to cool down for about
15 minutes.
CAUTION:
The engine may overheat if the ATV is
overloaded. If this happens, reduce the
load to specification.
After restarting, make sure that the
coolant warning light is off. Continuous
use while the light is on may cause
damage to the engine.
Headlight indicator “ ”
When the headlights are selected, this
indicator is lighted.
Parking light indicator“ ”
When the light switch is in the parking light
position “ ”, this indicator is lighted.
Emergency flashers “ ”
When the emergency flasher switch is
depressed this indicator is lighted.
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