Craftsman 108.27807 Operator's Manual
Operator’s Manual
WARNING
ALL TERRAIN VEHICLE
Craftsman 300 Electric Start Engine
2 Wheel or 4-Wheel Drive
Automatic Transmission
Model Number: 108.27807
Before operating this vehicle, the owner and each operator must:
• Understand that this vehicle was not designed or manufactured to
meet specifications for use on public roads, streets, highways, and
thoroughfares.
• Read and have an understanding of all the instructions for proper
assembly and safe operation as well as the instructions concerning the
engine and all other portions of the vehicle.
• View “Operations and Safety” video.
• Be at least 16 years of age.
For answers to your questions about this product, call:
1-800-643-7332
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
8 a.m.– 5 p.m. ET, Mon – Fri
PN 83155
Table of Contents
Section
1. Introduction
2. Understanding Warnings
3. Safety Warnings
4. Warning Decals
5. Daily Pre-Ride Inspection
6. Operation Warnings
7. Vehicle Identification
8. Basic System Functions
9. Starting the Engine
10. Vehicle Break-in Period
11. Riding Gear
12. Riding
13. Carrying Loads
14. CVT System
15. Battery
16. Exhaust System
17. Maintenance
18. Storage
19. Troubleshooting
20. Tools
21. System Specifications
22. Wiring Diagram
23. Warranty
Page
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4
5
8
16
17
27
28
39
41
41
42
49
50
51
53
54
72
74
77
78
80
81
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1. Introduction1
Congratulations on the purchase of your All Terrain Vehicle (ATV). We take pride in
offering you this product engineered and manufactured to the highest
performance and quality standards. We are sure that you will enjoy superior levels
of performance, reliability, riding comfort, and safety. Should you experience any
problem you cannot easily remedy, contact 1-800-643-7332 for an authorized
service center.
This manual is provided to help the owner and operators of this ATV become
familiar with the operating characteristics, and the many features offered on this
ATV. Please read and observe the safety warnings detailed in this manual. Failure
to follow these warnings increases the possibility of accidents leading to DEATH
or SERIOUS INJURY!
Follow a regular schedule for maintaining and caring for your ATV, including
storage, as outlined in this manual.
Important Safety Notice
Never make any modifications to the engine, drive system, mechanical or
electrical systems of your ATV. Never install after market parts or accessories
intended to increase the speed or power of your ATV.
Additionally, failure to follow these requirements will void the Warranty on your
ATV.
NOTE:
mowers, blades, sprayers, winches and windshields will change the handling
characteristics of your ATV.
Please be certain that any accessory added has been approved by Manco (the
manufacturer of this Craftsman ATV). Contact Manco Customer Service at
1-800-643-7332 or 1-260-432-1596.
The addition and use of certain accessories including, (but not limited to)
Practice Responsible ATV Riding
Make sure that you understand and follow all local, state/province, and federal
riding laws and requirements. Many parks, recreation areas and trails that allow
ATV riding have their own safety rules as well. Be smart, check before you ride.
Remember, respect your vehicle, respect the environment, and respect the
property of others. You are responsible for your safety and the safety of others
around you when you ride.
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2. Understanding Warnings
ATTENTION: Read and understand warnings and owner’s manual before
operation. This is an adult vehicle only— it is not a toy.
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
manual carefully. Follow their instructions to remain safe.
The following precautionary signals and words are used throughout this manual to
convey the following messages:
This is the Safety Alert Symbol. When you see this symbol on your machine or in
this manual, be alert to the potential for personal injury. Your safety is involved!
WARNING
Indicates a potential hazard, which could result in severe injury or death.
CAUTION
Indicates a potential hazard which may result in minor personal injury or damage
to the ATV.
CAUTION
Caution when used without the alert symbol indicates a situation that can result in
damage to the machine.
NOTE
The word “NOTE” in this manual will alert you to key information or instructions.
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3. Safety Warnings
WARNING
AN ATV 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, if you fail to take proper precautions.
Know your vehicle before you begin riding!
Read this manual thoroughly prior to operating your vehicle. Operating this vehicle
carries with it responsibilities for your personal safety, the safety of others, and the
protection of our environment.
Serious 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 instruction. Take a training course.
Beginners should receive training from a certified instructor. Contact an
authorized ATV dealer to find out about the training courses nearest you.
• Never allow anyone who is not an adult to operate this ATV.
• Never permit a guest to operate this ATV unless the guest has read this
manual and all product labels, and has completed a certified training course.
• Always avoid operating an ATV on any paved surfaces, including sidewalks,
driveways, parking lots and streets.
• Never operate an ATV without wearing 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 as outlined in Section 11 “Riding
Gear”.
• Never consume alcohol or drugs before or while operating this ATV.
• Never operate at excessive speeds. Always travel at a speed which is proper
for the terrain, visibility, operating conditions, and your experience.
• Never attempt wheelies, jumps or other stunts.
• Always inspect your ATV each time you use it to make sure it is in safe
operating condition as outlined in Section 5 “Daily Pre-Ride Inspection”.
• Always follow the maintenance procedures and schedules described in this
manual as outlined in Section 17 “Maintenance”.
• Always keep both hands on the handlebars and both feet on the footrests of
the ATV during operation.
• Always go slowly and be extra careful when operating on unfamiliar terrain.
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Always be alert to changing terrain conditions when operating the ATV.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning as described Section 12 “Riding –
Making Turns”. Practice turning at low speeds before attempting to turn at
faster speeds. Do not turn at excessive speed.
• Always have the ATV checked by an authorized dealer if it has been involved in
an accident.
• Never operate ATV on hills too steep for the ATV or for your abilities. Practice
on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in Section 12
“Riding – Traveling Uphill”. 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 throttle suddenly or make sudden gear changes.
Never go over the top of any hill at high speed.
• Always follow proper procedures for going down hills and for braking on hills as
described in Section 12 “Riding – Traveling Downhill”. 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 which would
cause the vehicle to lean sharply to one side. Go straight down the hill where
possible.
• Always follow proper procedures for crossing the side of a hill as described in
Section 12 “Riding – Side Hilling”. Avoid hills with excessively slippery or loose
surfaces. Shift your weight to the up side of the ATV. Never attempt to turn the
ATV around on any hill until you have mastered level-ground turning technique
described in Section 12 “Riding – Making Turns”. Avoid crossing the side of a
steep hill if possible.
• Always use proper procedures if you stall or roll backwards when climbing a hill.
To avoid stalling, maintain a steady speed when climbing a hill. If you stall,
follow the special procedure described in Section 12 “Riding – Turning around
on a Hill”.
• 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 Section 12
“Riding – Trail Obstacles”
• Always be careful of skidding or sliding. On slippery surfaces, such as ice, go
slowly and be very cautious in order to reduce the chance of skidding or sliding
out of control (See Section 12 “Riding – Riding on Slippery Surfaces”).
• Avoid operating the ATV through deep or fast flowing water. Avoid water which
exceeds the recommended maximum depth of 8 inches, as detailed in Section
12 “Riding – Crossing Streams”. 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.
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• Wet brakes may have reduced stopping ability. Test your brakes after leaving
water. If necessary apply them lightly several times to let friction dry out the
pads.
• 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. Avoid turning at
sharp angles in reverse as described in Section 12 “Riding – Operating in
Reverse”.
• Always use the size and type tires specified in this manual, as detailed in
Section 21 – “System Specifications”. Always maintain proper tire pressure as
described in this manual.
• Never modify an ATV through improper installation or use of accessories.
• Never exceed the stated load capacity for an ATV as stated in Section 21 –
“System Specifications”. Cargo should be properly distributed and securely
attached. Reduce speed and follow instructions in this manual for carrying
cargo or pulling a trailer. Allow greater distance for braking.
SAFETY TRAINING
We strongly recommend that all new ATV riders attend a professional training
class. To obtain more information on ATV training courses in your area call
1-800-887-2887. Once you have completed this training, you will be reimbursed
for the cost of the class for all first time riders in your immediate family. Fill out and
return the Rider Training Coupon that you received with your new ATV to receive
the reimbursement plus a certificate for up to $100 in free merchandise.
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4. Warning Decals
Warning decals have been placed on the vehicle for your protection. Read and
follow the instructions on each decal carefully. In the event that any decal
becomes illegible or comes off, contact 1-800-643-7332.
NOTE: Illustrations used in this manual are for general representation only. Your
model may differ.
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10
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Refer to Page 13
12
Emission Control Information:
EMISSION CONTROL INFORMATION
IMPORTED BY Sunright International of America, Inc.
HANGSU LINHAI POWER MACHINERY GROUP
ENGINE DISPLACEMENT: 275cc
MAXIUM BRAKE HORSEPOWER:
ENGINE FAMILY:
THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE
EM
THIS VEHICLE CONFORMS TO US ENVIRONMENTAL PROTECTION AGENCY REGULATIONS APPLICABLE TO 2006
MODEL YEAR ALL-TERRAIN VEHICLES AND IS CERTIFIED TO 1.5 GM/KM HC+NO
EMISSION STANDARDS.
THIS VEHICLE CONFORMS TO CALIFORNIA ARB REGULATIONS APPLICABLE TO 2006 MODEL YEAR NEW
OFF-HIGHWAY RECREATIONAL VEHICLES AND IS CERTIFIED TO 1.2 GM/KM HC ENGINE FAMILY EXHAUST
EMISSIONS STANDARDS.
THE WARRANTED USEFUL LIFE OF THIS ENGINE FOR THE PURPOSE OF MEETING US EPA STANDARDS IS 60
MONTHS OR 10,000 KILOMETERS, WHICHEVER OCCURS FIRST.
ENGINE TUNE-UP SPECIFICATIONS:
SPARK PLUG TYPE: DR7EA GAP.0.6MM-0.7MM
FUEL: UNLEADED 89 OCTANE OR HIGHER
OIL: SAE 15W40
WARM IDEL SPEED: 1500 RPM IN NEUTRAL
WARNING – SEE OWNERS GUIDE
NO OTHER ADJUSTABLE PARAMETERS
MADE IN CHINA
DATE MANUFACTURED.
13
ENGINE FAMILY EXHAUST
X
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5. Daily Pre-Ride Inspection
WA
RNING
You must inspect your ATV each time before riding to ensure it is in proper working
order. If proper inspection is not done, severe injury or death could result.
Use the following checklist to verify your machine is in proper working order each
time you ride.
Item/Inspection Procedure
1. Tires: check condition and pressures.
2. Fuel tank: fill the fuel tank to its proper level.
3. All brakes: check operation, adjustment and fluid level (includes auxiliary
brake).
4. Throttle: check for free operation and closing.
5. Headlight / Tail light / Brake light: check operation of all indicator lights and
switches.
6. Engine stop switch: check for proper function.
7. Wheels: check for tightness of wheel nuts and axle nuts; check that axle nuts
are secured by cotter pins.
8. Air cleaner element: check for dirt; clean or replace.
9. Steering: check for free operation noting any unusual looseness in any area.
10. Loose parts: visually inspect vehicle for any damaged components or loose
nuts/bolts or fasteners.
11. Operator: wear proper riding gear; helmets, goggles and clothing.
12. Engine coolant: check for proper level at the recovery bottle.
13. 4WD Units Only: pull the handlebar to one side or ride the ATV at a low speed.
Steering should remain balanced from left to right in 2WD and 4WD positions.
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6. Operation Warnings
WARNING
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if operator does not know 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 then regularly practice techniques described in this manual.
For more information about the training course, contact 1-800-887-2887.
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 of a severe head
injury or death in the event of an accident. Operating without eye protection can
result in an accident and increases your chances of a severe injury in the event of
an accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet, which fits properly. You should also wear: eye
protection (goggles or face shield); gloves; boots; long-sleeved shirt or jacket; and
long pants.
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WARNING
WARNING
POTENTIAL HAZARD
Carrying a passenger on this
ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to
balance and control this ATV.
Could cause an accident,
resulting in harm to you and /or
your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger.
POTENTIAL HAZARD
Operating this ATV on paved
surfaces, including sidewalks,
paths, parking lots, and
driveways.
WHAT CAN HAPPEN
Paved surfaces may seriously
affect handling and control of
the ATV, and may cause the
vehicle to go out of control.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement.
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WARNING
WARNING
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment. Could cause you to react more slowly. Could
affect your balance and perception. Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while operating this ATV.
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the ATV, which can result in an
accident.
HOW TO AVOID THE HAZARD
Always travel at a speed that is proper for the terrain, visibility, operating
conditions, and your experience.
POTENTIAL HAZARD
Attempting wheelies, jumps and
other stunts.
WHAT CAN HAPPEN
Increases the chance of an
accident, including an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as
wheelies or jumps.
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WARNING
WARNING
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating. Failure to properly
maintain ATV.
WHAT CAN HAPPEN
Increases the possibility of accident or equipment damage.
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 procedures outlined in Section 5
“Pre-Ride Inspection” and maintenance procedures described in Section 17
“Maintenance”.
POTENTIAL HAZARD
Removing hand from handlebars or feet from footrests during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can 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, causing
injury or an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the footrests of your
ATV during operation.
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 overturning or going out of control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the ATV.
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WARNING
WARNING
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively rough, slippery or loose
terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could result in an accident,
including overturn.
HOW TO AVOID THE 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 these kinds of terrain.
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for climbing hills as described in Section 12
“Riding – Traveling Uphill”. Always 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. The ATV could flip over
backwards. Never go over the top of any hill at high speed – an obstacle, sharp
drop, or another vehicle or person could be on the other side of the hill.
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
ATV could go out of control, causing a collision or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning as described in Section 12 “Riding –
Making Turns”.
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WARNING
WARNING
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on extremely steep hills than on level
surfaces or small hills.
HOW TO AVOID THE HAZARD
Never operate the ATV on hills too steep for the ATV or for your abilities. Practice
on smaller hills before attempting large hills. Never operate ATV on hills with an
incline steeper than 15 degrees.
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for going down hills as described in Section 12
“Riding – Traveling Downhill”.
NOTE:
downhill. 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 which would cause the vehicle to lean sharply to one
side. Go straight down the hill where possible.
A special technique is required when braking as you go
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any hill until you have mastered the level
ground turning technique as described in Section 12 “Riding – Making Turns”. Be
very careful when turning on any hill. Avoid crossing the side of a steep hill if
possible.
When crossing the side of a hill:
Always follow proper procedures as described in Section 11 “Riding – Side Hilling”.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the
uphill side of the ATV.
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WARNING
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards, or
improperly dismounting while
climbing a hill.
WHAT CAN HAPPEN
Could result in ATV overturning.
HOW TO AVOID THE HAZARD
Maintain steady speed when
climbing a hill. If you lose all forward speed, keep weight uphill and apply the
brakes. Lock the 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 single-lever brake gradually. 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 Section 12 “Riding – Turning around on a
Hill”.
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. Use extreme caution when
riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid
obstacles, always follow proper procedures as described in Section 12 “Riding –
Trail Obstacles”.
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WARNING
WARNING
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
You may lose control of the ATV. You may also regain traction unexpectedly, which
may cause the ATV to overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces, such as ice, go slowly and be very cautious in order to
reduce the chance or skidding or sliding out of control. Always follow proper
procedures as described in Section 12 “Riding – Riding on Slippery Surfaces”.
POTENTIAL HAZARD
Operating this ATV through deep or fast flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which could lead to an
accident.
HOW TO AVOID THE HAZARD
Never operate the ATV through water which exceeds the recommended maximum
depth in this manual (see Section 12 “Riding – Crossing Streams”). Avoid
operating the ATV through deep or fast flowing water. Remember that wet brakes
may have reduced stopping ability. Test your brakes after leaving water. If
necessary, apply them several times to let friction dry out the pads.
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind you, resulting in severe injury.
HOW TO AVOID THE HAZARD
When you select reverse gear, make sure there are no obstacles or people behind
you. When it is safe to proceed, go slowly. Always follow proper procedures as
described in Section 12 “Riding – Operating in Reverse”.
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