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

3
4
5

8
16
17
27
28
39

41
41
42
49
50
51

53
54
72
74
77
78

80
81

2

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.

3

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.

4

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.

5

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.

6

• 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.

7

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.

8

9

10

11

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

14

15

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.

16

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.

17

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.

18

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.

19

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.

20

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”.

21

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.

22

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”.

23

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”.

24

WARNING

WARNING

WARNING

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires on this ATV, or operation of this ATV with improper or uneven
tire pressure, may cause loss of control, and increases the risk of an accident.

HOW TO AVOID THE HAZARD

Always use the size and type tires specified in Section 21 “System Specifications”
for this vehicle. Always maintain proper tire pressure specified as well.

POTENTIAL HAZARD

Operating this ATV with improper modifications or accessories.

WHAT CAN HAPPEN

Improper installation of 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 accessories. All
parts and accessories added to this vehicle should be genuine or equivalent
components designed for use on this ATV, and should be installed and used
according to instructions supplied with the part. If you have questions, contact
1-800-643-7332.

POTENTIAL HAZARD

Overloading this ATV or carrying or towing cargo improperly.

WHAT CAN HAPPEN

Could cause changes in vehicle handling, which could lead to an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV specified in Section 21 “System
Specifications”. Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer and allow greater distance
for braking. Always follow proper procedures as described in Section 13 “Carrying
Loads”.

POTENTIAL HAZARD

Riding on frozen lakes and rivers.

25

WHAT CAN HAPPEN

WARNING

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 before you are sure the ice is thick
enough and sound enough to support the machine and its operator, as well as the
force that is created by a moving vehicle.

• After a rollover or an accident, have a qualified service dealer check the
complete machine including, but not limited to, brakes, throttle and steering for
possible damage.

• Safe operation of this rider-interactive vehicle requires good judgment and
physical skills. Persons with cognitive or physical disabilities who operate this
vehicle have an increased risk of overturns and loss of control, which could
result in severe injury or death.

• Keep combustible materials away from exhaust system. Fire may result.

26

7. Vehicle Identification

1

2

Record these numbers from your ATV in the spaces provided.

1. Frame VIN (found on the left side, below engine, by rear swing arm)

2. Engine Serial Number (left front side of engine crankcase)

The vehicle VIN and engine serial numbers are important for model identification
when registering your vehicle, obtaining insurance, or whenever replacement
parts are required. Also, these numbers are essential to the recovery and
identification of your ATV if it is ever stolen.

Frame VIN

Engine Serial #

27

Remove the spare key and store in a safe place.
Your key can only be duplicated by obtaining a key blank and having it cut by
mating it with your existing key. Record key number in space below.

Key Number

8. Basic System Functions

Electrical Switches

1

2

6

7

8

5

28

WARNING

3

4

Pictures are for Reference Only

1. Main Switch – This key switch must be turned clockwise to the “on” position to

start the engine.

2. Hazard Light Switch (when equipped) – When the switch is pushed to “ “, the

four signal lights are on and the buzzer is sounding.

3. Engine Start Button – To start the engine.

4. Engine Stop Switch – To stop the engine.

5. Override Button – press the override button BEFORE backing up to obtain

additional power.

6. Bright Light Switch – Will change the light setting from dim to bright.

7. Blinker Switch – Will activate both left and right blinkers.

8. Horn Button – Will activate the horn.

Never activate the override button while throttle is open as loss of control
may result, causing severe personal injury or death.

29

Light Switches and Indicator Lights

WARNING

This ATV is NOT equipped with highway-approved lighting. This ATV is designed
for off-road use only and must not be ridden on streets or highways. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness.

Switches

The light switch is located on the left hand handlebar. In addition to turning the
lights on and off, it also switches the lights between High and Lo on models
equipped with Hi – Lo beams.

Indicator Lights

The ATV has indicator lights. The configuration of these lights differs with
individual models and not every model is equipped with all the lights. This
information will help you identify the lights on your machine and their function.

With engine running, verify function of indicator lights each time ATV is used.

NOTE: The taillight is on whenever the main switch (key) is in the “on” position.
Turn the key off to prevent battery drain.

1. High Beam Indicator – Blue

2. Transmission Reverse –

Purple

3. Turn Signal Indicator –

Green

4. 4WD Indicator - Yellow

5. Transmission Neutral –

Green

6. High Temp – Red

(Will light only if engine
overheats, at the same time,
a buzzer sounds)

4

5

1 2 3

6

30

WARNING

WARNING

Throttle

Do not start or operate an ATV with sticking or improperly operating throttle control.
A stuck or improperly operating throttle could cause an accident resulting in 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 the throttle lever sticking during riding and cause an accident.
Always check the lever for free movement and return before starting the engine
and occasionally during riding.

Washing or operating the ATV in freezing temperatures can result in water
freezing in the throttle cable conduit and/or on the throttle mechanism. This may
result in the throttle sticking which can cause the engine to continue to run and
result in loss of control.

Throttle Lever

Pressing the throttle lever (1) with your thumb controls engine speed and vehicle
movement. The throttle lever is spring-loaded and engine speed returns to idle
when the lever is released.

1

Speed Adjustment

1

To limit throttle travel and top speed, the ATV is
equipped with a throttle adjuster screw. The
screw can be turned in to lower the top speed

2

and out to increase the top speed. After
adjustment, the locknut must be tightened down
against the throttle housing.

1. Locknut

2. Throttle Adjuster Screw

31

WARNING

WARNING

Front and Rear Brake Control

Never operate the ATV with a spongy feeling brake lever. Operating the ATV with a
spongy brake lever can result in loss of braking. Loss of braking could cause an
accident.

The front and rear brake
control is located on the
left handlebar and
operated by the left hand.
The front and rear brakes
are hydraulically activated
disc type brakes, which
are activated by one
control only. Always test
brake lever travel and
reservoir fluid level before
riding. When squeezed,
the lever should feel firm.
Any sponginess would indicate a possible fluid leak or low master cylinder fluid
level which must be corrected before riding. Contact 1-800-643-7332 for proper
diagnosis and repairs.

Setting the Parking Brake

Front and Rear Brake Control Lever

Always check to be sure that the parking brake has been disengaged before
operating the ATV. An accident could result causing severe injury if the parking
brake is left on while the ATV is operated.

1. Squeeze the left hand
brake lever two or
three times and hold it.

2. Push the park brake
lock (1) into the
notches (2) on the
master cylinder body.
Release the brake
lever.

3. To release the parking
brake lock, squeeze
the brake lever. It will

2

1

32

return to its released position.

WARNING

WARNING

WARNING

Auxiliary Brake

Important Safeguards

• The parking brake may relax when left on for a long period time. This could
cause an accident.

• Do not leave the vehicle on a hill depending on the parking brake for more than
five minutes.

• Always block the downhill side of the wheels if leaving the ATV on a hill or park
the ATV in a side hill position.

Auxiliary Brake Operation

Use caution when
applying the auxiliary
brake. Do not
aggressively apply the
auxiliary brake when
going forward or the rear
wheels may skid and
slide sideways causing
loss of control.

Aggressively applying
the auxiliary brake when backing down a hill may cause the ATV to become
unstable and tip over.

Your ATV has an auxiliary brake, provided as a safety feature, which operates a
rear brake on your unit. Step on the pedal located on the right footboard to operate
the auxiliary brake. The auxiliary brake is intended as a backup to the main brake
system in the event the main system becomes inoperative.

Brake Fluid Levels

Once a bottle of brake fluid is opened, use what is necessary and discard the rest.
Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning that it rapidly absorbs moisture from the air. This causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and the
possibility of severe injury.

33

Master Cylinder

WARNING

The brake fluid in the master
cylinder, which is located on the
left handlebar, should be
checked before each ride. There
is an indicator window (1) on the
top of the master cylinder. This
window will appear dark when
the fluid level is full. When fluid
needs to be added, the window
will be clear.

When checking brake fluid, the ATV must be on level ground and the

NOTE:

handlebars must be straight. If fluid level is low add DOT 3 only.

Auxiliary Brake

The brake fluid level for the auxiliary brake should be checked before each ride.
The reservoir is located under the seat. The fluid should be kept between the
maximum and minimum marks.

1

Automatic Transmission Gear Selector Operation

Engaging a lower gear when the engine speed is too high could cause the wheels
to stop rotating leading to loss of control which could lead to the possibility of death
or serious injury.

To change gears, stop the vehicle and with the engine idling, move the lever to the
desired gear. Shifting gears with the engine speed above idle or while the vehicle
is moving could cause transmission damage.

The transmission gear selector is located on the
right side of the vehicle. The transmission
selector lever has four positions: high forward;
neutral; reverse; and low forward.

Always place the transmission in gear with the
parking brake locked whenever the vehicle is left
unattended. Shift linkage adjustment is important
to assure proper transmission function. Should
you experience any shifting problem, contact
1-800-643-7332.

CAUTION

34

NOTE: There

W

ARNING

extend belt life, use low forward gear in heavy pulling situations and in situations
when you are operating below 7mph (11km/h) for extended periods of time.

is a torque converter belt used to drive the transmission.

To

Engine Cooling System

Coolant level – Recovery bottle

The recovery bottle,
located under the seat,
must be maintained
between the minimum
and maximum levels
indicated on the
recovery bottle
the seat and the coolant
reservoir cap to add
coolant to appropriate level.

The engine coolant level is controlled or maintained by the recovery system. The
recovery system components are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose. As coolant operating temperature increases,
the expanding (heated) excess coolant is forced out of the radiator past the
pressure cap and into the recovery bottle. As engine coolant temperature
decreases, the contracting (cooled) coolant is drawn back up from the tank past
the pressure cap and into the radiator.

. Remove

FULL

LOW

Fill Location

NOTE: Some coolant level drop on new machines is normal as the system is
purging itself of trapped air. Observe coolant levels and maintain as recommended
by adding coolant to the recovery bottle. We recommend the use of a 50/50
mixture of high quality aluminum compatible anti-freeze coolant and distilled water.
(Always follow the anti-freeze manufacturer’s mixing recommendations for the
freeze protection required in your area.)

Radiator Coolant Level

If the cooling system has been drained for maintenance and/or repair, slowly add
coolant as necessary through the radiator filler neck. It is recommended that the
system be completely drained every two years and a fresh mixture of antifreeze
and water be added so that the coolant maintains its ability to protect the engine.
Use of a non-standard pressure cap will not allow the recovery system to function
properly. If the cap should need replacement contact 1-800-643-7332 for the
correct replacement part.

Never remove the pressure cap (1) when the engine is warm or hot. Escaping
steam can cause severe burns. The engine must be cool before removing the
pressure cap.

35

WARNING

Pressure Cap

Fuel System

• Gasoline is highly flammable and explosive under certain conditions.

• The engine exhaust from this product contains chemicals known, in certain

quantities, to cause cancer, birth defects or other reproductive harm.

CAUTION:

can attract moisture which leads to separation and formation of acids during
storage. Acidic gas can damage the fuel system of an engine while in storage. To
avoid engine problems, the fuel system should be emptied before storage for 30
days or longer. Drain the gas tank, start the engine and let it run until the fuel lines
and carburetor are empty. Use fresh fuel next season. See storage instructions in
Section 17 “Maintenance” for additional information.

CAUTION:

permanent damage may occur.

Additional Fuel System Safety Instructions

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine turned off 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 over fill 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.

• Never start the engine or 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 the fuel valve whenever the ATV is stored or parked.

Alcohol blended fuels (called gasohol or using ethanol or methanol)

Never use engine or carburetor cleaner products in the fuel tank or

36

The fuel tank filler cap (1) is located directly behind the handlebar. Refer to Section
19 “Specifications” for tank capacity. Use regular unleaded gasoline. The fuel
valve selector is located on the left side of the front fender and has three positions:

OFF: For vehicle storage and whenever transporting.
ON: For normal operation.
RES: For reserve supply in the event of main supply exhaustion.

1

NOTE: The reserve supply has about a 6 mile /10km range of gas. Always refill the
gas tank as soon as possible after having used the reserve supply. Always return
valve to ON position after refueling the machine.

Fuel Filter

The filter should be replaced every 100 hours of operation or annually. Do not
attempt to clean the fuel filter.

37

Oil System

WARNING

Use only SAE 15W/40 OIL. Never substitute or mix oil brands. Serious engine
damage and voiding of warranty can result.

The oil fill is located on the right side of the engine.

To check the oil:

1. Set machine on a level surface.

2. Start the engine and let it idle for 20-30 seconds.

3. Stop the engine, remove the dipstick (1) and wipe dry with a clean cloth.

4. Put dipstick into the oil fill hole, remove it, and read the oil level.

5. If the oil level is between the full and add marks (2). Add oil as indicated by the

CAUTION

level on the dipstick. Do not overfill.

4-Wheel Drive System (4WD)

Extremely heavy steering feel is a symptom of malfunction of the front gear case
(differential). Loss of control could result, even in 2-Wheel Drive (2WD) position. If
you experience any of these steering symptoms, contact 1-800-643-7332 for an
authorized service dealer. Asymmetrical heavy steering is a symptom of
malfunction of the inner or outer CV joints on one side of the unit. Loss of control
could result, even in 2WD position. If you experience any of these steering
symptoms, contact 1-800-643-7332 for an authorized service dealer.

38

CAUTION:

WARNING

with the engine idling, move the lever to desired position. Shifting while the vehicle
is moving or the rear wheels are spinning could cause transmission and drive
system damage.

To engage or disengage the 4WD drive system, stop the vehicle and

4-Wheel Drive ATVs are equipped with an
electronic shift. The shift selector is located
on the right side handle bar. The selector
lever has two positions: 2WD and 4WD. In
2WD (2-Wheel Drive), only rear drive is
engaged. In 4WD, both rear and front drives
are engaged.

The 4WD indicator will light when the front drive is engaged. After 4WD is engaged
steering effort should increase but remain balanced from left to right.

NOTE: When shifting to the 2WD position from 4WD, the engagement shifter may
appear to return to the engaged position, however, the 4WD will be disengaged.
The 4WD shifter should finally disengage when the unit is ridden on a hard surface
or in reverse. The 4WD indicator light will come off when the 4WD is disengaged. If
the 4WD continues to remain engaged after following these instructions, contact
1-800-643-7332 for an authorized service dealer.

NOTE: Heavier steering effort and feel will be experienced when 4WD is engaged.

2WD 4WD

9. Starting the Engine

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.

CAUTION:

or engine damage could result.

CAUTION:

If the battery is under-charging, the ATV will not run.

You must allow your vehicle adequate warm up time before operating

This ATV is only equipped with an electric start system.

Starting Procedure

The following procedure will assure all fuel lines are full and the engine will operate
properly.

1. Make sure that the fuel tank is at least half full (approx. 2 gallons) with fresh,
clean gasoline and the fuel valve selector is in the ON position.

2. Sit on the vehicle. Check that the engine stop switch is in the RUN position.

3. Turn the key switch to ON. Hold the brake lever and place transmission in

39

neutral. Press the engine start button. NEVER press the engine start button for
more than 5 seconds at a time or you can flood the engine.

4. If the engine does not start, turn the key switch off, wait 15 seconds and repeat
steps 3 and 4 two more times.

5. If after step 4 the engine still does not start , press and release the throttle lever
¼ of its full travel 3 times to prime the carburetor before attempting to start the
engine again.

CAUTION:

the starting procedure. Doing so will flood the engine and cause fouling of the

spark plug.

NEVER press the throttle more than ¼ of its full travel during

Cold Weather Starting

Perform starting procedure steps 1 through 5.

NOTE: While pressing the engine start button it may be necessary to hold the
throttle lever not more than ¼ of the full travel to accommodate the auto-choking
system in a cold weather.

REMEMBER:

• Always double-check that the engine stop switch is in the RUN position.

• Turn the fuel valve selector to OFF when ATV is not in use or is being

transported.

• Never press the engine start button for more than five seconds at a time or you
can flood the engine.

(less than 400 F)

40

10. Vehicle Break-in Period

CAUTION

Do not operate at full throttle or high speeds for extended periods during the
break-in period. Excessive heat can build up and cause damage to close fitting
engine parts.

CAUTION:

break-in period to a top speed of 25 MPH.

The break-in period for your new ATV is defined as the first 50 hours of
operation.

period. Careful treatment of a new engine will result in more efficient performance
and longer life for the engine. Perform the following procedures carefully.

1. Fill fuel tank with fresh, clean fuel.

2. Check oil reservoir level indicated on dipstick. Add oil if necessary.

3. Drive slowly at first. Select an area which is open and will give you room to
familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at a sustained idle.

5. Perform regular checks on fluid levels, controls, and all important areas on the
vehicle as outlined earlier on the daily pre-ride inspection checklist found in
Section 5 “Daily Pre-Ride Inspection”.

6. Don’t pull loads.

7. Change oil and filter after first 20 hours or 200 miles / 320 km.

Speed adjustment should be limited during the

No single action on your part is as important as a proper break-in

11. Riding Gear

Safe Riding Gear

ATV riding requires special protective clothing, which will make your ride more
comfortable and reduces the chance of injury.

1. Helmet – Your helmet is the most important piece of protective gear for safe
riding. A helmet can prevent a severe head injury.

2. Eye Protection – A pair of goggles or helmet face shield offers the best
protection for your eyes

3. Gloves – Off-road style.

4. Boots – A pair of strong over the calf type boots with heels, such as

moto-cross boots.

5. Clothing – To protect your body, long sleeves and pants should always be
worn. Riding pants with kneepads, a jersey and shoulder pads provide the best
protection.

.

41

12. Riding

WARNING

WARNING

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. See
Section 5 “Daily Pre-Ride Inspection”

1. Sit upright with both feet on footrests and both hand on the handlebars.

2. After starting the engine and allowing it to warm up, shift the transmission into
gear.

3. Check you surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin driving. Vehicle
speed is controlled by the amount of throttle opening.

6. Drive slowly, practice maneuvering and using the throttle and brakes on level
surfaces

Making Turns

Practice making turns at slow speeds. This ATV is equipped with a solid rear axle,
which 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 wheels when
turning and the inside tire must slip traction slightly. To turn, steer in the direction of
the turn leaning your weight on the outer footrest. This technique alters the
balance of traction between the rear wheels allowing the turn to be made smoothly.
The same leaning technique should be used for turning in reverse.

Riding on Slippery Surfaces

Failure to exercise care when operating the ATV on slippery surfaces can be
dangerous. Loss of tire traction and vehicle control can result in an accident,
including an overturn.

Whenever riding on slippery surfaces such as wet trails, loose gravel, or during
cold freezing weather, special attention must be given to preventing vehicle
turnover. Always observe the following:

42

Always:

WARNING

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp
turns which can cause skids.

3. Correct a skid by turning the handlebars in the direction of the skid and shifting
your body weight forward.

4. Never apply brakes during a skid. Complete loss of ATV control can result.

5. Do not operate on excessively slippery surfaces.

6. Always reduce speed and use additional caution.

Traveling Uphill

Exercise extreme caution when traveling in hilly terrain. Braking and handling are
greatly affected. Loss of vehicle control or overturning of the ATV could occur
causing severe injury or death.

Whenever traveling uphill always travel straight uphill and

1. Avoid steep hills (15° incline maximum).

2. Keep both feet on the footrests.

3. Transfer your weight foreward.

4. Proceed at a steady rate of speed and throttle opening.

5. Remain alert and be prepared to take emergency action. This may include

quick dismounting of the ATV.

:

43

Side Hilling

WARNING

WARNING

Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle
control or overturning of the ATV could occur causing severe injury or death.

Side hilling your ATV is one of the most dangerous types of riding and should be
avoided. If you do enter into a situation where side hilling is necessary, always:

1. Slow down.

2. Lean into the hill transferring your upper body weight toward the hill while
keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle direction.

4. If vehicle begins to tip, quickly turn the front wheel downhill, if possible, or
dismount on the uphill side immediately!

Traveling Downhill

When traveling downhill do not travel at excessive speeds. It is dangerous and can
cause loss of vehicle control and tipping, resulting in severe injury or death.

Whenever descending a hill, always:

1. Drive directly downhill.

2. Transfer your weight to the rear of
the vehicle.

3. Slow down.

4. Apply the brakes slightly to aid in
slowing.

Familiarize yourself with the auxiliary
rear brake pedal and its use in the event of losing the primary brakes.

44

Turning Around On A Hill

WARNING

WARNING

Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could
occur resulting in severe injury or death.

If the ATV stalls while climbing a hill, never back it down the hill! One maneuver,
which can be used when it is necessary to turn around while climbing a hill, is the
K-turn.

1. Stop and lock the parking
brake while maintaining
body weight uphill.

2. Leave transmission in
forward and shut off engine.

3. Dismount on uphill side of
ATV. If facing straight uphill
dismount on left side of ATV.

4. Staying uphill of ATV, turn
handlebars full left (while facing front of ATV).

5. While holding brake lever down, release parking brake lock and slowly allow
ATV to roll around to your right until ATV is pointing across the hill or slightly
downward.

6. Lock the parking brake and remount ATV from the uphill side, maintaining body
weight uphill.

7. Restart engine with transmission still in forward, release the parking brake, and
proceed slowly, controlling speed with the brake lever, until ATV is on
reasonably level ground.

Crossing Streams

Never operate the ATV through deep or fast flowing water.

Your ATV can operate through water
up to maximum recommended
depth of 8 inches.

Before crossing steams always:

1. Determine water depths and
current.

2. Choose a crossing where both
banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

45

4. After crossing, dry the brakes by applying light pressure to the lever until
braking action is normal.

NOTE: After running the vehicle in water, it is critical your machine is serviced as
outlined in the maintenance chart in Section 17 “Maintenance”. The following
areas need special attention: engine oil, transmission oil, rear gear case, and all
grease fittings.

If your ATV becomes immersed or if water has been ingested into the CVT system,
take it to your dealer before starting the engine. Major engine damage can result if
the machine is not thoroughly inspected.
If it is impossible to take it to a dealer before starting, follow the steps below.

1. Move the ATV to dry land

2. Turn the fuel valve

3. Remove the spark plug.

4. Loosen the carburetor

5. Turn the engine over

6. Dry the spark plug and

7. Tighten the carburetor drain screw (1).

8. Turn the fuel valve to “ON”.

9. Attempt to start the engine. If necessary repeat the “drying” procedure.

10. Take the machine to your dealer for service as soon as possible whether you

CAUTION

or at the very least, to
water depth not more
than 8 inch (200mm).

selector to “OFF”.

drain screw (1).

several times with electric
start.

reinstall or replace with a
new plug.

succeed in starting it or not.

46

Trail Obstacles

WARNING

WARNING

WARNING

WARNING

Not all obstacles are visible. Travel with caution on trails. Severe injury or death
can occur if vehicle comes in contact with a hidden obstacle.

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.

Operating in Reverse

Operating your ATV in reverse
can be dangerous! You could
hit an obstacle or person
behind you; or the vehicle
could tip over rearward on a
steep incline causing severe
injury or death.

Avoid turning at sharp angles in reverse as tip over and severe injury may result.
Opening the throttle more than required may cause excessive fuel to build in the

exhaust, which may result in engine popping and/or engine damage.

47

Backing up

1. Avoid backing up on steep inclines.

2. Always back up slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while operating in reverse.

6. Only press the override button BEFORE backing up. Pressing the button while

throttle is open can result in loss of control, causing severe personal injury or
death.

NOTE: This ATV is equipped with a reverse speed limiter. Do not operate at
wide-open throttle. Only open the throttle enough to maintain a desired speed.

Parking on an Incline

Whenever the vehicle is parked on an incline:

1. Turn the engine off.

2. Place the transmission in gear.

3. Set the parking brake.

4. Shut off fuel supply.

5. Avoid parking on an incline. If it is necessary to park on an incline, always

block the rear wheels on the downhill side as shown below.

6. Do not depend on the parking brake alone when leaving the ATV on a hill for

more than five minutes.

48

13. Carrying Loads

WARNING

1/3 of load on front

Correct loading of this vehicle is necessary to maintain proper stability and
operating characteristics. Never exceed the load weights specified in Section 21
“Specifications” of this manual. Overloading or incorrect positioning of the load
affects the vehicle’s turning, stopping distance and stability. Failure to follow
loading requirements could cause severe injury or death.

Important Safeguards for Carrying Loads

To reduce risk of injury or machine damage when carrying loads, read and follow
the warnings listed below:

• Reduce speed and allow greater distance for braking when carrying loads.

• Load weight

distribution should
be 1/3 on the front
rack and 2/3 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.

• Heavy loads can cause braking and control problems. Use extreme caution
when applying brakes with a loaded vehicle. Avoid terrain or situations which
may require backing downhill.

• All loads must be carried as low and horizontally on the racks as possible.
Carrying loads high and vertically on the racks raises the center of gravity of
the vehicle and creates a less stable operating condition. When 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. Avoid handling loads
which cannot be centered.

• Avoid operating the vehicle with loads extending over the rack sides. Stability
and maneuverability may be adversely affected, causing the vehicle to
overturn – extreme caution must be used.

• Do not block the headlight, taillight, or the reflectors when carrying loads on the
racks.

2/3 of load on rear

49

• Always attach a tow load to the hitch point designated for your ATV.

WARNING

• The vehicle should never exceed 10 mph (16km/h) while towing a load on a
level grass surface. Vehicle speed should never exceed 5 mph (8km/h) when
towing loads in rough terrain, while cornering, or while ascending or
descending a hill.

• Use of low forward gear is recommended in heavy pulling situations to extend
belt life.

14. CVT System

The CVT (Continuously Variable Transmission) system rotates at high speeds,
creating large amounts of force on clutch components. 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. Any modification will cause
the system to be out of balance, creating vibration and additional loads on
components.

• If you experience any problems with the CVT, contact 1-800-643-7332 for the
name of an authorized service center.

• The CVT housing must be securely in place during operation. See illustrated
parts list.

(Continuously Variable Transmission)

Low Range Use May Reduce
CVT Operating Temperatures

The basic operation of the CVT system is dependent on engine speed and vehicle
torque requirements. As engine speed increases, the force exerted on the
movable drive sheave by the fly-weights also increases. This, in turn, increases
the amount of “pinch” applied to the drive belt. Similarly, if the engine speed
decreases, the amount of centrifugal force decreases, reducing the amount of belt
“pinch.”

On this ATV, the approximate gear ratio difference between high and low range is
1:2.05. This difference in gearing affects the operation of the CVT, especially at
speeds less than 7 MPH, due to the system’s dependence on engine speed.

By switching to low range while operating at low ground speeds, the air
temperature in the clutch will be reduced. Reducing the temperature inside the
clutch cover extends the life of the CVT components (belt, cover, etc.).

50

When To Use Low or High Range

WARNING

WARNING

CAUTIO

N

The following lists provide a guideline for when to use low range or high range
during operation of your vehicle.

Low Range

• Basic operation at speeds less than 7 MPH (11km/h)

• Heavy pulling

• Riding through rough terrain (swamps, mountains, etc.) at low ground speeds

High Range

• Basic operation at speeds greater than 7 MPH (11km/h)

• High ground speeds

15. Battery

Whenever removing the battery, disconnect the negative (black) cable first. When
reinstalling the battery, connect the negative (black) cable last or explosive
situation could result causing serious injury or death.

Battery electrolyte is poisonous - KEEP OUT OF REACH OF CHILDREN. It
contains sulfuric acid. Serious burns can result from contact with skin, eyes or
clothing. If contact occurs:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always wear eye
protection when working around batteries.

If electrolyte spills onto ATV, immediately wash it off with a solution of
one-tablespoon baking soda and one cup water to prevent damage to the ATV.

51

Replenishing the Battery

WARNING

Fluid

A poorly maintained battery will
deteriorate rapidly. Check the battery
fluid level often. The fluid level should
be kept between the upper and lower
level marks. To refill use only distilled
water. Tap water contains minerals
which are harmful to a battery.

Battery Removal –

1. Disconnect hold down straps holding the electrical box and battery in position
and remove battery cover.

2. Remove the battery vent tube from the battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positive) battery cable next.

5. Lift the battery out of the ATV, being careful not to tip it sideways and spill
electrolyte.

see illustrated parts list

Battery Installation and Connections

To avoid the possibility of explosion, always connect battery cables in the order
specified. Red (positive) cable first; black (negative) cable last. An exploding
battery can cause serious injury or death.

CAUTION

Your ATV is equipped with a 14Amp Battery. This may not be sufficient to provide
power for optional equipment. When installing optional equipment please upgrade
your battery as necessary. Contact 1-800-643-7332 for the proper battery.

Battery terminals and connections should be kept free of corrosion.
If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a
solution of one-tablespoon baking soda and one cup water. Rinse well with tap
water and dry off with clean rags. Coat the terminals with dielectric grease or
petroleum jelly. Be careful not to allow cleaning solution or tap water into the
battery.

52

Battery Installation

WARNING

WARNING

1. Set the battery in its holder.

2. Install the battery vent tube. It must be free from obstructions and securely
installed. If not, battery gases could accumulate and cause an explosion. The
tube should be routed away from the frame and body to prevent corrosion.
Avoid skin contact with electrolyte; severe burns could result.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall battery cover and attach the hold down strap.

6. Verify that cables are properly routed.

NOTE: When parking the ATV for any amount of time make sure that the main
switch (key) is turned to the “OFF” position. Doing so will prevent battery drain.

NOTE: When your ATV is placed in storage for one month or more, the battery
should be removed, charged to proper level, and stored in a cool dry place. Before
reusing, take the battery for testing and recharging. Contact 1-800-643-7332 for
an authorized service center. When installing a new battery, make certain it is fully
charged prior to it is initial use. Using a new battery that has not been fully charged
can damage the battery resulting in a shorter life of the battery, it can also hinder
vehicle performance.

16. Exhaust System

DO NOT TAMPER WITH NOISE CONTROL SYSTEM (MUFFLER)!

Exhaust system components are very hot during and after use of ATV
Do not touch exhaust system components. Serious burns can
result. Be especially careful when traveling through tall grass. The potential for fire
exists.

When cleaning the spark arrester, you must follow the safe guards listed below to
avoid serious injury.

• Do not perform this operation immediately after the engine has been run
because the exhaust system becomes very hot.

• Keep combustible materials away from exhaust system. Fire may result.

.

Spark Arrester

In the state of California the spark arrester is required by law (section 4442 of the
California Public Resources Code). Other states may have similar laws. Federal

53

laws apply on federal lands. A spark arrester for the muffler is available by

WARNING

contacting Manco Customer Service at
1-800-643-7332 or 1-260-432-1596.

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1. Remove the arrester screw (1) located on the bottom of the muffler, pull out

the spark arrester (2) (the mesh).

2. Clean the arrester or replace it.

17. Maintenance

Service and adjustment are critical. If you are not familiar with safe service and
adjustment procedures, have a qualified dealer perform these operations.

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest, most
reliable condition. Inspection, adjustment, and lubrication intervals of important
components are explained in the tables on the following pages.

Maintenance intervals are based upon average riding conditions and an average
vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe
use, such as operation in wet or dusty areas, should be inspected and serviced
more frequently. Inspect, clean, lubricate, adjust or replace parts as necessary.

NOTE: Inspection may reveal the need for replacement parts. Always use genuine
parts available by contacting 1-800-643-7332.

54

Maintenance Table Codes

(See illustrated parts list for view of mentioned ATV parts.)

D

– Due to the nature of these adjustments, items marked with this symbol are
recommended for repair or replacement by an authorized service center. Call
1-800-643-7332 for service.

• – Check more often under severe use, such as dirty or wet conditions.

NI

– Not Illustrated.

Grease

Grease M

*

Hours are based on 10 mph (16Km/h) average.

– Light- weight lithium-soap grease.

- Molybdenum disulfide (MoS2 ) grease (water resistant).

– When suspension action becomes stiff or after washing.

Maintenance Table

Item Hours When Remarks

Brake System Pre-ride Pre-ride Pre-ride inspection item
Auxiliary Brake Pre-ride Pre-ride Pre-ride inspection item
Tires Pre-ride Pre-ride Pre-ride inspection item
Wheels Pre-ride Pre-ride Pre-ride inspection item
Frame nuts, bolts,

fasteners
Air Filter -

•

Pre-Cleaner
Coolant/Level

Inspection
Air Box Sediment

•

Tube
Headlamp

Inspection

Tail lamp inspection Daily Daily

Air Filter -

•

Main Element
Transmission Oil

•

Level

Battery 20 hrs Monthly

Pre-ride Pre-ride Pre-ride inspection item

Daily Daily Inspect - Clean

Daily Daily

Daily Daily

Daily Daily

Weekly Weekly

20 hrs Monthly Inspect monthly;

Replace engine coolant
annually.

Drain deposits whenever
visible.

Check operation daily;
Apply dielectric grease
to connector when
replaced

Check operation daily;
Apply dielectric grease
to socket when replaced

Inspect; replace if
necessary

Change annually
Check/clean Terminals;

Check fluid level

55

Item Hours When Remarks

D Brake pad wear 10 hrs Monthly

Rear Gear case Oil 100 hrs Monthly

•

Front Gear case Oil

•

(Only for 4WD)
Engine Cylinder

Head and Cylinder
Base Fasteners

General Lubrication 50 hrs 3 months

•

Engine

•

Oil-Level/Change

Oil Filter 50 hrs 6 months Inspect-clean

•

Engine breather
hose

Carburetor Float
Bowl

D Throttle Cable 50 hrs 6 months

Coolant strength 100 hrs 6 months

Shift linkage 50 hrs 6 months Inspect, adjust
D Drive belt 50 hrs 6 months

Steering 50 hrs 6 months Inspect daily, lubricate

•

Rear Axle 50 hrs 6 months

•

Front Suspension 50 hrs 6 months

•

Rear Suspension 50 hrs 6 months

•

Spark Plug 100 hrs 12 months

D Ignition Timing 100 hrs 12 months

D Fuel System 100 hrs 12 months

D Fuel Filter 100 hrs 12 months Replace annually

100 hrs Monthly

25 hrs 3 months

30 hrs 3 months

100 hrs 6 months Inspect

50 hrs 6 months

Visually Inspect
periodically

Check monthly and
change annually

Check monthly and
change annually

Inspect (re-torque
required at first service
only)

*Lubricate all fittings,
pivots, cables, etc.

Check Level Daily;
Break in Service at 1
month. Change oil more
often in cold weather
use.

Drain bowl periodically
and prior to storage

Pre-ride inspection item.
Inspect –adjust,
lubricate, replace if
necessary.

Inspect strength
seasonally

Inspect, replace if
necessary

Inspect bearings,
lubricate

Inspect-lubricate, tighten
fasteners

Inspect, tighten
fasteners

Inspect-replace if
necessary

Inspect and adjust as
needed

Check for leaks at tank
cap, lines, fuel valve,
filter, and carburetor.
Replace lines annually.

56

Item Hours When Remarks

Radiator 100 hrs 12 months

Cooling System
hoses

D Spark arrester 10 hrs Monthly

D Clutches (Drive and

Driven)

D Engine mounts 25 hrs 3 months

D Valve clearance 100 hrs 12 months Inspect/adjust
D Shift selector box

(H/L/R/N)

D Brake fluid 200 hrs 24 months Change every two years
Idle Speed As Required As Required Adjust
D Toe adjustment As Required As Required

Headlight Aim As Required As Required Adjust as necessary

50 hrs 6 months

25 hrs 3 months Inspect, clean

200 hrs 24 months

Inspect/clean external
surface

Inspect/replace if
necessary

Clean out-replace if
necessary

Inspect to see if badly
worn or missing

Change grease every
two years

Periodic inspection,
adjust when parts are
replaced

Lubrication Recommendations

Item Lubricant / Fluid Method Frequency

1. Engine Oil SAE 15W/40

2. Brake Fluid DOT 3 Only

3. Transmission

Oil

4. Rear
Gearcase Oil

5. Front
Gearcase Oil

6. Front A-arm

•
Pivot Shaft

SEA 80W/90GL5

SEA 80W/90GL5

SEA 80W/90GL5

Grease

Proper fluid level is #2
in illustration 1

Maintain level between
fill lines. See Section 8
“Basic System
Functions – Brake
Fluid Level”

Proper fluid level is #2
in illustration 3

See Section 17
“MAINTENANCE –
Front/Rear Gearcase
Lubrication”

See Section 17
“MAINTENANCE –
Front/Rear Gearcase
Lubrication”

Locate fitting on pivot
shaft and grease with
grease gun

Check level
daily

Change every
two years or
200 hours

Change
annually or at

100 hours
Change

annually or at
100 hours

Change
annually or at
100 hours

Every 3 months
or 50 hours

57

2

2

Item Lubricant / Fluid Method Frequency

7. Steering

•
Post Bushings

8. Front Wheel

• D

Bearings

9. Tie rods Grease

11. Shift
Linkages

NI. Ball joints Inspect

• D

12. Prop Shaft &

•
Shaft Yoke

13. Rear Axle

•
Bearing

14. Swing Arm

•
Bearing

15. Throttle

• D

Cable

Grease

Grease

Grease

Grease

Grease Locate fittings

Grease

Grease M

Locate fitting on pivot
shaft and grease with
grease gun

Inspect and replace
bearings if necessary

Locate fittings and
grease

Locate fittings and
grease

Inspect and replace it if
necessary

Locate fitting and
grease

and grease
Locate fittings and

grease
Grease, inspect and

replace it if necessary

Every 3 months
or 50 hours

Semi-annually

Semi-annually

Semi-annually

Semi-annually

Semi-annually

Every 3 months
or 50 hours

Monthly or
every 20 hours

Monthly or
every 20 hours

58

59

Periodic Maintenance Record

Use the following table to record periodic maintenance work.

Maintenance
Interval

First 5 Hrs

10 Hrs

15 Hrs

20 Hrs

25 Hrs

50 Hrs

75 Hrs

100 Hrs

Service
Date

Service
Dealer

Remarks

60

Handlebar Adjustment

WARNING

Improper adjustment of the handlebars or incorrect torque of the adjuster block
tightening bolts can cause limited steering or loosening of the handlebars,
resulting in loss of control and possible serious personal injury or death.

Your ATV has handlebars which can be adjusted for your personal fit.

1. Remove the handlebar cover.

2. Loosen the four bolts.

3. Adjust handlebar to desired
height. Be sure handlebars
do not hit gas tank or any
other part of machine when
turned fully to the left or right.

4. Torque handlebar adjuster
bolts to 10-12 ft.Ibs (14-16
Nm).

NOTE: Tighten bolts so there is an equal gap at the front and rear of the handlebar
block. Improper gap will result in improper fit of upper part.

Miscellaneous Adjustments

The following items should be checked occasionally for tightness, or if they have
been loosened during maintenance service.

Wheel Nut Torque Specifications

Bolt Size Specification
Front

M10 X 1.25

Rear

M12 X 1.25

NOTE: An authorized service center must service all nuts that have a cotter pin
installed. Call 1-800-643-7332 for service.

20 Ft.Lbs 27N.m

50 Ft.Lbs 69N.m

61

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component
operations. An authorized service center must perform service work. Call
1-800-643-7332 for service.

Front Rear

Flange nuts: Install with flat side
against wheel.

Tapered Nuts: Install with tapered
side against wheel.

Rear Spring Adjustment

The rear shock absorber spring is adjusted by rotating
the adjuster to increase or decrease spring tension. Use
supplied rear spring adjustment spanner. See section 20
“Tools”. Turn the adjustment to
the right to assure proper tension.

Rear Spring Adjustment

Air Filter Service

1. Remove seat.

2. Release clips and remove cover.

3. Loosen clamp and remove filter.

4. Remove fabric type pre-filter from
main filter. Wash pre-filter in soapy
water and dry it.

5. Reinstall pre-filter over main filter.
Replace main filter as required.

6. Reinstall filter into air box and tighten
clamp. Do not over tighten clamp or
filter damage may occur.

Pre-filter

Main Filter

62

Steering Inspection

WARNING

The steering assembly of the ATV should be checked periodically for loose nuts
and bolts. If loose nuts and bolts are found, have your dealer tighten them before
riding your vehicle.

Camber and Caster

The camber and caster are non-adjustable.

Toe Alignment Check

Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can
result from improper adjustment. Contact 1-800-643-7332 to arrange for proper
adjustment.

The recommended toe alignment is 1/8˝ to 1/4˝ (3 to 6mm) toe out.

1. Set the handlebars in a

straight -ahead position and hold
them in this position.

2. Measure A and B. A minus

3. B should be 1/16˝ to 1/8˝(1.5 to

3mm).

4. If this measurement needs to be

adjusted, contact your dealer for
service.

63

Front Brake

WARNING

Once a bottle of brake fluid is opened, use what is necessary and discard the rest.
Do not store or use a partial bottle of fluid. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. This causes the boiling temperature of the
brake fluid to drop, which can lead to early brake fade and the possibility of serious
injury.

The front and rear brakes are hydraulic disc brakes and are activated by the hand
lever. The foot pedal on the right floorboard activates an auxiliary rear brake.
These brakes are self-adjusting and require no adjustment.

The following checks are recommended to keep the brake system in good
operating condition. How often they need checking depends upon the type of
driving that has been done.

• Keep fluid level in the master cylinder reservoirs as described in section 7

“Control and Part Functions”. Normal functioning of the cylinder diaphragm is
to extend into the reservoir as fluid level drops. If the fluid level is low and the
diaphragm is not extended, a leak is indicated and the diaphragm should be
replaced. Always fill the reservoir as indicated whenever the cover is loosened
or removed to insure proper diaphragm operation. Use DOT 3 brake fluid.

• Check brake system for fluid leaks.

• Check brake for excessive travel or

spongy feel.

• Check friction pads for wear, damage and

looseness.

• Check security and surface condition of

the discs.

• Pads should be changed when friction

material (A) is worn to 3/64˝ (1mm).

Rear Brake

The left rear brake is a hydraulic disc type brake, which is activated by the same
handlebar lever that activates the front brake system. It is self adjusting and
requires no maintenance other than periodic checks of the pads for wear.

• Pads should be changed when the friction material is worn to 3/64˝ (1mm).

• Inspect the brake disc and pad surface for excessive wear.

Auxiliary Brake System

Your ATV’s auxiliary brake system is intended for use as a backup for the main
brake system. Should the main system fail, the right rear brake can be activated by
depressing the foot pedal located on the right side footwell. The hydraulic brake
system will not require adjustment.

64

NOTE: Since this is a rear brake only, it will not be as effective as the hand brake,
which brakes all 4 wheels simultaneously.

Carburetor/ Engine Idle RPM Adjustment

If the engine idle speed is not satisfactory, and all other conditions are favorable,
the carburetor can be adjusted as follows:

1. Warm up the engine by running

the vehicle approximately five
minutes.

2. Place the transmission in gear

with the parking brake applied.

3. Adjust the carburetor idle screw

(3) in or out until the desired idle
RPM is reached. Turning the
screw in (clockwise) will raise
RPM. Turning the screw out
(counterclockwise) will lower
RPM. Note: The standard idle
RPM is 1500±10%

Throttle Cable Free-Play Adjustment

Throttle cable free play is adjusted at the handlebar.

1. Slide the boots off inline cable adjuster; loosen adjuster locknut.

2. Turn adjuster until 1/16˝ to 1/8˝ (2 to 3mm) free-play is achieved at thumb
throttle lever. Note: While adjusting free-play, it is important you flip the
throttle lever back and forth.

3. Tighten locknut and slide boots over cable adjuster.

Throttle Lever

65

Spark Plugs

WARNING

WARNING

Inspect the following:

1. Insulator (1) for abnormal

color. Normal color is a
medium to light tan.
Replace if necessary.

2. Electrode (2) for

wear/damage. Replace or
clean spark plug with spark
plug cleaner or a wire
brush.

3. Spark plug gap (3): 0.60 to 0.70mm.

Adjust gap as necessary
when out of specification.

Standard spark plug:
NGK DR7EA

Spark Plug Removal and Replacement

Never attempt to remove a spark plug while the engine is warm. The exhaust
system or engine could burn you causing severe injury.

Remove the spark plug by rotating counterclockwise. Reverse the procedure for
spark plug installation. Torque to 17ft.Ibs (23N.m).

Oil and Oil Screen Change

Oil may be hot. Do not allow hot oil to come into contact with skin as severe burns
may result

The recommended oil change interval is 30 hours, or every 3 months, whichever
comes first. Suggested oil change during the break-in period is at 20 hours, or one
month, whichever comes first. Only use high quality detergent oil rated with API
service classification SG-SL. The recommended oil for this ATV is 15W/40. ). Be
sure to change the oil screen (see illustrated parts list) whenever changing oil.
Severe use operation requires more frequent service. Severe use includes
continuous use in dusty or wet conditions, and cold weather riding.

NOTE: Cold weather riding is defined as all riding in temperatures below 10°F
(-12C), and riding in temperatures between 10°F (-12C) and 30°F (0C) at slow
speeds of less than 5 mph (8km/h).

To change oil:

66

1. Place vehicle on a level surface.

WARNING

2. Run engine for two or three minutes until warm; stop engine.

3. Clean area around drain plug.

4. Place a drain pan beneath engine crankcase and remove drain plug.

5. Allow oil to drain completely.

6. Replace sealing washer O-ring of drain plug.

7. Reinstall drain plug and torque to 14 ft.Ibs (19N.m).

Radiator Coolant Level Inspection

Never remove the pressure cap when the engine is warm or hot. Escaping steam
can cause severe burns. The engine must be cool before removing the pressure
cap.

To ensure that the coolant maintains its ability to protect the engine, it is
recommended that the system be completely drained every two years and a fresh
50/50 mixture of antifreeze and water be added. It is also necessary to inspect the
level of coolant in the radiator if the recovery bottle has run dry.

To add coolant, make sure the engine is cool, remove radiator pressure cap, and
using a funnel, slowly add coolant mixture as necessary through the radiator filler
neck.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to
function properly. If the cap should need replacement contact 1-800-643-7332 for
the correct replacement part.

Transmission Oil Check

The transmission fill plug (1) is located
on the right side of the machine. The
transmission lubricant level should be
checked monthly or 20 hours,
whichever comes first. Transmission oil
should be changed annually. With the
ATV on a level surface, remove fill plug
and check the lubricant level. The
correct transmission lubricant to use is
SEA 80W/90 GL5 Lubricant. For the
correct fluid level see section 17
“Maintenance – Lubrication Recommendations”.

Transmission Oil Changing Procedure

1. Remove the four screws on the foot well and gently pull outward for access to

67

transmission oil reservoir.

2. Remove fill plug.

3. Remove the transmission drain plug located on the bottom left hand side and

drain the oil. Catch and discard used oil properly.

4. Clean and reinstall the drain plug torque to 14 ft.lbs. (20Nm)

5. Add the correct amount of SAE 80W/90GL5 Lubricant until oil reaches the

bottom of the filler hole

6. Check for leaks.

7. Reinstall foot well and screws removed in step 1. Reinstall fill plug.

Front/Rear Gear Case Lubrication

Checking the Level

1. ATV should be on level surface.

2. Remove fill plug (1) and visually inspect lubricant level. Lubricant should be

1-5/8” (41mm) below the top of the fill hole on the rear gear case and even with
the fill hole on the front gear case.

3. Reinstall fill plug. Tighten securely (14 ft.lbs/20N.m).

Changing the Oil

1. ATV should be on level surface.

2. Remove drain plug (3). Catch and discard used lubricant properly.

3. Clean and reinstall the drain plug with a new sealing washer (Reference parts

manual) and tighten securely (14 ft. lbs/20N.m).

4. Remove fill plug (1) and add 10 ounces (300ml) of gear lubricant to the rear

gear case, fill until full on the front gear case.

5. Reinstall the fill plug. Tighten securely (14 ft. lbs/20N.m).

6. Check for leaks.

NOTE: The correct gear case lubricant to use is SEA 80W/90 GL5 weight gear
lube.

68

Front Gear Case

WARNING

1

Rear Gear Case

3

Wheel Safeguards

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.

Maintain proper tire pressure according to chart below. Improper tire inflation may
affect ATV maneuverability. Do not use improper tires. The use of non-standard
size or type tires may affect ATV handling.
Make certain the wheels are installed properly. If wheels are improperly installed it
could affect vehicle handling and tire wear.

Tire Pressure

Front Rear

27.6kPa / 4PSI 27.6kPa / 4PSI

69

Wheel Removal Procedure

1. Stop the engine, place the transmission in gear and lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the footrest

frame. The stand must be sturdy enough to safely support the weight of the
ATV.

4. Remove the wheel nuts and remove the wheel.

Wheel Installation

1. With the transmission in gear and the parking brake locked, 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 correct 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 specifications in the chart

below.

Bolt Size Specification
Front

M10 X 1.25

Rear

M12 X 1.25

20Ft.Lbs 27N.m

50Ft.Lbs 69N.m

Tire Inspection &
Replacement

Always replace tires when tread
depth (1) is worn to 1/8˝ (3mm) or less.
When replacing tires always use
original equipment size and type. See
Section 21 “Specifications – Drive
System” for tire sizes.

70

Headlight / Tail Light / Brake Light Lamp Replacement

WARNING

CAUTION

Keep your headlights and taillights clean. Poor light while riding can result in an
accident causing severe injury or death.

Do not service while headlight is hot. Serious burns may result. Do not touch a
halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot
spot, which will shorten the life of the lamp.

If the light does not work the lamp may need to be replaced.

1. Remove the lens.

2. Remove lamp and replace it with recommended bulb. See illustrated parts list.

3. Test light to see that it is working.

4. Reinstall the lens.

Indicator Lamp Replacement

1. Remove mounting panel.

2. Unplug light from harness, depress

locking tabs (A) and remove.

3. Install new light and reassemble panel.

Headlight Beam Adjustment

The headlight beam can be adjusted up and down.

1. Place the vehicle on a level surface with the headlight approximately 25 ft.
(7.6m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a
mark on the wall at the same height.

3. Sit in the seat. Start engine and turn headlight switch to high beam.

4. Observe headlight aim. The most intense part of the headlight beam should
be aimed 2 ft. (51mm) below the mark placed on the wall in step 2. Note:
Rider weight must be included on the seat.

5. Loosen headlight pivot bolt (see illustrated parts list) and adjust the beam to
desired position.

6. Tighten nut and bolt.

Cleaning Your ATV

Keeping your ATV clean will extend the life of various components

.

71

Washing

WARNING

CAUTION

Never use a high-pressure type car wash system, it can cause damage to the
wheel bearings, transmission seals, body panels, brakes, warning labels, and
water might enter the engine or exhaust system.

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 lower parts last. Rinse with water frequently and dry with a chamois to
prevent water spots.
1-800-643-7332 for replacement.

NOTE: If warning labels are damaged, contact

Waxing

Certain products, including insect repellants and chemicals, will damage plastic
surfaces. Care must be taken when using these products near plastic surfaces.

Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the
use of harsh cleaners since they can scratch the body finish.

Transporting

Whenever the ATV is to be transported the following measures should be taken.

1. Turn off the engine and remove the key.

2. Turn the fuel valve to “OFF”.

3. Be certain the fuel cap, oil cap, and seat are installed correctly.

4. Always tie the frame of the ATV to the transporting unit securely using suitable
straps or rope.

Always place the transmission in gear and lock the parking brake.

18. Storage

ATV

• Clean the ATV thoroughly prior to storage.

• Inspect drive belt. If necessary to replace it, call 1-800-643-7332 for authorized

service center.

• Inspect all cables and lubricate if necessary.

• Inspect and clean, or replace the pre-filter and main filter. Clean the air box and

drain the sediment tube (see illustrated parts list).

• Inspect all fluid levels and replenish or change as necessary.

ENGINE OIL

• Run engine for two to three minutes until warm.

72

• Turn off the engine.

• Change oil and screen as described in Section 17 “Maintenance – Oil and Oil

Screen Change”.

FUEL SYSTEM

CAUTION: It is important to prevent gum deposits from forming in essential fuel

system parts such as the carburetor, fuel filter, fuel hose or tank during storage.
Also, alcohol blended fuels (called gasohol or using ethanol or methanol) can
attract moisture which leads to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in storage.

To avoid engine problems, the fuel system should be emptied before storage of 30
days or longer.

• To empty the fuel tank, start the engine and let it run until the fuel lines and

carburetor are empty. Turn the fuel valve to “OFF”.

• Never use engine or carburetor cleaner products in the fuel tank or permanent

damage may occur.

• Refill with fresh fuel next use.

CYLINDER

• When the engine is cool, remove the spark plug.

• Spray light oil (fog) into the engine cylinder through spark plug hole.

• Inspect the spark plug as detailed in Section 17 “Maintenance – Spark Plugs”.

Replace or clean and re-install the spark plug.

CAUTION:

protective film created by fogging.

(“fogging” the engine)

Do not start the engine during the storage period. This will disturb the

BATTERY

• Remove the battery and add distilled water as required to bring fluid to the

proper level.

• After a period of time in storage, battery may require recharging.

• To help prevent corrosion and power leakage during long periods of storage,

battery cables should be disconnected and battery cleaned thoroughly (See
Section 15 “Battery – Installation and Connections”).

• After cleaning, leave cables disconnected and place cables where they cannot

come in contact with battery terminals.

• If battery is removed from ATV for storage, do not store battery directly on

concrete or damp surfaces.

STORAGE AREA

• Set tire pressure and safely support the ATV with the tires 1” – 2˝ (25-50mm) off

the ground.

• Be sure the storage area is well ventilated.

• Cover the machine with an ATV cover (call 1-800-643-7332 to order cover). Do

not use plastic or coated materials. They do not allow enough ventilation to

73

prevent condensation, and may promote corrosion and oxidation.

CAUTION:

Never cover ATV with engine and exhaust areas still warm.

19. Troubleshooting

NOTE: The following table does not cover all the possible causes of trouble. It

should be helpful, however, as a general guide to troubleshooting. Where
applicable refer to the relative procedure in this manual for inspection, adjustment
and replacement of parts. Otherwise, contact 1-800-643-7332 for the name of

an authorized service center to perform adjustment and replacement.

PROBLEM CAUSE CORRECTION
Engine runs but
ATV does not
move
Hard to start 1. Dirty air filter.

Will not start

1. Worn out clutch.

2. Worn/slipping belt.

2. Faulty spark plug.

3. Weak/dead battery.

4. Stale or dirty fuel.

5. Carburetor out of
adjustment.

6. Loose or damaged
wiring.

7. Engine valves out of
adjustment.

1. Out of fuel.

2. Fuel tank valve not
turned to “ON”.

3. Engine Stop switch
not set to “Run”.

4. Faulty Engine Stop
switch.

5. Brake lever not
depressed.

6. Weak/dead battery.

7. Engine flooded.

8. Faulty spark plug.

9. Spark plug wire
loose.

10. Faulty starter relay.

1. Contact 1-800-643-7332.

2. Contact 1-800-643-7332.

1. Clean/replace air filter.

2. Clean/replace spark plug.

3. Recharge or replace
battery.

4. Empty fuel tank and refill
tank with fresh, clean fuel.

5. Contact 1-800-643-7332.

6. Check all wiring or contact
1-800-643-7332.

7. Contact 1-800-643-7332.

1. Fill fuel tank.

2. Turn fuel tank valve to “ON”
position.

3. Set the Engine
Stop Switch to “Run”.

4. Contact 1-800-643-7332.

5. Depress brake lever.

6. Recharge or replace
battery.

7. Wait several minutes before
attempting to start.

8. Clean/replace spark plug.

9. Connect spark plug wire.

10. Contact 1-800-643-7332.

74

PROBLEM CAUSE CORRECTION

Will not start
(continued)

11. Dirty air filter.

12. Dirty fuel filter.

13. Water in fuel.

14. Loose or damaged
wiring.

15. Carburetor out of
adjustment.

16. Engine valves out

11. Clean/replace air filter.

12. Contact 1-800-643-7332.

13. Empty fuel tank and
carburetor, refill tank with
fresh fuel and replace fuel
filter.

14. Check all wiring or contact
1-800-643-7332.

15. Contact 1-800-643-7332.

16. Contact 1-800-643-7332.

of adjustment.

Engine will not
turn over

Poor idle speed
performance

1. Weak or dead
battery.

2. Blown fuse.

3. Corroded battery
terminals.

4. Loose or damaged
wiring.

5. Faulty ignition switch.

6. Faulty starter.

1. Carburetor idle screw
out of adjustment.

2. Improperly adjusted
throttle cable.

3. Dirty air filter.

4. Faulty spark plug.

5. Engine valves out of

1. Recharge or replace
battery.

2. Replace fuse.

3. Clean terminals.

4. Check all wiring or contact
or contact 1-800-643-7332.

5. Contact 1-800-643-7332.

6. Contact 1-800-643-7332.

1. Adjust the idle screw as
detailed in Section 16
“Maintenance”.

2. Adjust throttle cable as
detailed in Section 16
“Maintenance”.

3. Clean/replace air filter.

4. Clean/replace spark plug.

5. Contact 1-800-643-7332.

adjustment.

Poor speed
performance

1. Worn out clutch.

2. Worn/damaged
gears.

3. Low engine oil level/
dirty oil.

4. Worn/slipping belt.

5. Faulty spark plug.

6. Dirty air filter.

7. Stale/dirty fuel.

8. Water in fuel.

1. Contact 1-800-643-7332.

2. Contact 1-800-643-7332.

3. Check oil level/ change oil.

4. Contact 1-800-643-7332.

5. Clean/replace spark plug.

6. Clean/replace air filter.

7. Empty fuel tank, replace
with fresh clean fuel.

8. Empty fuel tank and
carburetor, replace fuel

75

PROBLEM CAUSE CORRECTION

Poor speed
performance
(Continued)

Over heating or
over cooling

Belt Burning 1. Use of high range

9. Loose or damaged
wiring.

10. Carburetor out of
adjustment.

11. Engine valves out of
adjustment.

1. Incorrect coolant
level.

2. Faulty thermo switch.

3. Faulty thermostat.

4. Inoperative fan
motor.

5. Faulty radiator/
radiator cap.

6. Faulty water pump.

when starting out on
an incline.

2. Insufficient ATV
warm-up.

3. Towing or carrying
loads in high range.

4. Getting ATV stuck in
mud or snow or
climbing over large
objects from a
stopped position.

filter, refill with fresh fuel.

9. Contact 1-800-643-7332.

10. Contact 1-800-643-7332.

11. Contact 1-800-643-7332.

1. Check coolant level, fill as
necessary.

2. Contact 1-800-643-7332.

3. Contact 1-800-643-7332.

4. Contact 1-800-643-7332.

5. Contact 1-800-643-7332.

6. Contact 1-800-643-7332.

1. When starting out on incline
put ATV in low range.

2. Warm up ATV for at least 5
minutes, then with
trans-mission in neutral,
advance throttle to approx.
1/8 throttle in short bursts, 5
to 7 times.

3. Use low range only when
towing or carrying loads.

4. Shift transmission to low
range carefully; use fast,
aggressive throttle
application to engage
clutch. WARNING:
Excessive throttle may
cause loss of control and
vehicle overturn.

76

20. Tools included with ATV

(8, 10 mm)

2

Spark Plug Wrench

Open End Wrench

Open End
Wrench
(12, 14 mm)

77

21. System Specifications

Capacities

Fuel capacity 12.5L / 3.3gal

Engine Oil Capacity 1.4L / 1.7qt

Ground Clearance 183mm / 7.2in

Height 1170mm / 46in

Length 2096mm / 82.5in

Width 1170mm / 46in

Seat height 865mm / 34in

Wheel Base 1265mm / 49.8in

Turn Radius 3277mm / 129in

Dry Weight 280kg / 617lb

Front Rack 18kg / 39lb

Rear Rack 36kg / 79lb

Load Capacity

Rider & Payload)

Tongue Weight 54kg / 120 lbs

(Combined

150kg / 330lb

Tow Capacity 324kg / 715 lbs

Drive System

Drive System CVT

Front Tire 24X8-12

Rear Tire 24X11-10

Tire Pressure (Front) 27.6kPa 5PSI

Tire Pressure (Rear) 27.6kPa 5PSI

Brake System

Service Brake

Parking Brake All Wheel Hydraulic Lock

Auxiliary Brake Rear Brake Hydraulic Disc

Front Brake

Hydraulic Disc

Rear Brake

78

Engine

ATV300

Engine Type 4Stroke, Single Cylinder, SOHC

Bore x Stroke 70mm X 66.8mm

Displacement 275cc

Starter System Electric Start

Engine Cooling Liquid-Cooled

Lubrication System Wet Sump

Carburetor CVK30

Ignitions T.C.I

Spark Plug Type DR7EA (NGK)

Electrical Equipment

Battery 12V 14AH

Head light 35W / 35W

Brake/ Tail Light 21W / 5W

Rear Indicator 12V 1W

Fan Indicator Light 12V 1W

High Beam Light 12V 1W

Neutral Position Light 12V 1W

Heat Alarm Light 12V 1W

Flasher Light 12V 10W X 4

Turn Indicator Light 12V 1W

Mark Light 12V 5W

79

22. Wiring Diagram

80