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OWNER'S MANUAL
POWERSPORTS
800ATV - 2
No one under the
age of 16 should
operate this ATV
(888)-405-8725 Coleman Powersports
364 S. Smith Rd. Tempe, AZ. 85281

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Summary of Contents for Coleman 800ATV-2

  • Page 1 OWNER’S MANUAL POWERSPORTS 800ATV - 2 No one under the age of 16 should operate this ATV (888)-405-8725 Coleman Powersports 364 S. Smith Rd. Tempe, AZ. 85281...
  • Page 2 Owner Manual...
  • Page 3 Owner Manual INTRODUCTION Congratulations on your purchase of the Coleman Powersports 800ATV-2. This Owner’s / Operator’s manual will provide you information regarding safe operation, operational instructions, maintenance and care. Fully understanding this manual and following all of the instructions will provide the knowledge needed to have a safe and enjoyable ATV experience.
  • Page 4 Owner Manual IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS Particularly important information is noted in this manual using the INJURY OR DEATH. following symbols: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander or a person inspecting or repairing the ATV.
  • Page 5 Owner Manual IMPORTANT NOTICE Turning speed must be less than 19mph (30 km/h). This ATV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF - ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.
  • Page 6: Table Of Contents

    Owner Manual Coleman Powersports Limited Throttle Lever 4-13 Warranty Speed Limiter 4-15 Location of the Warning and Foot brake pedal – all wheel Specification Labels brakes 4-15 Parking brake – Park position Safety Information lever 4-16 Gear shift lever 4-17...
  • Page 7 Owner Manual Throttle Lever Braking Fittings and Fasteners Parking brake Lights Engine break-in Switches ATV break-in 6-10 Idling Braking system break-in 6-11 Ignition and Emergency Switches Modifications 6-11 Tires 5-10 Loading 6-12 How to Measure Tire Pressure 5-11 Tire Wear Limit Indicator 5-12 Your Vehicle Driving Your Vehicle...
  • Page 8 Owner Manual Riding Downhill 7-23 Spark Plug Inspection 8-19 Crossing Through Shallow Water 7-25 Air Filter Element Cleaning 8-21 Riding Over Rough Terrain 7-28 Spark Arrester Cleaning 8-25 Sliding and Skidding 7-29 V-belt Cooling Duct Check Hose 8-26 V-belt Case Drain Plug 8-26 Periodic Maintenance and Valve Clearance Adjustment...
  • Page 9 Owner Manual To drive ATV at every time, need Wheel Installation 8-35 to do daily inspection of EPS system 9-17 Battery 8-36 Solutions for common fault: 9-20 Battery Maintenance 8-37 Maintenance and repair’s Fuse Replacement 8-38 supplemental description: 9-26 Replacing A Headlight Bulb 8-39 EPS system periodic maintenance 9-26...
  • Page 10 Owner Manual...
  • Page 11 The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 1 year from the date of purchase shown on the sales receipt. During this period of time Coleman Powersports will, at its option, either repair or replace any original Coleman Powersports part which is covered by this warranty and is proven to be defective in workmanship or material.
  • Page 12 How to get service under this warranty: To get warranty service, call Coleman Powersports at 888-405-8725 for the location of your local servicing retailer / dealer. Please do not return the product to the retailer where the product was purchased unless instructed to do so by Coleman Powersports.
  • Page 13 Length of Implied Warranties: Any implied warranties are limited to the duration set forth in this warranty. Coleman Powersports does not make any claim as to the merchantability or fitness for a particular purpose which would extend longer than the duration of this written warranty.
  • Page 14: Location Of The Warning And Specification Labels

    Location of the Warning and Safety Labels LOCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 15 Location of the Warning and Safety Labels Read and understand all of the labels on ① your ATV. They contain important information for safe and proper operation of your ATV. ② Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your dealer.
  • Page 16 Location of the Warning and Safety Labels ④ ⑤...
  • Page 17 Location of the Warning and Safety Labels ⑥ ⑦...
  • Page 18 Location of the Warning and Safety Labels ⑧ ⑪ ⑨ ⑫ ⑩...
  • Page 19: Safety Information

    Safety Information SAFETY INFORMATION An ATV is a special vehicle, which is different from other vehicles such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described.
  • Page 20 Safety Information shirt or jacket, and long pants. Never use alcohol or drugs before or while operating an ATV.  Never operate at speeds too fast for your skills or the conditions. Always go at a speed that  is proper for the terrain, visibility and operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts.
  • Page 21 Safety Information Always follow proper procedures for climbing hills as described in this manual. Check the  terrain carefully before starting up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed.
  • Page 22 Safety Information remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over  large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.
  • Page 23 Safety Information WARNING If you swallow gasoline or inhale gasoline fumes, or get gasoline in your eyes, see your Improper handling of gasoline may cause fire doctor immediately. If gasoline spills on your and you could be burned. skin, wash with soap and water. If gasoline Remember: Always turn off the engine when refueling.
  • Page 24 Safety Information WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with good ventilation.
  • Page 25: Description And Machine Identification

    Description and Vehicle Identification DESCRIPTION AND MACHINE IDENTIFICATION 1. headlights 2. radiator part 3. shock absorber comp 4. meter 5. left handle bar 6. air filter 7. front seat 8. rear seat 9. back rest 10. carrier 11. rear bumper 12. front bumper 13. front carrier 14.
  • Page 26: Identification Number Records

    Description and Vehicle Identification NOTE: The ATV you have purchased may differ 3. MODEL LABEL INFORMATION: slightly from those shown in the figures of ○ this manual. ● Vehicle identification number Identification number records vehicle identification number Record the key identification number, stamped into the frame.
  • Page 27 Description and Vehicle Identification NOTE: The vehicle identification number is used to identify your machine. Model label The model label is affixed at the location shown in the illustration. Record the 1. Model label information on this label in the space provided.
  • Page 28: Control Functions

    Control Functions CONTROL FUNCTIONS The engine can be started only in this position Ignition switch and the headlights and taillights can be turned Switch functions in respective positions are as on when the light switch is on. follows: OFF: All electrical circuits are switched off. The key can be removed in this position.
  • Page 29: Indicator And Warning Lights

    Control Functions Indicator and Warning Lights 12. Battery Charge indicator Low-gear range indicator “L” This indicator light comes on when the drive select lever is in the “L” position. High-gear range indicator “H” This indicator light comes on when the drive select lever is in the “H”...
  • Page 30 Control Functions When the parking brake lever (left lever) is load to specification. fully applied and held in place this indicator After restarting, make sure that the  light comes on. Some models may be coolant warning light is off. Continuous equipped with a latch to lock the left lever in use while the light is on may cause the Park position.
  • Page 31: Speedometer Unit

    Control Functions Speedometer Unit Speedometer unit functions:  a speedometer (which shows the speed)  an odometer (which shows the total distance covered)  a tripometer (which can be cleared and then show any new distances traveled)  an RPM indicator (which shows the revolutions per minute of the engine) ...
  • Page 32 Control Functions odometer, to the tripometer, and then to the displayed mileage from miles to kilometers. hours meter; then it starts the cycle over. Clock time adjustment The odometer displays the total distance Press the left button and hold for three traveled by the ATV.
  • Page 33 Control Functions When riding on a flat road at a comparatively yellow 4WD selector buttons are pressed in high speed, adjust settings indicating the “4WD” function has been “2WD/UNLOCK” and there will be no symbols activated. This position also indicates that illuminated in either of the 4WD indicators.
  • Page 34: Fault Code Indicator

    Control Functions show automatically. CAUTION: The description for the fault codes are shown display indicators flash in Chapter 11 of this manual. speedometer does not show the speed while the ATV is in motion, ASK a dealer to check Fuel level indicator the speed sensor and circuits.
  • Page 35: Left Handlebar Switches

    Control Functions Left handlebar switches Set the switch to “ ” to turn on the high beams. Set the switch to “OFF” to turn off all the lights. Set the switch to“ ” to turn on the parking lights and the taillights. NOTE: Do not use the headlights more than fifteen 1.
  • Page 36 Control Functions NOTE: Horn button See starting instructions prior to starting the Press this button. The horn will sound. engine. (See P6-1—6-2) Emergency flasher button Press this button. The four turn signal lights Turn signal switch will flash continuously. At the same time a Moving the turn signal switch left or right, the buzzer will sound.
  • Page 37 4-10 Control Functions with a differential. The front differential has no “4 Wheel Drive/LOCK”switch lock, but automatically avoids wheel slip. To lock the rear differential when the ATV is in Rear differential can be locked, which allows the four-wheel drive mode, you move the the ATV to perform better in off road operation selector switch to the right and then press the on muddy surfaces.
  • Page 38 Control Functions 4-11 CAUTION: When ATV is in operation, DO NOT press the 2WD/4WD buttons. This may break the rear axle gears. 2 Wheel Drive: The engine only provides power to the rear “2WD”/ “4 WD” lever switch wheels. There are no symbols shown on “2WD/ “...
  • Page 39 4-12 Control Functions UNLOCK 2WD/4WD selection When “2WD” is selected, the engine only provides power to the rear wheels. WARNING POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 4WD LOCK, while the ATV is moving. WHAT CAN HAPPEN 1.
  • Page 40: Throttle Lever

    Control Functions 4-13  When the ATV is in 4WD, the left 4WD WARNING indicator “ ”.will have a flashing ‘o’ on POTENTIAL HAZARD the front axle. When driving too fast with DIFF.LOCK on. WHAT CAN HAPPEN Four wheels will rotate at the same speed. It is From 4WD to 2WD extremely difficult to turn.
  • Page 41 4-14 Control Functions WARNING POTENTIAL HAZARD Malfunction of the throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making the ATV difficult to speed up or slow down when needed, which could cause an accident. HOW TO AVOID THE HAZARD 1.
  • Page 42: Speed Limiter

    Control Functions 4-15 Speed limiter WARNING The speed limiter keeps the throttle from fully opening even when the throttle lever is POTENTIAL HAZARD pushed to the maximum. Turn the adjusting Improper adjustment of the speed limiter WHAT CAN HAPPEN screw to limit the maximum engine power The throttle cable could get damaged.
  • Page 43: Lever

    4-16 Control Functions down on the pedal will stop the ATV. This may be able to set the latch to maintain the brake pedal controls the entire brake system. ATV brake in the on position.. Holding the It applies brakes to all the wheels. lever down will also activate the park position indicator.
  • Page 44: Gear Shift Lever

    Control Functions 4-17 Gear shift lever Fuel tank cap The gear shift lever is used to shift your ATV The fuel tank filler neck cap is located on the into the low (L), high (H), neutral (N) and the right side of the ATV in the front of the rear reverse (R) positions.
  • Page 45: Seat

    4-18 Control Functions SEAT 2.After removing the rear seat, press the lock 1. Pull the drawstring of rear seat up; catch, pull up the front seat to remove it. meanwhile pull up the rear seat to remove it. 1. Rear seat 2.
  • Page 46: Front Sundry Box

    Control Functions 4-19 FRONT SUNDRY BOX REAR SUNDRY BOX The front sundry box is located under the front The rear sundry box is located under the rear plastic cover; pull up the drawstring to open plastic cover. Pull up the drawstring to open the front sundry box.
  • Page 47 4-20 Control Functions NOTE: Goods must be tied securely and placed in the middle of the luggage carrier. Otherwise, the ATV may be out of balance, and effect the driver's control of the ATV. Front/rear shock absorber adjustment The spring preload can be adjusted to match 1.
  • Page 48 Control Functions 4-21 Spring Adjustment Principles: WARNING When there is only the operator riding on a flat road, adjust the shock absorbers to be a little POTENTIAL HAZARD softer. Improper shock absorber adjustment. Driving at higher speeds or on level surfaces WHAT CAN HAPPEN or flat roads, adjust the shock absorber to be Uneven adjustment can cause poor handling...
  • Page 49: Auxiliary Dc Jack

    4-22 Control Functions 1. Special wrench Auxiliary DC jack 1. Spring preload adjusting ring 2. Position indicator The auxiliary DC jack is located at the front NOTE: right side of the ATV by the ignition switch. A special wrench can be obtained at a dealer The auxiliary DC jack can be used for work to make these adjustments.
  • Page 50 Control Functions 4-23 4. When the auxiliary DC jack is not being used, cover it with the cap. 1. Auxiliary DC jack cap How to use the auxiliary DC jack 1. Auxiliary DC jack 1. Set the light switch to “OFF”, which turns off all the lights.
  • Page 51: Steering Lock

    4-24 Control Functions CAUTION: Steering Lock Do not use accessories requiring more This vehicle is equipped with steering lock,  than the above maximum capacity. This which can guard against theft while parking. may overload the circuit and cause fuses to blow.
  • Page 52: Pre Operation Checks

    Pre Operation Check List Before using this ATV, check the following points: ITEM ROUTINE PAGE Check the operation, free play, fluid levels and look for any fluid leaks. ● P5-4, P5-5 Brakes Add DOT 4 brake fluid if necessary. ● P8-28, P8-29 Check to see if the disc brake rotor and the brake pads are worn beyond limits.
  • Page 53 Pre Operation Check List Axle boots Check each boot for tears or leaks. P8-19 ● Instrument Panel Check and be sure all the instrument indicators are working properly. P4-5 ● Warning Lights Check and be sure all the warning lights function normally on the panel. P4-2 ●...
  • Page 54: Brake System

    Pre Operation Check List Brake System P8-28-P8-29) Brake levers and brake pedal Disc Brake Rotor Check whether there is free travel in the front Check the disc brake rotors, they should be brake lever, if not, adjust it. within limits. (See pages P8-28-P8-29) Check whether there is free travel in the brake pedal, if not, adjust it.
  • Page 55: Fuel

    Pre Operation Check List Brake operation Fuel Test the brakes at slow speeds after starting Make sure there is sufficient gasoline in the out to make sure they are working properly. If tank. the brakes do not provide proper brake Recommended fuel: performance, inspect the brake pads and UNLEADED GASOLINE ONLY...
  • Page 56 Pre Operation Check List Your engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.
  • Page 57: Engine Oil

    Pre Operation Check List Engine oil WARNING Make sure the engine oil is at the specified POTENTIAL HAZARD level. Add oil as necessary. (See page 8-9— Improper care when refueling. 8-13.) WHAT CAN HAPPEN Fuel can spill, which can cause a fire and CAUTION: severe injury.
  • Page 58: Differential Gear Oil

    Pre Operation Check List Coolant Recommended engine oil type and Use the specialized antifreeze engine quantity: coolant. See page 10-2 Check the coolant level in the coolant reservoir when the engine is cold. (The Differential gear oil coolant level will vary with engine...
  • Page 59 Pre Operation Check List CAUTION: WARNING Hard water or salt water is harmful to the POTENTIAL HAZARD engine. You may use soft water if you can not Removing the radiator cap while the engine get distilled water. However, find antifreeze and radiator are still hot.
  • Page 60: Throttle Lever

    Pre Operation Check List Throttle lever dealer repair as necessary for proper Check to see that the throttle lever operates operation. correctly. It must open smoothly and spring Idling back to the idle position when released. Have a dealer repair as necessary for proper High idle speed may cause engine damage.
  • Page 61: Tires

    5-10 Pre Operation Check List Tire WARNING Recommended tire pressures Front 10 psi (0.70kgf/cm , 69 kpa) POTENTIAL HAZARD Rear 10 psi (0.70kgf/cm , 69 kpa) Operating this ATV with improper tires, or Check and adjust tire pressures when the tires with improper or uneven tire pressure.
  • Page 62: Specifications

    Pre Operation Check List 5-11 Higher pressures may cause the tire to burst. Inflate the tires very slowly and carefully. Rapid inflation could cause the tire to burst. This ATV is factory equipped with off-road tires, with maximum speed limits for “J” class. Always keep speeds under 62 mph (100 km/h).
  • Page 63: Tire Wear Limit

    5-12 Pre Operation Check List Recommended Minimum Maximum pressure 10 psi 9psi 11psi Front (0.70kpf/cm (0.63kpf/cm (0.77kpf/cm 69 kpa) 62kpa) 76kpa) 10 psi 9psi 11psi Rear (0.70kpf/cm (0.63kpf/cm (0.77kpf/cm 69 kpa) 62kpa) 76kpa) Tire wear limit a. Tire wear limit When the tire tread height decreases to (a) 0.12 in.
  • Page 64: Operation

    Operation Starting a cold engine WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating an ATV without being familiar with Freezing control cables in cold weather. all controls. WHAT CAN HAPPEN WHAT CAN HAPPEN You could be unable to control the ATV, which Loss of control, which could cause an could lead to an accident or collision.
  • Page 65: Starting A Warm Engine

    Operation NOTE: Warming the engine To obtain the maximum engine life, always When the gear shift is in the Neutral (N) warm up the engine before starting off. position, see if the “N” light on the display Never accelerate hard with a cold engine! is lit up.
  • Page 66 Operation Shifting: 3. Turn the ignition switch/key to “OFF”. Neutral to High and High to Low 1. Bring the ATV to a complete stop and When turning off the ignition switch there is allow the throttle lever to return to idle. a three minute run time for the fan to Wait for the engine to idle at 1400 rpm.
  • Page 67 Operation 1. Bring the ATV to a complete stop and return the throttle lever to the idle position. Wait for the engine to drop below 1400 rpm。Apply the brakes. 2. Press in the gear shift handle button. 3. Shift from neutral to reverse or from reverse to neutral by moving the gear shift lever along the shift guide.
  • Page 68: Shifting Between 2Wd And 4Wd

    Operation NOTE: WARNING When in reverse, the reverse indicator light in the display panel should be on. If the POTENTIAL HAZARD light does not come on, have a dealer Improperly operating in reverse. inspect the electrical circuits. WHAT CAN HAPPEN Due to the synchronizing mechanism in the You could hit an obstacle or person behind engine, the light may not come on until the...
  • Page 69: Braking

    Operation special attention to the following points: WARNING 1. Leave enough distance for braking. POTENTIAL HAZARD 2. Longer braking distance is needed when When turning at a high speed with the an ATV is operated at a higher speed. differential locked. 3.
  • Page 70: Parking Brake

    Operation Only when the brake performance be driven. returns to normal can the ATV be driven as usual. WARNING POTENTIAL HAZARD Parking brake The brakes get wet. Stop the ATV using the brake pedal。 WHAT CAN HAPPEN ● Shift the gear shift lever into “H”, “L”, or ●...
  • Page 71 Operation Parking on a slope 1. Bring the ATV to a stop by applying the WARNING brakes. 2. Shift the gear select lever into “H”, “L”, or POTENTIAL HAZARD “R” position. Parking on a hill or other incline. 3. Then turn the ignition switch off. WHAT CAN HAPPEN 4.
  • Page 72 Operation Within the break-in period, be cautious when riding your ATV. Do not overload it. Do not speed up quickly. Always keep your speed below 25mph (40 km/h). After the break-in period, your ATV will perform better. CAUTION: For the first three hours, if you run your engine at full throttle, the engine may overheat, which could ruin the oil seals and ATV break-in...
  • Page 73: Engine Break-In

    6-10 Operation However, momentary (2-3 seconds Engine break-in maximum) full throttle operation under load There is never a more important period in will not harm the engine. the life of your ATV than the period Each full throttle acceleration sequence between 0 and 25 hours.
  • Page 74: Braking System Break-In

    Operation 6-11 Rapid brake application before the break-in 10-25 hours: period may harm the brake pads. Avoid prolonged operation above 3/4 Break-in is required when new brake pads throttle. Rev the ATV freely but do not use or brake rotors are installed. full throttle at any time.
  • Page 75: Loading

    6-12 Operation Loading the cargo at the rear of the front carrier Overloading this ATV or carrying or towing and at the front of the rear carrier. cargo improperly could cause changes in Center the load from side to side. the ATV handling which could lead to an Tie down cargo securely to the carriers.
  • Page 76 Operation 6-13 turn at very slow speeds. WARNING Avoid hills and rough terrain. Choose ● POTENTIAL HAZARD terrain carefully. Added weight affects Overloading this ATV or carrying or towing the stability and handling of the ATV. cargo improperly. WHAT CAN HAPPEN Will cause changes in vehicle handling which could lead to an accident.
  • Page 77: Your Vehicle

    Your Vehicle DRIVING YOUR VEHICLE begin to ride, be sure you have read this This ATV is mainly for utility use, but may Owner’s Manual completely and understand also be used for recreation. This section, the operation of the controls. Pay particular ‘Riding Your ATV’, provides general ATV attention to the safety information on pages riding instructions for recreational riding.
  • Page 78 Your Vehicle handling performance characteristics. No person under the age of 16 should operate this ATV. WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN Failure to follow the age recommendations for The risk of an accident is greatly increased if this ATV.
  • Page 79 Your Vehicle WARNING POTENTIAL HAZARD Carrying more than one passenger on this ATV. WHAT CAN HAPPEN The extra passenger(s) could reduce your ability to balance and control this ATV. This could lead to an accident, resulting in harm to you and/or your passenger(s). This ATV is designed to carry the operator, HOW TO AVOID THE HAZARD 1 passenger only and cargo...
  • Page 80: Apparel

    Your Vehicle Apparel WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident.
  • Page 81 Your Vehicle Do not operate an ATV or any vehicle after consuming alcohol or drugs. HOW TO AVOID THE HAZARD Operator’s performance capability will be Always wear an approved motorcycle helmet affected by the influence of alcohol or drugs. that fits properly. You should also wear: eye protection (goggles or a face shield)
  • Page 82 Your Vehicle Pre-operation checks WARNING Always perform the pre-operation check list on page 5-1 before riding. This is for your POTENTIAL HAZARD safety and proper care of the ATV. Operating this ATV after consuming alcohol or drugs. WARNING WHAT CAN HAPPEN POTENTIAL HAZARD Could seriously affect your judgment.
  • Page 83 Your Vehicle WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV with improper tires, or with Operating this ATV at speeds too fast for your improper or uneven tire pressure. skills or the conditions. WHAT CAN HAPPEN WHAT CAN HAPPEN Use of improper tires on this ATV, or operation Increases your chances of losing control of of this ATV with improper or un-even tire...
  • Page 84: Speed Limiter

    Your Vehicle Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum.
  • Page 85: During Operation

    Your Vehicle MAXIMUM LOADING LIMIT: Vehicle loading limit: 518 lbs (235 kg) Total weight of cargo, rider, passenger and accessories, and trailer hitch vertical load. Front carrier:44 lbs (20 kg) Rear carrier:77 lbs (35 kg) Storage box:6.5 lbs (3.0 kg) Trailer hitch:...
  • Page 86 Your Vehicle 7-10 Avoid doing wheelies and jumping. You may WARNING lose control of the ATV or roll over. POTENTIAL HAZARD WARNING Removing hands from handlebars or feet from footboards during operation. Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases chance accident,...
  • Page 87: Modifications

    7-11 Your Vehicle Do Not modify your ATV Modifications WARNING WARNING POTENTIAL HAZARD Improper installation of accessories or Operating this with improper modification of this vehicle could lead modifications to an accident in some situations. WHAT CAN HAPPEN Improper installation accessories modification of this vehicle may cause changes in handling and loss of control which...
  • Page 88: Exhaust System

    Your Vehicle 7-12 Exhaust system The exhaust system on the ATV is very hot HOW TO AVOID THE HAZARD during and following operation. To prevent Do not operate, idle, or park the ATV in dry burns avoid touching the exhaust system. grass or other dry ground cover.
  • Page 89: Conditions

    7-13 Your Vehicle Pay attention to road conditions Go slowly and be extra careful when operating Know the terrain where you ride. Ride on unfamiliar terrain. Always be alert to cautiously in unfamiliar areas. Stay alert for changing surface conditions when operating the holes, rocks, or roots in the terrain, and for ATV.
  • Page 90 Your Vehicle 7-14 WARNING Operating on excessively rough, slippery or loose terrain could cause loss of traction or vehicle control, which could result in an accident, including an overturn. Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV When riding in an area where you might not on such terrain.
  • Page 91 7-15 Your Vehicle WARNING Caution: ● Select a large, flat area off-road to become Always mount a caution flag on the ATV to make you more visible. Keep a lookout for familiar with your ATV. other vehicles. ● Make sure that this area is free of Do not ride in areas posted “no trespassing”.
  • Page 92 Your Vehicle 7-16 engage and you will start to accelerate. operations on more difficult terrain. ● If the throttle is applied too abruptly, the ● Always avoid riding on paved surfaces: the front wheels may lift off the ground ATV is designed for off-road use, and resulting in a loss of steering control.
  • Page 93: Turning Your Atv

    7-17 Your Vehicle CAUTION: be mastered first at low speeds. WARNING Do not shift from low gear “L” to high “H” “N” “R” or any other shift maneuver without first POTENTIAL HAZARD coming to a complete stop. This could Turning improperly. damage the engine or drive train.
  • Page 94 Your Vehicle 7-18 As you approach a curve, slow down and begin to turn the handlebars in the desired direction. As you do so, put your weight on the footboard to the outside of the turn (opposite the direction you are turning) and lean your upper body into the turn.
  • Page 95: Climbing Uphill

    7-19 Your Vehicle Climbing uphill moving forward on the seat. Use proper riding techniques to keep your Once you have learned this technique you ATV from overturning on hills. Be sure that should be able to do it at higher speeds or in you can maneuver your ATV effectively on tighter curves.
  • Page 96 Your Vehicle 7-20 It is important when climbing a hill to make sure that your weight is transferred forward Never open the throttle too quickly. on the ATV. This can be accomplished by The ATV could flip over backwards. leaning forward and, on steeper inclines, Never crest a hill at high speed.
  • Page 97 7-21 Your Vehicle requires you to properly position your weight If you are climbing a hill and you find that you to maintain proper balance. Be sure that you have misjudged being able to make it to the have mastered the basic riding skills on flat top, you should turn the ATV around while ground before attempting to cross a sloped you still have forward motion (provided you...
  • Page 98 Your Vehicle 7-22 WARNING Improperly crossing hills or turning on hills, could cause loss of control or cause the ATV to overturn. Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground.
  • Page 99: Riding Downhill

    7-23 Your Vehicle ● If you are unable to continue up the hill, a steep hill if possible. dismount the ATV on the uphill side. When crossing the side of a hill: Physically turn the ATV around and then Always follow proper procedures as descend the hill.
  • Page 100 Your Vehicle 7-24 wheels on the downhill side. Avoid sudden 4WD or 4WD-LOCK before beginning to descend the hill. application of either the front or rear ● Improper braking may cause a loss of brakes because the wheels on the uphill traction.
  • Page 101: Crossing Through Shallow Water

    7-25 Your Vehicle Crossing through shallow water WARNING The ATV can be used to cross slow moving, Going down a hill improperly could cause shallow water of up to a maximum of 35 cm loss of control or cause the ATV to overturn. (14 inches) in depth.
  • Page 102 Your Vehicle 7-26 Never operate this ATV in fast flowing water or in water deeper than that specified in your Owner’s Manual. 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 linings.
  • Page 103 7-27 Your Vehicle CAUTION: After riding your ATV in water, be sure to drain any trapped water by removing the check hose plugs at the bottom of the air filter case, V-belt cooling duct and the gear shift lever box. Also, remove the V-belt case drain plug to drain any water that may have accumulated.
  • Page 104: Riding Over Rough Terrain

    Your Vehicle 7-28 Riding over rough terrain Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to a rollover or accident. Be sure to keep your feet placed firmly on the floorboards at all times.
  • Page 105 7-29 Your Vehicle positioning your weight over the front ● With practice, over a period of time, skill at wheels will sometimes help. controlled sliding can be developed. The ● If the rear wheels of your ATV start to slide terrain should be chosen carefully before sideways, control can usually be regained attempting such maneuvers, since both...
  • Page 106 Your Vehicle 7-30 and/ or steer to the outside of the turn. 3.If your ATV starts to slide sideways: On extremely slippery surfaces, such as ice, ● Steer in the direction of the slide if you go slowly and be very cautious in order to have the room.
  • Page 107 7-31 Your Vehicle ● Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. ● If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.
  • Page 108: Periodic Maintenance And Adjustment

    Periodic Maintenance and Adjustment Periodic Maintenance And Adjustment WARNING Periodic inspection, adjustment POTENTIAL HAZARD lubrication will keep your ATV in the safest Operating this ATV with improper most efficient condition. Safety modifications. maintenance is an obligation of the ATV WHAT CAN HAPPEN owner.
  • Page 109: Periodic Maintenance Chart For The Emission Control System

    Periodic Maintenance and Adjustment Periodic maintenance chart for the emission control system ● For an ATV, which is not equipped with an odometer or an hour meter, follow the monthly maintenance intervals. ● For an ATV, which is equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. ●...
  • Page 110: General Maintenance And Lubrication Chart

    Periodic Maintenance and Adjustment General maintenance and lubrication chart INITIAL EVERY Month Whichever ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (Mi) (200) (750) (1,500) (1,500) (3,000) Hours Engine oil ● Replace (Warm engine before draining.) ○ ○ ○ ○ ●...
  • Page 111 Periodic Maintenance and Adjustment INITIAL EVERY Whichever Month ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (200) (750) (1,500) (1,500) (3,000) (Mi) Hours Front and rear ● Check operation. ○ ○ suspension* ● Correct if necessary. Upper and lower arm pivot and ●...
  • Page 112: Efi System

    Periodic Maintenance and Adjustment EFI System An EFI system is different from a carburetor engine. An EFI engine is composed of advanced parts such as an ECU, EFI wires, sensors and an implementation system. Parts are shown below: 1. high voltage wire 2.ignition signal plug 3. ignition coil 1.
  • Page 113 Periodic Maintenance and Adjustment Throttle Valve To adjust the inlet airflow. Idle control step motor To stabilize the idle speed control Fuel Injection Tap To inject the fuel into the cylinder. Inlet temperature sensor water temperature sensor To monitor the air intake temperature to the engine.
  • Page 114 Periodic Maintenance and Adjustment the throttle valve. The output power and consumption and less emissions. torque are adjusted by changing the injection quantity. EFI system examination If the EFI system fails, the associated fault Water Temperature Sensor code is shown on the display panel. You can analyze the system using an EFI fault This sensor is used to monitor the water detector (purchased from your dealer).
  • Page 115: Engine Oil And Oil Filter

    Periodic Maintenance and Adjustment Engine oil and oil filter The engine oil level should be checked before each use. In addition, the oil and the oil filter must be changed and replaced at the intervals specified periodic maintenance and lubrication chart. Checking the engine oil level 1.
  • Page 116 Periodic Maintenance and Adjustment 1. Start the engine. Warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil drain bolt to drain the oil from the crankcase.
  • Page 117 8-10 Periodic Maintenance and Adjustment CAUTION: Make sure to select the correct style filter with the proper sized O-ring. 1. Engine oil filter 2. Oil filter B CAUTION: If there is no need to replace the oil filter, skip 1. O-ring step 4-6.
  • Page 118 Periodic Maintenance and Adjustment 8-11 8. Fill with the specified amount of the recommended oil. Replace the dipstick and tighten it. Recommended oil: Oil quantity: Oil filler not replaced: 1.97 US qt (1.67 lmp qt, 1.9L) Oil filler replaced: 2.08 US qt (1.76 lmp qt, 2.0L) 1.
  • Page 119: Final Gear Oil

    8-12 Periodic Maintenance and Adjustment 9. Start the engine and warm it up for several minutes. While warming up, check for oil leaks. If oil leaks are found, turn the engine off immediately and check for the source. 10. Turn the engine off, and then check the oil level and fill it if necessary.
  • Page 120: Differential Gear Oil

    Periodic Maintenance and Adjustment 8-13 4. Install the drain bolt and tighten it to the specified torque. Tightening torque: 5. Fill the final gear case with the specified Final gear oil filler bolt: 17ft·lbf (2.3m·kgf, 23 Nm) amount of the recommended oil. Tightening torque: 7.
  • Page 121 8-14 Periodic Maintenance and Adjustment Replacing the differential gear oil 1. Place the ATV on a level surface. 2. Place a container under the differential gear case to collect the used oil. 3. Remove the differential gear oil filler bolt and drain bolt to drain the oil.
  • Page 122: Cooling System

    Periodic Maintenance and Adjustment 8-15 Cooling system 5. Fill the differential gear case with the recommended oil. 1. Place the ATV on a level surface. Recommended oil: 2. Check the coolant level in the coolant SAE 90 API GL-5 gear oil reservoir when the engine is cold, as the Oil quantity: coolant...
  • Page 123: Coolant Replacement

    8-16 Periodic Maintenance and Adjustment 3. If the coolant is at or below the minimum the coolant temperature in the radiator. level mark, remove the reservoir cap. Add If your ATV overheats, see P4-4 for details. coolant to the maximum level mark, replace the reservoir cap, and install the side panel.
  • Page 124 Periodic Maintenance and Adjustment 8-17 2. Place a container under the engine, and then remove the coolant drain bolt. (Use a trough or a similar object as shown to prevent coolant from spilling on the footrest.) 1.the radiator cap. 4. Remove the coolant reservoir cap. 5.
  • Page 125 8-18 Periodic Maintenance and Adjustment Antifreeze and water mixing ratio: 1:1 6. After draining the coolant, thoroughly flush Total amount: the cooling system with clean tap water. 1.87 US qt (1.58 lmp qt, 1.8 L) 7. Replace the coolant drain bolt washer if it Coolant reservoir capacity is damaged.
  • Page 126: Axle Boots

    Periodic Maintenance and Adjustment 8-19 NOTE: If any leaks are found, have a dealer check the cooling system. Axle boots Check the protective boots for holes or tears. If any damage is found, have them replaced by a dealer. 1.Rear axle boot (×2 each side) Spark plug inspection Removal 1.
  • Page 127: Spark Plug Inspection

    8-20 Periodic Maintenance and Adjustment electrode is a medium to light tan color for an 1. Remove the spark plug cap. ATV that is being ridden normally. Do not Use the spark plug wrench in the tool kit to attempt to diagnose such problems yourself. remove the spark plug as shown.
  • Page 128: Air Filter Element Cleaning

    Periodic Maintenance and Adjustment 8-21 Spark plug gap: .032 - .035 in. NOTE: (0.8-0.9 mm) If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight.
  • Page 129 8-22 Periodic Maintenance and Adjustment 1. Fasteners 2. Air filter case cover 1.Air filter case check hose 4. Remove the air filter element. 1. Remove the cover panels on the right side of the fuel tank. 2. Remove the air filter from the ATV. 3.
  • Page 130 Periodic Maintenance and Adjustment 8-23 1. Air filter element 5. Remove the air filter element from its 7. Squeeze the excess solvent out of the air frame. filter element and let it dry. NOTE: Do not twist the air filter element when squeezing it.
  • Page 131 8-24 Periodic Maintenance and Adjustment 12. Install the air filter case cover and be WARNING sure to connect the hose. 13. Install the air filter to the ATV. Make sure Never operate an engine without the air filter the air filter and the hose connections are air element installed.
  • Page 132: Spark Arrester Cleaning

    Periodic Maintenance and Adjustment 8-25 Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe and the spark arrester by pulling it out of the muffler. 3.
  • Page 133: V-Belt Cooling Duct Check Hose

    8-26 Periodic Maintenance and Adjustment V-belt cooling duct check hose 1. Tailpipe 2. Spark arrester If dust or water collects in the V-belt cooling WARNING duct check hose, remove the hose and clean When cleaning the spark arrester, always let the exhaust system cool prior to touching V-belt case drain plug exhaust components.
  • Page 134: Valve Clearance Adjustment

    Periodic Maintenance and Adjustment 8-27 Throttle lever adjustment NOTE: ADJUSTING METHOD: 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 0.12 - 0.20 in (3-5 mm). 3. Tighten the locknut. 1. V-belt case drain plug Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or...
  • Page 135: Front/Rear Brake Pad Inspection

    8-28 Periodic Maintenance and Adjustment Front/rear brake pad inspection Brake fluid level checking Check the brake pads for damage and wear. Insufficient brake fluid may allow air to enter If a brake pad thickness is less than 0.04 in the brake system, possibly causing the (1 mm), have a dealer replace the pads as a brakes to become ineffective.
  • Page 136: Brake Fluid Replacement

    Periodic Maintenance and Adjustment 8-29 3. Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance. 4. Be careful that water does not enter the master cylinder reservoirs when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.
  • Page 137: Front Brake Lever Free Play

    8-30 Periodic Maintenance and Adjustment Replace the oil seals every two years. Replace the brake hoses every four years. Change parts immediately if they are  broken or leaking. brake lever free play Front The front brake lever should have a free play of zero mm (zero in) at the lever end.
  • Page 138: Lever

    Periodic Maintenance and Adjustment 8-31 Adjusting the parking brake lever WARNING The free play of the parking brake lever POTENTIAL HAZARD should be between 0.02 – 0.060 in. Operating with improperly serviced or (.5-1.5mm). adjusted brakes. Loosen the locknut. ● WHAT CAN HAPPEN Turn the adjusting bolt in direction A to ●...
  • Page 139: Adjusting The Brake Pedal

    8-32 Periodic Maintenance and Adjustment 1. Turn the adjusting nut while holding the Adjusting the brake pedal rear brake light switch in place. To make the The top of the brake pedal should be brake light come on sooner, turn the positioned 3 3/8 in.
  • Page 140: Lubricating The Brake Lever And Brake Pedal

    Periodic Maintenance and Adjustment 8-33 Inspection and lubricate cable Lubricating the brake lever and brake pedal WARNING Use lithium grease to lubricate rotating parts. If control cables protective cover gets CAUTION: damaged, corrosion may happen. It also In order to get close to the rotation points of makes the wire twisted, so the cable may not the brake pedal, the side panel should be work.
  • Page 141: Rear Knuckle Upper And Lower Pivot Lubrication

    8-34 Periodic Maintenance and Adjustment Rotation point 1. Rotating point Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun. 1. Rotation point...
  • Page 142: Wheel Removal

    Periodic Maintenance and Adjustment 8-35 1. Nut (×4) 1. Upper knuckle 2. Lower knuckle Wheel installation Recommended 1. Install the wheel and the tapered nut. lubricant: Lithium-soap-based grease NOTE: Wheel removal The arrow mark on the tire must point in the 1.
  • Page 143: Battery

    8-36 Periodic Maintenance and Adjustment the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55.42 ft·lbf (7.5m·kgf, 75 Nm) Rear: 55.42 ft·lbf (7.5m·kgf, 75 Nm) 1. Arrow mark Battery This ATV is equipped with a sealed-type battery.
  • Page 144: Battery Maintenance

    Periodic Maintenance and Adjustment 8-37 CAUTION: Do not try to open the caps on the top of the battery, wear protection. Keep battery, as this may cause damage the children far away from the battery. battery. EXTERNAL: Flush with water. Store battery only after it has been fully INTERNAL: Drink a lot of water or milk.
  • Page 145: Fuse Replacement

    8-38 Periodic Maintenance and Adjustment immediately blows again, consult a dealer. 2. Before re-using, the battery should be fully charged using a specialized charger. CAUTION: A special battery charger is required for recharging a sealed-type battery. 3. Always make sure the positive and negative connections are correct when putting the battery back in the ATV.
  • Page 146: Replacing A Headlight Bulb

    Periodic Maintenance and Adjustment 8-39 Specified fuses: Replacing a headlight bulb Dash board、ECU switch battery fuse Headlight fuse If a headlight bulb burns out, replace it as Auxiliary DC jack fuse follows. EPS、relay fuse 1. Taking off the cover of headlight Brake、steering fuse Backup fuse (5A、10A、15A)
  • Page 147 8-40 Periodic Maintenance and Adjustment 4. Remove the defective bulb by pulling it out. WARNING Before touching or removing a bulb, allow enough time for it to cool. 5. Insert a new headlight bulb into the bulb holder by pushing it in. CAUTION: 1.Rubber sleeve, waterproof 3.
  • Page 148: Replacing A Taillight

    Periodic Maintenance and Adjustment 8-41 1. Do not touch the glass part of the bulb. 6. Install the bulb holder by pushing it in and 1.Rubber sleeve, waterproof 2. cross plate head screw turning it clockwise. 7. Install the bulb holder cover and the cover at the rear of the headlight.
  • Page 149 8-42 Periodic Maintenance and Adjustment holder by pushing it inward and turning it counterclockwise. 4. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 5. Install the bulb holder (together with the bulb) then install the cover. 1.
  • Page 150: Atv Common Fault Inspection And Solution Charts

    Periodic Maintenance and Adjustment 8-43 ATV common fault inspection and solution charts This section provides inspection and solution charts for common faults for the 800 ATV, it will help you maintain the ATV more efficiently for safe use. Some ATV maintenance requires special techniques. If you encounter a problem which you cannot solve, please contact a dealer.
  • Page 151 8-44 Periodic Maintenance and Adjustment Sheet 1: Inspection and solution table for common faults Problems Solutions 1. Check if the frame and support brackets are deformed or broken. Repair and touch-up paint as necessary Panel damaged during 2. Replace any damaged body panels. off-road driving 3.
  • Page 152 Periodic Maintenance and Adjustment 8-45 Sheet 2: Inspection methods / solutions for common faults in the Brake system. Problems Solutions 1. Check if the parking brake lever returns to the normal position. 2. Check if the brake discs on the front or rear wheels are deformed. Brake system seizing 3.
  • Page 153 8-46 Periodic Maintenance and Adjustment Problems Solutions 1. Check to see if there is any brake component wear beyond limits or different wear between the left and right side. 2. Check if the brake force for the front brake has been reduced allowing the rear wheels to lock before the front wheels during Pulling left or right during braking.
  • Page 154 Periodic Maintenance and Adjustment 8-47 Sheet 3: Inspection methods / solutions for common faults in the Electrical system. Problems Solutions 1. Check to be sure the light switch is working. Lights not working 2. Check to see if the wires are damaged. 3.
  • Page 155 8-48 Periodic Maintenance and Adjustment Sheet 4: Inspection methods / solutions for common faults in the operational systems. Problems Solutions 1. Check to see if the nuts on the steering column, steering knuckles and steering stem are damaged or loose. Tighten if necessary. Steering wheel gap is too 2.
  • Page 156 Periodic Maintenance and Adjustment 8-49 Problems Solutions 1. Check to see if the wheel rim is deformed. Wheels bounce when 2. Check to see if the front or the rear axle is bent. moving 3. Check to see if the tire is deformed or damaged. 1.
  • Page 157 8-50 Periodic Maintenance and Adjustment Sheet 5: Inspection methods / solutions for common problems with the engine. Problems Solutions Engine idle cannot 1. Check to be sure the throttle cable is NOT seized. adjusted using a computer 2. Check to see if the ECU is damaged. 1.
  • Page 158 Periodic Maintenance and Adjustment 8-51 Problems Solutions 1. Check to see if the cooling fins on the water cooler are blocked. 2. Check to see if the temperature sensor on the water cooler is damaged and if the cooling fan is operating properly. Coolant overheats or boils 3.
  • Page 159: Advantages Of Eps System:

    Electric Power Steering System ELECTRIC POWER STEERING SYSTEM ADVANTAGES OF EPS SYSTEM: 1) High efficiency: A traditional hydraulic INTRODUCTION power steering system is mechanical This ATV is equipped with Electric Power and hydraulic, it has an efficiency of only Steering System (EPS). To keep the 60%-70%.
  • Page 160: Important Information For Safety:

    Electric Power Steering System consumption 4%-6%. However, the EPS system, hydraulic circuit system runs the power steering motor, hydraulic hoses and fittings so oil leaks only when steering, this generates power may occur. steering without increasing fuel consumption. IMPORTANT INFORMATION 3) The power characteristics of the EPS FOR SAFETY: system can be controlled by software, so...
  • Page 161 Electric Power Steering System INTRODUCTION OF EPS SYSTEM Following the maintenance procedures What is EPS system  The EPS system (Electric Power Steering listed in this chapter will ensure long life System) is a complete set of parts, including of the EPS system. a special ECU only for the EPS system This chapter...
  • Page 162: Typical Parts Of Eps System

    Electric Power Steering System Construction of EPS Typical parts of EPS system 1. Structure chart of EPS EPS systems typically have the following parts: Steering torque sensor   Motor to generate torque power EPS system control unit (ECU)  ...
  • Page 163 Electric Power Steering System 3. ECU: Steering Torque Sensor : Sensor The ECU is a sophisticated electronic piece installation on the reducer of equipment, and controls all the power performance of EPS. Never attempt to repair the ECU. Your dealer will have the expertise to repair or replace the unit.
  • Page 164 Electric Power Steering System environment. The membrane also prevents The ECU mounts next to the Electrical Motor moisture intrusion. of the EPS system. Do not remove or replace the membrane by other parts. On the shell of the ECU unit, there are cables with electric plugs.
  • Page 165 Electric Power Steering System Outside view of reducer 4. Reducer installation: Install the reducer on the frame of the ATV. Install the motor and steering torque sensor on reducer.
  • Page 166 Electric Power Steering System Electronic connectivity diagram of EPS ⑧ Main switch ⑨ Fuse system: 7. Meter: The meter is an important part of the ATV. The meter works together with EPS system and monitors the working condition of the EPS system.
  • Page 167 Electric Power Steering System Fault code diagram Fault indica Fault light Fault style code syste #1 fault of steering F00001 torque sensor #2 fault of steering F00002 torque sensor F00006 ECU overheating low voltage battery F00005 alarm ① Fault code indicator of EPS system Dynamic motor without...
  • Page 168: Operation And Use Of Eps System

    9-10 Electric Power Steering System OPERATION AND USE OF EPS CAUTION:  SYSTEM If main switch is not off, the ECU can be EPS system operation destroyed by battery power in on-off Operate using the following steps: condition during the following connection Assemble your new ATV according the ...
  • Page 169 Electric Power Steering System 9-11 ● Fixing the socket of wire harness to the CAUTION: ○ positive pole ( + pole) of battery with screw/nut, while fixing the socket of EPS If all plug connectors are not hooked up on ○...
  • Page 170 9-12 Electric Power Steering System CAUTION: If the fault indicator light of the EPS  system is lit, this means the EPS system Driving the ATV with a faulty EPS system has found some fault during the ECU may cause an accident, severe injury or self-checking process.
  • Page 171 Electric Power Steering System 9-13 steering torque of the EPS system will be reduced.  The EPS system supplies different power torque depending on the speed and steering angle. See chart below for Power Steering torques according to speed: ① Battery low voltage warning light CAUTION: When lit, the battery low voltage warning light indicates the battery has a loss of...
  • Page 172 9-14 Electric Power Steering System relatively small. This can achieve an ② T2:power torque on steering gear which is supplied by EPS system outstanding auto-centering effect. This ③ Power Torque In Static Condition means, when ATV is driven in a straight-line, ④...
  • Page 173 Electric Power Steering System 9-15 With the EPS system shut down, the ATV repair of the EPS system as soon as will be able to continue to complete the possible. steering function through the mechanical EPS SYSTEM’S INSPECTION, structure of the steering system. However, MAINTENANCE, REPAIR:...
  • Page 174 9-16 Electric Power Steering System Malfunction assortment: When the ECU detects the storage  Long, continuous, fast steering, battery’s voltage is lower than 9VDC  especially when ambient through the sensor, the EPS fault temperature is very high, may cause a indicator light consol...
  • Page 175 Electric Power Steering System 9-17 consol. The ECU will also send the speed sensor fault code to the consol. Steering wheel’s range of free When ECU detects its own fault and is clearance is:0-15mm(0-0.59in.)  not working normally, the EPS fault If the free clearance is over range, check indicator light will illuminate on the parts below, if any defect is found, repair or...
  • Page 176 9-18 Electric Power Steering System Turn the handlebars from left to right and the “ON” position. right to left. Make sure steering is smooth Turn the handlebars left and right and there is no blockage. successively, turning force on both sides should be equal.
  • Page 177 Electric Power Steering System 9-19 Turn the Handlebars left to right then If any problems are found, take your ATV to right to left; turning should be smooth, an authorized service center. no binding, no recoil forces opposite of operating force.
  • Page 178: Solutions For Common Fault:

    9-20 Electric Power Steering System Solutions for common fault: 1. Main switch is turned on, however there is no power steering. FAULT PHENOMENON FAULT POINT SOLUTION ECU has a blown fuse in the fuse Meter warning fault Replace fuses or take to box (see figure 1), or ECU is code:F00010 service center for repair...
  • Page 179 Electric Power Steering System 9-21 Figure 1:Fuse box Figure 2:ECU initialization connector’s position ① ECU dedicated fuse ① ECU initialization connector 2. Power steering only works turning left or it only works turning right when the main switch turned on. Fault phenomenon Fault point Solution...
  • Page 180 9-22 Electric Power Steering System 3. Power steering works somewhat, however there are gaps where it does not work during the steering process. Steering sometimes binds, is rough or backswings. Fault phenomenon Fault point Solution Mechanical portion of the Steering system mechanical parts Retighten loose bolts.
  • Page 181 Electric Power Steering System 9-23 Meter warning fault code: The speed sensor is damaged, or Replace speed sensor. F00011 from the meter to the ECU the Check and repair cables. speed signal ‘s guide wire circuit is Replace connector broken or ECU connectors are assembly.
  • Page 182 9-24 Electric Power Steering System ECU is damaged, or the ECU No meter alarm Service center for repair software program has an error. 6. Power steering somewhat works, however, the power of steering left to right is different. Fault phenomenon Fault point Solution channels’...
  • Page 183 Electric Power Steering System 9-25 7. Open main switch, steering to the same direction automatically. Fault phenomenon Fault point Solution No meter alarm Sensor is loose To dealers for repair. No meter alarm , The initialization parameter of ECU Restart initialization Sensor is not loose.
  • Page 184: Maintenance And Repair's Supplemental Description:

    9-26 Electric Power Steering System Maintenance and repair’s supplemental previous steps of the initialization process. description: Because different mechanical 1. Restart initialization to ECU parameter: clearances of the ATV, it may require 3-5 Park ATV on flat ground and keep the times to be repeated in order to get the ...
  • Page 185: Eps System Parameter Table

    Electric Power Steering System 9-27 parameters. -40℃~+85℃ 2. Working voltage:(9~16V) DC NOTE: 3. The seal type:IP65 Before adjusting the ECU every time, 4. Input shaft rotation angle:large than ±45° please check the clearance of mechanical 5. Wheel rotation speed: parts and adjust the four wheels fixed 10round/min~15round/min position of ATV.
  • Page 186 9-28 Electric Power Steering System Rated operational current:35A±3A  Rated output torque :1.8N·m±0.16N·m ...
  • Page 187: Cleaning And Storage

    Cleaning and Storage 10-1 Cleaning CAUTION: Keeping the ATV clean will not only keep the The use of high pressure sprayers (power ATV looking nice but will extend the life of the washers, car wash sites) can damage the ATV. ATV.
  • Page 188: Storage

    10-2 Cleaning and Storage Storage Wipe off seat with a non abrasive cleaner. Wax outside of ATV with a non abrasive wax. If storing ATV (60 days or longer) it is When finished cleaning ATV, start up and let important that the ATV be prepared for idle for a short period of time.
  • Page 189 Cleaning and Storage 10-3 exhaust pipe to prevent moisture from entering. If stored in a humid or salty environment, coat all metal parts with a thin coat of oil. Make sure oil does not get on any rubber parts or the seat cover of the ATV. Remove and fully charge the battery.
  • Page 190 11-1 Specification Model HS800ATV-2 Dimensions: Overall length 98.8 in (2,510mm) Overall width 48.0 in (1,220mm) Overall height 54.7 in (1,390mm) Seat height 35.4in (900mm) Wheelbase 58.7 in (1490mm) Ground clearance 12.2 in (310mm) Minimum turning radius 97in (2480mm) Basic weight: 926 lb (420kg) With oil and full fuel tank Engine:...
  • Page 191 Specifications 11-2 Model HS800ATV-2 Engine oil: Type API Service SE, SF, SG type or higher Recommended engine oil classification CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD”...
  • Page 192 11-3 Specification Model HS800ATV-2 Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.42 US qt (0.4 L ,0.35 Imp qt) Differential gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.10 US qt (0.10 L ,0.08 Imp qt,) Radiator capacity (including all routes): 2.64 US qt (2.50 L ,2.20 Imp qt,) Air filter:...
  • Page 193 Specifications 11-4 Model HS800ATV-2 Transmission: Primary reduction system CVT-belt Secondary reduction system Shaft drive CVT reduction ratio 0.68-2.7 Transmission type CVT-belt automatic Operation Right hand operation Reverse gear 5.45 Sub transmission ratio 5.29 High 2.866 Tire: Tubeless Type 26×9-12 Size front rear 26×10-12...
  • Page 194 11-5 Specification Model HS800ATV-2 Brake: Front brake type Dual disc brake operation right hand operation Rear brake type Dual disc brake operation right foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring / oil damper Rear shock absorber Coil spring / oil damper Wheel travel:...
  • Page 195 Specifications 11-6 Model HS800ATV-2 Bulb voltage, wattage ×quantity: Head light 12 V, 30 W / 30 W×2 Tail/brake light 12 V, 5 W / 21 W×1 Indicator light: Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High-range indicator light Low-range indicator light Differential gear lock indicator light...
  • Page 196 12-1 Fault Code of Electronic Injection System Fault Code of Electronic Injection System DTC Description Related Calibration Number P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh Coolant/Oil Temperature Sensor Circuit P0117...
  • Page 197 Fault Code of Electronic Injection System 12-2 P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh P0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh P0032 O2S Heater Circuit Low Voltage KsDGDM_O2_HeaterShortLow P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow...
  • Page 198 12-3 Fault Code of Electronic Injection System P0563 System Voltage High KsDGDM_SysVoltHigh 1379 P0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1616 P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low 1693 5779 P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 1694 5780 P0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow P0138 O2S 2 Circuit High Voltage...
  • Page 199 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 13-1 YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) is pleased to explain the emission control system warranty on your 2013 Off-Road ATV or UTV vehicle. New off-road motor vehicles must be designed, built and equipped to meet California’s anti-smog standards.
  • Page 200 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 13-2 As the vehicle owner, you should be aware that HISUN may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you use your vehicle in any type of competitive event, this warranty is immediately and completely void.
  • Page 201 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 13-3 (2) misuse, (3) repairs improperly performed or replacements improperly installed, unless performed by a HISUN authorized dealer, (4) use of improper replacement parts or accessories not conforming to specifications set forth by HISUN, which adversely affect performance and/or (5) Use in competitive racing or related events.
  • Page 202 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 13-4 C. No dealer is authorized to modify this Limited Emission Control System Warranty issued by HISUN. IV. LEGAL RIGHTS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
  • Page 203 POWERSPORTS (888)-405-8725 Coleman Powersports 364 S. Smith Rd. Tempe, AZ. 85281...

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