Page 1 OWNER’S MANUAL POWERSPORTS Model: HS500ATV No one under the age of 16 should operate this ATV (888) 405-8725 Coleman Powersports 1775 E. University Dr., Tempe, AZ 85281 colemanpowered.com...
Page 2 Owner Manual...
Page 3 Owner Manual INTRODUCTION Congratulations on your purchase of the HS500ATV-4. 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 herein will provide the knowledge needed to have safe and enjoyable ATV operation.
Page 4 Owner Manual IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS Particularly important information is distinguished in this manual by the INJURY OR DEATH. following notations: The Safety Alert Symbol means ATTENTION! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
Page 5 Owner Manual IMPORTANT NOTICE Turning speed must be slower than 30km/h. (19 mph) 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 Limited Warranty Location of the Warning and Throttle Lever 4-14 Specification Labels Speed Limiter 4-15 Front Brake Lever 4-17 Safety Information Brake Pedal and Rear Brake Lever 4-17 Description and Vehicle Drive Select Lever 4-18 Identification Fuel Tank Cap...
Page 7 Owner Manual Coolant Driving Your Vehicle Throttle lever Ride With Care and Good Fittings and Fasteners Judgment Lights Apparel Switches Speed Limiter Tires Loading and Accessories How to Measure Tire Pressure 5-10 During Operation Tire Wear Limit 5-11 Modifications 7-11 Exhaust System 7-11 Operation...
Page 8 Owner Manual Owner’s Manual and Tool Kit Select Lever Safety System Periodic Maintenance Chart for Cable Adjustment 8-38 the Emission Control System Throttle Lever Adjustment 8-38 General Maintenance and Front Brake Pad Check 8-38 Lubrication Chart Checking the Rear Brake Pads 8-39 Panel Removal and Installation Checking the Brake Fluid Level...
Page 9 Owner Manual Fuse Replacement 8-49 Replacing A Headlight Bulb 8-51 Headlight Beam Adjustment 8-53 Tail/Brake Light Bulb Replacement 8-53 Check and Solution to Common Problems in Vehicle 8-55 Cleaning and Storage Cleaning Storage Specifications 10-1 11-1 Fault code of Electronic Injection System 12-1 USA EPA Emissions Limited...
Page 10 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 that is covered by this warranty and is proven to be defective in workmanship or material.
Page 11 / dealer. Please do not return the product to the retailer where the product was purchased unless instructed to do so by Coleman Powersports. The retailer of this product does not make any warranty of its own and has no authority to implement this warranty on behalf of Coleman Powersports without the approval of Coleman Powersports.
Page 12 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 that would extend longer than the duration of this written warranty.
Page 13: Location Of The Warning And Specification Labels
Location of the Warning and Safety Labels LOCATION OF THE WARNING AND SPECIFICATION LABELS ⑪ ② ⑫...
Page 14 Location of the Warning and Safety Labels Read and understand all of the labels on ② your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your ③...
Page 15 Location of the Warning and Safety Labels ④ ⑤ ⑥...
Page 16 Location of the Warning and Safety Labels ⑦ ⑧...
Page 17 Location of the Warning and Safety Labels ⑨ ⑩ ⑪ ⑫...
Page 18: Safety Information
Safety Information SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.
Page 19 Safety Information Never operate an ATV without wearing an approved motorcycle helmet that fits properly.  You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. ...
Page 20 Safety Information Always follow proper procedures for turning as described in this manual. Practice turning  at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on ...
Page 21 Safety Information steep hill if possible. Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid  stalling, use proper gear range and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill.
Page 22 Safety Information 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 slow.  Always use the size and type of tires specified in this manual. ...
Page 23 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 adequate ventilation.
Page 24 Safety Information WARNING POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. HOW TO AVOID THE HAZARD Always turn off the engine when refueling. Do not refuel right after the engine has been running and is still very hot.
Page 25 Description and Vehicle Identification...
Page 26: Identification Number Records
Description and Vehicle Identification Identification number records Vehicle identification number Record the vehicle identification number The vehicle identification number is stamped (VIN), model number and key identification into the frame. number in the spaces provided. These numbers will be needed for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen.
Page 27: Control Functions
Control Functions CONTROL FUNCTIONS The engine can be started only at this Main switch position and the headlights and taillight come Functions of the respective switch positions on when the light switch is on. are as follows: OFF: All electrical circuits are switched off. The key can be removed in this position.
Page 28: Indicator And Warning Lights
Control Functions Indicator and Warning Lights 12. Far light indicator Low-Range Indicator Light “L” This indicator light comes on when the drive select lever is in the “L” position. Mechanical Parking Brake Indicator Light “ ” This indicator light comes on when the mechanical parking brake is applied.
Page 29 Control Functions Reverse Indicator Light “R”  After restarting, make sure that the light This indicator light comes on when the drive is out. Continuous use while the light is on may cause damage to the engine. select lever is in the “R” reverse position. High beam indicator Coolant Temperature Warning Light “...
Page 30: Use Of Eps System
Control Functions Use of EPS system When the ignition switch is turned to the  The EPS is an important part of the ATV. “ON” position, the EPS system will The EPS system monitors the working automatically enter into its working state. condition of the ATV.
Page 31: Speedometer Unit
Control Functions Speedometer unit functions: Speedometer Unit  a speedometer (which shows the speed)  an odometer (which shows the total distance covered)  a trip meter (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 button on the left side toggles the display button on the display. This will also change from the odometer, to the trip meter, and then displayed mileage from miles to the hours meter; then it starts the cycle kilometers.
Page 33: Differential Gear Lock Indicator
Control Functions means the differential is not operational and Four-wheel drive indicator “ ” is locked. When riding an ATV on muddy and There are two 4WD indicators on the display slippery roads or when climbing a steep hill, panel. The left 4WD indicator has a blinking make sure the 4WD lock indicator is on.
Page 34: Fault Code Indicator
Control Functions in the yellow and the gray buttons to the will be shown in rolling sequence. When 2WD unlocked position. There should be no fault codes are present, in order to see the symbols showing in either the left or right time, press the clock button, the time will be 4WD indicators.
Page 35: Handlebar Switches
Control Functions 1. Light switch “ / OFF/” 1. Fuel level indicator 2. Fuel level warning indicator 2. Start switch “ ” 3. Left/right turning switch Handlebar switches 4. Engine stop switch “ ” 5. Horn switch 6. Emergency light switch Light switch “...
Page 36 4-10 Control Functions beam and the taillight. this switch is pushed. Set the switch to “ ” to turn on the high CAUTION: beam and the taillight. See starting instructions prior to starting Set the switch to “OFF” to turn off all the lights.
Page 37: Horn Switch
Control Functions 4-11 is set to “ ”. Horn switch Press this switch, horn activates. Emergency light switch Press this switch, Front left/right turning light Rear left/right turning light blink simultaneously. 1. On-Command four-wheel drive switch “2WD”/“4WD” On-Command four-wheel drive and 2.
Page 38 4-12 Control Functions terrain and the conditions. Two-wheel drive (2WD): Power is supplied to WARNING POTENTIAL HAZARD the rear wheels only. Changing from 2WD to 4WD or from 2WD to 2WD-Differential UNLOCK, or Four-wheel drive (4WD): Power is  vice-versa while the vehicle is moving. supplied to the rear and front wheels.
Page 39 Control Functions 4-13 indicator will come On-Command Four-Wheel-Drive Switch multi-function display. “2WD/4WD” To change from 4WD to 2WD stop the vehicle, and then set the switch to “2WD”。the 4WD indicator will go out in the multi-function display. Differential gear lock switch “LOCK”/ “4WD”...
Page 40: Throttle Lever
4-14 Control Functions To lock the differential gear in 4WD, make the differential is locked, so it takes sure the On-Command four-wheel-drive switch is set to “4WD”, stop the ATV, move more effort to turn the vehicle. The amount of effort required is greater the the lever to position (b), and then set the switch to “LOCK”.
Page 41: Speed Limiter
Control Functions 4-15 Regulate the speed of the machine by it returns to the idle position as soon as the varying the throttle position. Because the lever is released. throttle is spring-loaded, the machine will WARNING decelerate, and the engine will return to an POTENTIAL HAZARD idle any time the hand is removed from the Malfunction of throttle.
Page 42 4-16 Control Functions opening, even when the throttle lever is WARNING pushed to the maximum. Turning in the adjusting screw limits the maximum engine POTENTIAL HAZARD power available decreases Improper adjustment of the speed limiter and maximum speed of the ATV. throttle.
Page 43: Front Brake Lever
Control Functions 4-17 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 1. Brake pedal 1. Brake lever Brake pedal and rear brake lever The brake pedal is located on the right side of the ATV and the rear brake lever is located on the left handlebar.
Page 44: Drive Select Lever
4-18 Control Functions Drive select lever Fuel tank cap The drive select lever is used to shift your Remove the fuel tank cap by turning it machine into the low, high, neutral, reverse counterclockwise. and park positions. (Refer to pages 6-2—6-4 for the drive select lever operation.) Fuel tank cap 1.
Page 45: Seat
Control Functions 4-19 SEAT NOTE: Make sure that the seat is securely filed. To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. 1.Projection（×2） 2.Seat holder（×2） 1.Seat 2.Seat lock lever Storage compartment To install the seat, insert the projections on The storage compartment is located under the front of the seat into the seat holders and...
Page 46: Front Carrier
4-20 Control Functions Front carrier When storing the owner’s manual or other documents in the storage compartment, be Front carrier Maximum load limit: sure to wrap them in a plastic bag so that 20kg(44lb) they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment.
Page 47: Rear Carrier
Control Functions 4-21 Rear carrier Front and rear shock absorber adjustment Rear carrier Maximum load limit: 35kg(77lb) The spring preload can be adjusted to suit the rider’s weight and riding conditions. NOTE: When adjusting the rear shock absorber, the rear wheels need to be removed. (See pages 8-47 —...
Page 48 4-22 Control Functions Standard position: B A- Minimum (soft) E- Maximum (hard) 1. Spring preload adjusting ring 2. Position indicator NOTE: 1. Special wrench A special wrench can be obtained at a dealer to make this adjustment.
Page 49: Auxiliary Dc Jack
Control Functions 4-23 suitable work lights, radios, etc. WARNING The auxiliary DC jack should only be used while the engine is running. POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident.
Page 50 4-24 Control Functions insert the accessory power plug into the 4. When the auxiliary DC jack is not being jack. used, cover it with the cap. CAUTION: Do not use accessories requiring more  than the above maximum capacity. This may overload the circuit and cause the fuse to blow.
Page 51: Pre Operation Checks
Pre Operation Checks Before using this machine, check the following points: ITEM ROUTINE PAGE Check operation, free play, fluid level and fluid leakage. 5-2-5-3, ● Brakes Fill with DOT 4 brake fluid if necessary. 8-41-8-43 ● Check for proper operation, condition and free play. Parking brake ●...
Page 52: Front And Rear Brakes
Pre Operation Checks Front and rear brakes WARNING Brake levers and brake pedal Check that there is no free play in the front POTENTIAL HAZARD brake lever. If there is free play, have a Failure to inspect the ATV before operating. dealer adjust it.
Page 53: Brake Fluid Leakage
Pre Operation Checks Brake fluid level out to make sure they are working properly. If Check the brake fluid level. Add fluid if the brakes do not provide proper braking performance, inspect the brake pads for necessary. (See pages 8-39—8-41.) wear.(See page 8-38-8-39.) Recommended brake fluid: DOT 4 WARNING...
Page 54: Fuel
Pre Operation Checks Fuel Your engine has been designed to use Make sure there is sufficient gasoline in the regular unleaded gasoline with a pump tank. 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 Recommended fuel: brand of gasoline or premium unleaded fuel.
Page 55 Pre Operation Checks abnormally and exhaust to be deteriorated. WARNING POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.
Page 56: Engine Oil
Pre Operation Checks Engine Oil Recommended engine oil type and Make sure the engine oil is at the specified quantity: level. Add oil as necessary. See page 10-2 CAUTION: Final gear oil  In order to prevent clutch slippage (since Make sure the final gear oil is at the specified the engine oil also lubricates the clutch), level.
Page 57: Differential Gear Oil
Pre Operation Checks Differential gear oil to bring the level up to maximum level mark. Make sure the differential gear oil is at the Change the coolant every two years. (See specified level. Add oil as necessary. (See pages 8-25-8-26 for details.) pages 8-23 for details.) CAUTION: Hard water or salt water is harmful to the...
Page 58: Specifications
Pre Operation Checks Have a dealer repair as necessary for proper WARNING operation. POTENTIAL HAZARD Fittings and fasteners Removing the radiator cap when the engine Always check the tightness of chassis fittings and radiator are still hot. and fasteners before a ride. Take the WHAT CAN HAPPEN machine to a dealer or refer to the Service You could be burned by hot fluid and steam...
Page 59: Tires
Pre Operation Checks Tires WARNING Check and adjust tire pressures when the tires are cold. POTENTIAL HAZARD Tire pressures must be equal on both sides. Operating this ATV with improper tires, or with 3. Tire pressure below the minimum specified improper or uneven tire pressure.
Page 60: How To Measure Tire Pressure
5-10 Pre Operation Checks How to measure tire pressure Use a low-pressure tire gauge. Recommended Minimum Maximum pressure NOTE: 10psi (70kpa 9 psi (63kpa, 11psi,(77kpa, Front (0.70kgf/ cm 0.64kgf/ cm 0.77kgf/ cm The low-pressure tire gauge is included as standard equipment.
Page 61: Tire Wear Limit
Pre Operation Checks 5-11 Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit...
Page 62: Operation
Operation Starting a cold engine WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating ATV without being familiar with all Freezing control cables in cold weather. WHAT CAN HAPPEN controls. WHAT CAN HAPPEN You could be unable to control the ATV, which Loss of control, which could cause an accident could lead to an accident or collision.
Page 63: Warming Up
Operation opened slightly. When the driving select lever is in the neutral or park position, if the indicator light does not Warming up come on, ask the dealer to inspect the To get maximum engine life, always warm up respective electrical circuit. the engine before starting off.
Page 64 Operation Shifting: Neutral to High and High to completely shifted into position. 3. Open the throttle lever gradually. 1. Bring the ATV to a complete stop and return the throttle lever to the closed position. Shifting: Neutral to Reverse 2. Apply the brakes, then shift by moving the NOTE: drive select lever along the shift guide.
Page 65 Operation 4. Check behind for people or obstacles, and then release the brake pedal. 5. Open the throttle lever gradually and continue to watch to the rear while backing. WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN 1. Drive select lever You could hit an obstacle or person behind you, NOTE: resulting in serious injury.
Page 66: Engine Break-In
Operation Use of any engine oil not mentioned in this Vehicle Break-in Period ● manual will cause severe damage to the The break-in period for your new ATV vehicle is engine。 the first 25 hours of operation, or the time it takes to use the first three tanks full of gasoline.
Page 67 Operation full throttle operation under load does not harm Rev the vehicle freely but do not use full throttle the engine. at any time. Each full throttle acceleration sequence should After Break-In: be followed with a substantial rest period for the The vehicle can now be operated normally.
Page 68: Parking
Operation Parking rocks or other objects. When parking, stop the engine and shift the Do not park the ATV at all on hills that are so drive select lever into the park position, then steep you could not walk up them easily. turn the fuel cock to the “OFF”...
Page 69: Accessories And Loading
Operation Your dealer has a variety of genuine accessories. Accessories should be rigidly and securely mounted. An accessory which will shift position or come off while you are riding could affect your ability to control the ATV. Do not mount an accessory where it could interfere with your ability to control the ATV.
Page 70 Operation Loading Do not exceed the maximum tongue weight. Cargo or a trailer can change the stability and You can measure tongue weight with a handling of an ATV. You must use common bathroom scale. Put the tongue of the loaded sense and good judgment when carrying cargo trailer on the scale with the tongue at hitch or towing a trailer.
Page 71 Operation 6-10 going. WARNING Drive more slowly than you would without a load. The more weight you carry, the slower you POTENTIAL HAZARD should go. Although conditions vary, it is good Overloading this ATV or carrying or towing cargo practice not to exceed low range whenever you improperly.
Page 72: Driving 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 riding attention to the safety information on pages instructions for recreational riding.
Page 73 Your Vehicle the machine’s handling and performance maneuvers. characteristics. Not recommended for children under 16 WARNING years of age. POTENTIAL HAZARD WARNING Operating this ATV without proper instruction. WHAT CAN HAPPEN POTENTIAL HAZARD The risk of an accident is greatly increased if Failure to follow the age recommendations for the operator does not know how to operate this ATV.
Page 74 Your Vehicle This ATV is designed to carry operator and cargo only - passengers prohibited. 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 harm and/or...
Page 75: 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 76 Your Vehicle Do not operate after consuming alcohol or drugs. HOW TO AVOID THE HAZARD Operator’s performance capability is reduced Always wear an approved motorcycle helmet by the influence of alcohol or drugs. that fits properly. You should also wear: eye protection (goggles or face shield) gloves...
Page 77: Judgment
Your Vehicle Always perform the pre-operation checks WARNING listed on page 5-1 before riding for safety and proper care of the ATV. POTENTIAL HAZARD Operating this ATV after consuming alcohol or WARNING drugs. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before operating. Could seriously affect your judgment.
Page 78 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 79: Speed Limiter
Your Vehicle Speed limiter 1. Locknut 2.Adjusting screw Loading and accessories For riders less experienced with this model, this model is equipped with a speed limiter in Use extra caution when riding the ATV with the throttle lever housing. The speed limiter additional loads, such as accessories or keeps the throttle from fully opening, even cargo.
Page 80: During Operation
Your Vehicle During operation WARNING Always keep your feet on the footboards POTENTIAL HAZARD during operation. Otherwise your feet may Overloading this ATV or carrying or towing contact the rear wheels. cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident.
Page 81 Your Vehicle 7-10 Avoid wheelies and jumping. You may lose WARNING control of the ATV or overturn. WARNING POTENTIAL HAZARD POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN WHAT CAN HAPPEN Removing even one hand or foot can reduce Increases...
Page 82: Modifications
7-11 Your Vehicle Modifications Exhaust system WARNING The exhaust system on the ATV is very hot during and following operation. To prevent POTENTIAL HAZARD burns, avoid touching the exhaust system. Operating this with improper modifications. Park the ATV in a place where pedestrians or WHAT CAN HAPPEN children are not likely to touch it.
Page 83: Be Careful Where You Ride
Your Vehicle 7-12 BE CAREFUL WHERE YOU RIDE HOW TO AVOID THE HAZARD This ATV is designed for off-road use only. Riding on paved surfaces can cause loss of Do not operate, idle, or park the ATV in dry control. grass or other dry ground cover.
Page 84 7-13 Your Vehicle WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
Page 85 Your Vehicle 7-14 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
Page 86 7-15 Your Vehicle 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 an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and...
Page 87 Your Vehicle 7-16 When riding in an area where you might not WARNING easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the POTENTIAL HAZARD flag pole bracket as a trailer hitch. Operating in areas where you might not be seen by other off-road vehicles.
Page 88 7-17 Your Vehicle ride areas posted “ no Select a large, flat area off-road to become trespassing”. familiar with your ATV. Make sure that this Do not ride on private property without area is free of obstacles and other riders. You getting permission.
Page 89: Turning Your Atv
Your Vehicle 7-18 clothing to come in contact with these high “H” or vice versa without coming to a components. complete stop. Damage to the engine or With the engine idling, shift the drive select drive train may occur. lever to the low position “L” or the high position “H”.
Page 90 7-19 Your Vehicle As you approach a curve, slow down and WARNING begin to turn the handlebars in the desired POTENTIAL HAZARD direction. As you do so, put your weight on Turning improperly. the footboard to the outside of the turn WHAT CAN HAPPEN (opposite your desired direction) and lean ATV could go out of control, causing a...
Page 91 Your Vehicle 7-20 to position more of your weight over the front wheels by moving forward on the seat. Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to...
Page 92: Climbing Uphill
7-21 Your Vehicle CLIMBING UPHILL WARNING Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can POTENTIAL HAZARD maneuver your ATV well on flat ground Operating on excessively steep hills. before attempting any incline and then WHAT CAN HAPPEN practice riding first on gentle slopes.
Page 93 Your Vehicle 7-22 standing on the footboards and leaning forward over the handlebars. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
Page 94 7-23 Your Vehicle If you are climbing a hill and you find that you on level ground. Be very careful when turning on have not properly judged your ability to make any hill. Avoid crossing the side of a steep hill if it to the top, you should turn the ATV around possible.
Page 95 Your Vehicle 7-24 If your ATV has stalled or stopped and you application of either the front or rear brake believe you can continue up the hill, restart because the wheels on the uphill side could carefully to make sure you do not lift the front come off the ground.
Page 96 7-25 Your Vehicle WARNING 4WD or 4WD-LOCK: Apply both front and POTENTIAL HAZARD rear brakes gradually. Stalling, rolling backwards or improperly When fully stopped, shift to the parking dismounting while climbing a hill. position “P”. WHAT CAN HAPPEN Could result in ATV overturning. Dismount on uphill side or to a side if HOW TO AVOID THE HAZARD pointed straight uphill.
Page 97: Riding Downhill
Your Vehicle 7-26 RIDING DOWNHILL When this ATV is in 4WD or 4WD-LOCK, all When riding your ATV downhill, shift your wheels (front and rear) are interconnected by weight as far to the rear and uphill side of the the drive train. This means that applying ATV as possible.
Page 98 7-27 Your Vehicle WARNING cause the vehicle to lean sharply to one side. POTENTIAL HAZARD Go straight down the hill where possible. Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner’s Manual.
Page 99: Crossing A Slope
Your Vehicle 7-28 CROSSING A SLOPE balance, gradually steer again in the Traversing a sloping surface on your ATV direction you wish to travel. WARNING requires you to properly position your weight to maintain proper balance. Be sure that you POTENTIAL HAZARD have learned the basic riding skills on flat Improperly crossing hills or turning on hills.
Page 100: Crossing Through Shallow Water
7-29 Your Vehicle CROSSING THROUGH SHALLOW WATER Always follow proper procedures as de- scribed The ATV can be used to cross slow moving, in the Owner’s Manual. shallow water of up to a maximum of 35 cm Avoid hills with excessively slippery or loose (14 inches) in depth.
Page 101 Your Vehicle 7-30 WARNING 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 this ATV in fast flowing water or in water deeper than that specified in your Test your brakes after leaving the water.
Page 102 7-31 Your Vehicle the ATV in fresh water if it has been operated in salt water or muddy conditions. CAUTION: Air filter case check hose After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose and the drive select lever box check hose.
Page 103: Riding Over Rough Terrain
Your Vehicle 7-32 1. V-belt cooling duct check hose (Left side) 1.Drive select lever box check hose 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 an upset or accident.
Page 104: Sliding And Skidding
7-33 Your Vehicle SLIDING AND SKIDDING Avoid jumping the ATV as loss of control and damage to the ATV may result. Care should be used when riding on loose or WARNING slippery surfaces since the ATV may slide. If POTENTIAL HAZARD unexpected and uncorrected, sliding could Improperly operating over obstacles.
Page 105 Your Vehicle 7-34 If the rear wheels of your ATV start to slide With practice, over a period of time, skill at sideways, control can usually be regained (if controlled sliding can be developed. The there is room to do so) by steering in the terrain should be chosen carefully before direction of the slide.
Page 106 7-35 Your Vehicle 2．If your ATV begins to tip while turning: practicing at low speeds and on level, ● Lean more into the turn to regain balance. ● If necessary, gradually let off the throttle smooth terrain. and/ or steer to the outside of the turn. On extremely slippery surfaces, such as (See pages 7-18—7-20.) ice, go slowly and be very cautious in...
Page 107 Your Vehicle 7-36 ● If the ATV starts to slip backwards DO NOT CHECK YOUR BRAKES FOR PROPER USE THE REAR BRAKE - the ATV may tip OPERATION when you come out of the over on top of you. water. ●...
Page 108: Adjustment
Periodic Maintenance and Adjustment Owner’s manual and tool kit Periodic Maintenance And Adjustment It is recommended to place this owner’s Periodic inspection, adjustment manual in a vinyl bag and always carry it in lubrication will keep your machine in the the storage box.
Page 109 Periodic Maintenance and Adjustment The service information included in this manual is intended to provide you, the owner, WARNING with necessary information POTENTIAL HAZARD completing your preventive Operating this with improper maintenance and minor repairs. The tools modifications. provided in the Owner’s tool kit are sufficient WHAT CAN HAPPEN for this purpose, except that a torque wrench Improper...
Page 110: Periodic Maintenance Chart For The Emission Control System
Periodic Maintenance and Adjustment Periodic maintenance chart for the emission control system ● For ATV, which is not equipped with an odometer or an hour meter, follow the month maintenance intervals. ● For ATV, which is equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
Page 111: 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 filter Clean. ● ○ ○ ○ element Replace if necessary. ● Engine oil strainer Clean.
Page 112 Periodic Maintenance and Adjustment 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 Upper and lower pivot Lubricate every 6 months with lithium-soap-based grease. ● ○ ○ ○ steering shaft Rear arm pivot Lubricate every 6 months with lithium-soap-based grease.
Page 113: Panel Removal And Installation
Periodic Maintenance and Adjustment Panel removal and installation The panels illustrated need to be removed to Refer to this section each time a panel has to perform some of the maintenance described be removed or reinstalled. in this chapter. 1. Panel D 2.
Page 114 Periodic Maintenance and Adjustment pull upward as shown. 1.Panel A 1. Panel D To install 1. Insert the panel projections in the numerical order shown in the illustration, and then push inward on the area shown. 2. Install the seat.
Page 115 Periodic Maintenance and Adjustment Panel B To remove Remove the bolts. To install Place the panel in the original position and install the bolts. 1.Panel A Panel B 2. Bolt (×2) CAUTION: When installing the panel, be sure not to pinch the cables or wires.
Page 116 Periodic Maintenance and Adjustment Panel C To remove 1. Remove the front carrier by removing the stay covers at the rear, then by removing the bolts. 1. Bolt (×2) (top) 1. Front carrier stay cover (×2) Bolt (×2) (top)
Page 117 Periodic Maintenance and Adjustment 8-10 To install 1. Place the panel in the original position and install the quick fasteners. 2. Install the front carrier by installing the bolts and tightening them to the specified torques. Tightening torques: Carrier bolt (top): 1.
Page 118 8-11 Periodic Maintenance and Adjustment Panel E Panel F To remove To remove Remove the bolts, and then take the panel Pull outward on the areas shown. off. To install Place the panel in the original position, and then install the bolts. 1.
Page 119 Periodic Maintenance and Adjustment 8-12 Panel G To install Place the panel in its original position. To remove 1. Remove the seat. (See page 4-19 for seat removal and installation procedures.) 2. Remove the rear carrier by removing the bolts. 1.
Page 120: Efi System
8-13 Periodic Maintenance and Adjustment To install 1. Place the panel and the seat under bracket in the original position. 2. Install the rear carrier by installing the bolts and tightening them to the specified torques. Tightening torques: Carrier bolt (top): 26 Nm (2.6m·kgf, 19ft·lbf) Carrier bolt (under fenders): 1.
Page 121 Periodic Maintenance and Adjustment 8-14 1. ECU 1. oxygen sensor assy 2. oxygen sensor threaded sleeve 3. exhaust Pipe 1. high voltage wire 2.ignition signal plug 3. ignition coil...
Page 122 8-15 Periodic Maintenance and Adjustment 1. idle speed stepper motor 2. air damper degree sensor 3. air damper Air damper For the purpose of adjustment of air intake volume. 1. fuel injector 2. water temperature sensor 3. intake air temperature sensor/ pressure sensor...
Page 123 Periodic Maintenance and Adjustment 8-16 Idle speed stepper motor Water temperature sensor To stabilize the idle speed For testing cooling water temperature, according to the temperature difference, Fuel injector ECU will automatically revise water injection Inject the fuel into the cylinder volume, to ensure the smooth operation of the engine all the time.
Page 124: Efi System Inspection
8-17 Periodic Maintenance and Adjustment EFI System inspection Engine oil and oil filter cartridge The engine oil level should be checked If the EFI system has a failure, the meter will before each ride. In addition, the oil must be display the appropriate failure code, you can changed and the oil filter cartridge replaced also use the special "EFI system failure...
Page 125 Periodic Maintenance and Adjustment 8-18 1. Maximum level mark 2. Minimum level mark 1. Engine oil filler cap 2. Dipstick 6. Insert the dipstick in the oil filler hole 7. If the engine oil is at or below the minimum (without screwing it in), then remove dipstick level mark,...
Page 126 8-19 Periodic Maintenance and Adjustment Changing engine oil (with or without oil NOTE: filter cartridge replacement) Skip steps 5-9 if the oil filter cartridge is not 1. Remove panel F. (See page 8-11 for panel being replaced. removal and installation procedures.) 2.
Page 127 Periodic Maintenance and Adjustment 8-20 NOTE: filter wrench, and then tighten it to the An oil filter wrench is available at a nearby specified torque with a torque wrench. dealer. 7. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge.
Page 128: Final Gear Oil
8-21 Periodic Maintenance and Adjustment Final gear oil CAUTION: The final gear case must be checked for oil In order to prevent clutch slippage (since the leakage before each ride. If any leakage is engine oil also lubricates the clutch), do not found, have a dealer check and repair the mix any chemical additives.
Page 129 Periodic Maintenance and Adjustment 8-22 amount of the recommended oil. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.25 L (0.22 Imp qt, 0.26 US qt) CAUTION: Be sure no foreign material enters the final gear case. 1.
Page 130: Differential Gear Oil
8-23 Periodic Maintenance and Adjustment Differential gear oil CAUTION: Checking the differential gear oil 1. Place the ATV on a level surface. Be sure no foreign material enters the 2. Remove the differential gear oil filler bolt differential gear case. and check the oil level.
Page 131: Cooling System
Periodic Maintenance and Adjustment 8-24 Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.28 L (0.25 Imp qt, 0.3 US qt) CAUTION: Be sure no foreign material enters the differential gear case. 6. Install the differential gear oil filler bolt, and 1.
Page 132 8-25 Periodic Maintenance and Adjustment reservoir when the engine is cold, as the coolant level will vary with engine temperature. NOTE: The coolant should be between the minimum and maximum level marks. 3. If the coolant is at or below the minimum level mark, remove panel D (See pages 8-6-8-7 for panel removal and installation 1.
Page 133: Changing The Coolant
Periodic Maintenance and Adjustment 8-26 Changing the coolant NOTE: WARNING If water is added, have a dealer check the antifreeze content of the coolant as soon as POTENTIAL HAZARD possible. Removing the radiator cap when the engine and radiator are still hot. The radiator fan operation is completely WHAT CAN HAPPEN automatic.
Page 134 8-27 Periodic Maintenance and Adjustment 4. Remove the front carrier and panel C. (See pages 8-9 for removal and installation procedures.) 1. Coolant drain bolt 1. Radiator cap 5. Remove the radiator cap. 6. Remove panel D. (See pages 8-6—8-7 for panel removal and installation procedures.) 7.
Page 135 Periodic Maintenance and Adjustment 8-28 from the coolant reservoir. 11. Install the coolant reservoir hose. 12. Pour the recommended coolant into the reservoir to the maximum level mark, and then install the reservoir cap and panel D. 13. Pour the recommended coolant into the radiator until it is full, and then install the radiator cap.
Page 136: Axle Boots
8-29 Periodic Maintenance and Adjustment If any damage is found, have them replaced CAUTION: by a dealer. Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. 14. Start the engine and let it idle for several minutes.
Page 137: Spark Plug Inspection
Periodic Maintenance and Adjustment 8-30 Spark plug inspection Removal 1. Remove panel A. (See pages 8-6—8-7 for panel removal and installation procedures.) 2. Remove the spark plug cap. 1. Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect.
Page 138 8-31 Periodic Maintenance and Adjustment Instead, take the ATV to a dealer. You should specified torque. periodically re-move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark...
Page 139: Air Filter Elements Cleaning
Periodic Maintenance and Adjustment 8-32 finger tight. Have the spark plug tightened to the specified torque as soon as possible. 4. Install the spark plug cap. 5. Install the panel. Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case.
Page 140 8-33 Periodic Maintenance and Adjustment 1. Holder (×5) 2. Air filter case cover 1. Frame 2. Air filter element Air filter element...
Page 141 Periodic Maintenance and Adjustment 8-34 5. Wash the air filter element gently but 7. Inspect the air filter element and replace it thoroughly in solvent. if damaged. 8. Apply roam air filter oil or other quality WARNING foam air filter oil to the air filter element. NOTE: POTENTIAL HAZARD The air filter element should be wet but not...
Page 142: Spark Arrester Cleaning
8-35 Periodic Maintenance and Adjustment 11. Install the air filter case cover and be sure air to enter, causing rapid engine wear and to connect the hose. possible engine damage. Additionally, 12. Install the seat. operation without the air filter element will affect carburetor jetting with subsequent poor NOTE: performance...
Page 143: V-Belt Cooling Duct Check Hose
Periodic Maintenance and Adjustment 8-36 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. Hot exhaust system WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD 1.
Page 144: V-Belt Case Drain Plug
8-37 Periodic Maintenance and Adjustment 1. V-belt cooling duct check hose (Left side) 1.V-belt case drain plug V-belt case drain plug Valve clearance adjustment After riding in water deep enough to allow it The correct valve clearance changes with to enter the V-belt case, remove this plug to use, resulting in improper fuel/air supply or drain the water from the case.
Page 145: Select Lever Safety System Cable Adjustment
Periodic Maintenance and Adjustment 8-38 Select lever safety system cable adjustment The select lever safety system cable stretches with use, resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a dealer. Throttle lever adjustment NOTE: Adjust the engine idling speed before...
Page 146: Checking The Rear Brake Pads
8-39 Periodic Maintenance and Adjustment 1. Brake pad 2. Brake pad plate 1. Brake pad a. Brake pad thickness a. Brake pad thickness NOTE: Checking the brake fluid level The wheels need to be removed to check the Insufficient brake fluid may let air enter the brake pads.
Page 147 Periodic Maintenance and Adjustment 8-40 system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. The rear brake fluid master cylinder reservoir is located behind panel B. (See page 8-8 for panel removal and installation procedures.) 1.
Page 148: Brake Fluid Replacement
8-41 Periodic Maintenance and Adjustment Front brake lever free play Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical The front brake lever should have a free play reaction and lead to poor brake performance. of zero mm (zero in) at the lever end.
Page 149: Adjusting The Rear Brake Lever
Periodic Maintenance and Adjustment 8-42 1. Loosen the locknut. WARNING POTENTIAL HAZARD Operating with improperly serviced or Adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which Could lead to an accident. HOW TO AVOID THE HAZARD After servicing: Make sure the brakes operate smoothly ...
Page 150: Adjusting The Brake Pedal
8-43 Periodic Maintenance and Adjustment dealer to make that adjustment. NOTE: When adjusting the brake lever free play: Be sure not to step on the brake pedal.  Make sure the brake pedal does not  move. Adjusting the brake pedal Distance between brake pedal and footrest The top of the brake pedal should be positioned 72 mm (2.8 in) above the top of...
Page 151: Switch
Periodic Maintenance and Adjustment 8-44 WARNING effect. If necessary, adjust the brake light switch as follows. POTENTIAL HAZARD 1. Remove panel B. (See page 8-8 for panel Operating with improperly serviced removal and installation procedures.) adjusted brakes. WHAT CAN HAPPEN 2.
Page 152: Cable Inspection And Lubrication
8-45 Periodic Maintenance and Adjustment The chain and cable lube or 3. Install the panel. SAE 10W/40 motor oil Lubricating the brake levers and Cable inspection and lubrication brake pedal WARNING Lubricate the pivoting parts. POTENTIAL HAZARD Damaged control cables. NOTE: WHAT CAN HAPPEN To access the brake pedal pivot, remove...
Page 153: Rear Knuckle Upper And Lower Pivot Lubrication
Periodic Maintenance and Adjustment 8-46 Rear knuckle upper and lower pivot lubrication Lubricate the knuckle upper and lower pivots with a grease gun.
Page 154: Wheel Removal
8-47 Periodic Maintenance and Adjustment 1. Upper knuckle 2. Lower knuckle 1. Nut (×4) Recommended lubricant: Wheel installation Lithium-soap-based grease 1. Install the wheel and the nuts. NOTE: Wheel removal The arrow mark on the tire must point 1. Loosen the wheel nuts. toward the rotating direction of the wheel.
Page 155: Battery
Periodic Maintenance and Adjustment 8-48 ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5m·kgf, 40ft·lbf) Rear: 55 Nm (5.5m·kgf, 40ft·lbf) Battery 1. Arrow mark This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery.
Page 156: Battery Maintenance
8-49 Periodic Maintenance and Adjustment Battery maintenance WARNING 1. When the machine is not used for a month POTENTIAL HAZARD or longer, remove the battery and store it in a Failure handle batteries battery cool, dark place. Completely recharge the electrolyte carefully.
Page 157 Periodic Maintenance and Adjustment 8-50 2. If a fuse is blown, turn off the main switch and the switch of the circuit in question. Then, Specified fuses: Main fuse: 30 A install a new fuse of the specified amperage. Speedometer unit Turn on the main switch.
Page 158: Replacing A Headlight Bulb
8-51 Periodic Maintenance and Adjustment 2. Remove the headlight bulb holder cover CAUTION: by pulling it off. To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
Page 159 Periodic Maintenance and Adjustment 8-52 4. Remove the defective bulb by pulling it out. CAUTION: Do not touch the glass part of the headlight WARNING bulb to keep it free from oil, otherwise the transparency of the glass; the luminosity of POTENTIAL HAZARD the bulb and the bulb life will be adversely A headlight bulb is hot when it is on and...
Page 160: Headlight Beam Adjustment
8-53 Periodic Maintenance and Adjustment 6. Install the bulb holder by pushing it in and turning it clockwise. 7. Install the bulb holder cover and the cover at the rear of the headlight. Headlight beam adjustment To raise the beam, turn the adjusting screw in direction a.
Page 161 Periodic Maintenance and Adjustment 8-54 1. Tail/brake light bulb holder 3. Remove the defective bulb from the bulb 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.
Page 162: Check And Solution To Common Problems In Vehicle
8-55 Periodic Maintenance and Adjustment Check and solution to Common Problems in Vehicle Following are tables of common problems and solutions when operating an ATV. Repairing an ATV requires technical skills, if you cannot repair the ATV yourself , please contact your dealer.
Page 163 Periodic Maintenance and Adjustment 8-56 Table1:Check and Solution of Common Problems in Appearance parts and impact fittings. Problems Solutions 1.Replace broken cover Plastic covers or fenders 2.Replace broken fender are broken or cracked 3.Make sure to replace any label on cover or fender 1.Check if the reduction gear box and differential in front and ATV’s skid plate rear bridge are damaged or if there is any oil leakage.
Page 164 8-57 Periodic Maintenance and Adjustment Table 2 Check and Solution of Common Problems in Brake System . ： Problems Solutions 1.Check parking brake, make sure it is released. 2.Check if the brake discs are deformed. Brake system is locked 3.Check if brake caliper or hydraulic cylinders are stuck, or the fixing parts of calipers are deformed.
Page 165 Periodic Maintenance and Adjustment 8-58 Problems Solutions 1.Check if the brake discs are deformed. Front and/or rear brakes making grinding noise. 2.Check if the calipers or hydraulic cylinders are stuck, or the fixing parts of calipers are deformed. 1.Check if left & right brake force deviation in front brakes are within specified limit.
Page 166 8-59 Periodic Maintenance and Adjustment Table 3: Check and Solution of Common Problems in Electrical System Problems Solutions 1.Check headlight switch. Lamps don't work. 2.Check for damaged or broken wires. 3.Check lamps or bulbs for damage. 1.Check 4wd control switch. 2.Check if the differential lock control magneto plug in rear ATV will not go into 4wd.
Page 167 Periodic Maintenance and Adjustment 8-60 3.Check if surface of speed sensor is contaminated with dust. Problems Solutions 1.Check if the switch is broken. Start switch on meter 2.Check if any wires are loose or broken. board won't work 3.Check if the ECU in electrical injection system is broken.
Page 168 8-61 Periodic Maintenance and Adjustment Table 4: Check and Solution of Common Problems in Running System Problems Solutions 1.Check the fix screws connecting the steering rod to the steering stem and knuckle to find out if they are loose or broken Steering is excessively 2.Check for loose or damaged ball joints on the ends of the...
Page 169 Periodic Maintenance and Adjustment 8-62 5.Check if rubber shock dampers are damaged. rubber shock dampers are located between the shock and the ATV Frame. Problems Solutions 1.Check the bearing in rear bridge bearing seat to find out if they are broken. 2.Check the sliding bearing connecting rear bridge and rocks to find out if they are worn or loose.
Page 170 8-63 Periodic Maintenance and Adjustment while operating 2.Check if rear wheel axles are bent, replace if necessary. 3.Check if tires are worn or deformed, replace if necessary. Problems Solutions 1.Check if overloaded. Check max. weight limit of ATV Shock absorbers 2.Check if the springs are worn from use, replace if become soft and lose necessary...
Page 171 Periodic Maintenance and Adjustment 8-64 repair. 4.Check the dust cover of constant velocity universal joint in right & left drive shafts. Table5: Check and Solution of Common Problems in Engine System Problems Solutions 1.Check the battery voltage for specified value Idle speed is not stable 2.Check rectifier output voltage for specified value 3.Check MEUI for failure.
Page 172 8-65 Periodic Maintenance and Adjustment 2.Check muffler connection point as it attaches to engine making sure bolts are tight, inspect muffler for leaks. 3.Grade of gasoline may be too low, higher octane may be needed. Check gasoline specifications. Engine is difficult to start 1.Check battery for voltage loss when temperature goes at low temperature down.
Page 173 Periodic Maintenance and Adjustment 8-66 1.Check battery, make sure battery is fully charged 2.Check starter motor for damage 3.Check if MEUI is in good working condition Engine will not start 4.Check if ignition system is working properly, inspect for loose or damaged wires 5.Check for fouled or damaged spark plug.
Page 174 8-67 Periodic Maintenance and Adjustment 4. Check fuel nozzle, make sure it is not plugged WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap.
Page 175: Cleaning And Storage
Cleaning and Storage CLEANING CAUTION: Frequent, thorough cleaning of your machine Excessive water pressure may cause water will not only enhance its appearance but also seepage and deterioration of wheel bearings, will improve its general performance and brakes, transmission seals and electrical extend the useful life of many components.
Page 176 Cleaning and Storage clothe. WARNING 6. Clean the seat with vinyl upholstery cleaner to keep the cover pliable and glossy. POTENTIAL HAZARD 7. Automotive type wax may be applied to all Operation with wet brakes after washing. painted and chrome plated surfaces. Avoid WHAT CAN HAPPEN combination cleaner-waxes.
Page 177: Storage
Cleaning and Storage STORAGE 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor Long-term storage (60 days or more) of your oil in the spark plug hole and reinstall the machine will require some preventive spark plug.
Page 178 Cleaning and Storage or more than 30 ℃ (86 °F). NOTE: Make any necessary repairs before storing the machine.
Page 179 Specifications 10-1 Model HS500ATV-2 Dimensions: 2,250mm (88.6in) Overall length 1,210mm (47.6in) Overall width 1,225mm (48.2in) Overall height 880mm (34.6in) Seat height 1,365mm (53.7in) Wheelbase 260mm (10.2in) Ground clearance 3,200mm (126.0in) Minimum turning radius Basic weight: With oil and full fuel tank...
Page 180 10-2 Specifications Model HS500ATV-2 Engine oil: Type API Service SE, SF, SG type or higher Recommended engine oil classification 1CAUTION: 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 181 Specifications 10-3 Model HS500ATV-2 Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.25 L (0.22 Imp qt, 0.26 US qt) Differential gear case oil: Type SAE80 API GL-5 Hypoid gear oil Quantity 0.28 L (0.25 Imp qt, 0.30 US qt) Radiator capacity (including all routes): 1.80 L (1.58 Imp qt, 1.90 US qt)
Page 182 10-4 Specifications Model HS500ATV-2 Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Left hand operation Reverse gear 1.471 Sub transmission ratio 2.059 high 1.238 Chassis: Frame type Steel tube frame Caster angle 5°...
Page 183 Specifications 10-5 Model HS500ATV-2 Brake: Front brake Type Dual disc brake Ⅰ: Operation Right hand operation Rear brake Type Single disc brake Operation Left hand and right foot operation Front brake Type Dual disc brake Ⅱ: Operation Right hand operation...
Page 184 10-6 Specifications Model HS500ATV-2 Electrical: Ignition system Generator system A.C. magneto Battery type YTX20L-BS Battery capacity 12 V, 21 Ah Headlight type: Krypton bulb Bulb voltage, wattage ×quantity: 12 V, 30 W / 30 W×2 Head light Tail/brake light 12 V, 5 W / 21 W×1...
Page 185 Specifications 10-7 Model HS500ATV-2 Fuses: Main fuse: 30 A Speedometer unit Signaling system fuse Four-wheel drive fuse: Auxiliary DC jack fuse: ECU: Headlight fuse: Backup fuse:...
Page 186: Fault Code Of Electronic
11-1 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 187 Fault Code of Electronic Injection System 11-2 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 188 11-3 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 189 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-1 YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) is pleased to explain the emission control system warranty on your 2012 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 190 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-2 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 191 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-3 (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 192 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 12-4 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 193 POWERSPORTS (888) 405-8725 Coleman Powersports 1775 E. University Dr. Tempe, AZ 85281 colemanpowered.com...

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