Related Manuals for Coleman Powersports AT125EX
Summary of Contents for Coleman Powersports AT125EX
- Page 1 AT125EX Owner’s Manual POWERSPORTS READ THIS MANUAL CAREFULLY! It contains important safety and service information.
- Page 2 WARNING Operating, servicing and maintaining a passenger vehicle or o -road vehicle can expose you to chemicals including engine exhaust , carbon monoxide, phthalates, and lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm.
- Page 3 ATV. This manual includes important safety information. It also includes general riding techniques, maintenance and inspection procedures. If you have any questions regarding the ATV , please contact Coleman Powersports 888-405-8725 or go to Colemanpowersportsusa.com AN IMPORTANT NOTE TO PARENTS: THIS ATV IS INTENDED FOR USE BY OPERATORS 10 YEARS OF AGE AND OLDER.
- Page 4 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Important information is distinguished in this manual by the following notations: This is the safety alert NOTICE symbol. It is used to alert you to potential personal injury hazards.
- Page 5 Please read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a new replacement label from Coleman Powersports...
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Page 6: Table Of Contents
Front & Rear Brakes ..................19 Electrical Connector Wiring Diagram ........... 58 Tire Wear Limits and Chassis Fasteners ..........20 Commonly Asked Questions ..............59 Starting Engine .................... 21 Coleman Powersports limited Warranty ..........60-62 Emission Control System Warranty ..........63-66 Engine Break-In .................... 22... - Page 7 CHILDREN MAY NOT BE ABLE TO OPERATE THIS VEHICLE SAFELY DUE TO PHYSICAL OR MENTAL LIMITATION. The ATV you purchased may differ slightly from the illustrations in this Owner’s Manual. NOTICE Please consult Coleman Powersports r with any questions not covered in this manual.
- Page 8 SAFETY INFORMATION Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. FOR OFF-ROAD USE ONLY. This ATV is designed for operation by a single driver at least 10 years of age, without passengers. Never operate an ATV on any public street, road or highway, even a dirt or gravel road.
- Page 9 SAFETY INFORMATION (continued) Never permit anyone other than an adult to start the ATV. Drain gasoline from the fuel tank and carburetor prior to transporting the ATV. Also for storage over 48hrs. The fuel tank and carburetor should be drained for any long periods of storage and for winter storage of the vehicle.
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Page 10: Engine Stop Lanyard Cord & Remote
ENGINE STOP LANYARD CORD & REMOTE The ATV has two emergency-stop engine switches. The primary emergency engine shut off witch is the lanyard cord and the secondary is the wireless engine shut off key fob. The wireless engine shut off key fob has a limited range that varies in different conditions DO NOT RELY solely on the key fob as the emergency engine shut off swich, especially during operator training. - Page 11 LANYARD CORD: The lanyard cord is designed for use by an adult supervising the child operating the ATV. When using the engine stop switch cord, be sure the speed limiter on the handlebar is adjusted and the engine speed limits the ATV to a walking speed.
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Page 12: Transporting
TRANSPORTING THE ATV Avoid Carbon Monoxide Poisoning! All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion, and eventually death. Carbon Monoxide is a colorless, odorless tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. -
Page 13: Description
DESCRIPTION LEFT SIDE RIGHT SIDE Fuel Cap Fuse 10 Amp Rear Air Filter Front Shock Battery (Under the Grab Bar (Under the Seat) Seat) Muffler Fuel On/Off Valve Gear Rear Shock Spark Plug Spark Arrester Engine Oil Foot Rest Shift Lever Dip Stick... -
Page 14: Control Layout
CONTROL LAYOUT Engine Start / Stop switch Rear Brake Lever Front Brake Lever Main Switch Instrument Cluster Speed Limiter Lanyard Throttle Lever Start Button Ignition OFF Ignition ON CONTROLS & FUNCTIONS IGNITION SWITCH The positions of the ignition switch are as follows. Ignition ON All electrical systems are supplied with power, and the engine can be started. -
Page 15: Instrument Cluster
INSTRUMENT CLUSTER The Instrument cluster displays important information about the ATV. Make sure the rider is familiar with all the information displayed before riding ATV. Instrument cluster icons 1. Engine RPM (multiplied by 1000r / min), with the change in engine RPM display will also change. 2. -
Page 16: Main Switch
MAIN SWITCH 1. Engine Run 2. Engine Stop Engine Start/Stop switch 3. Start Button Use this switch to "Stop" the engine in an emergency situation. The engine will not start when this switch is set to this position. Set this switch to "Run" position before starting the engine. START BUTTON Push start button to crank the engine with starter. -
Page 17: Speed Limiter
SPEED LIMITER The ATV is equipped with a vehicle speed limiter adjusting screw. Beginning riders should start with slowest setting to learn how to control this vehicle. Once the operator has demonstrated mastery of the ATV, the supervising adult can adjust speed limiter screw to increase the top speed . The vehicle speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. -
Page 18: Parking Brake
PARKING BRAKE Use the parking brake before starting the engine or after parking the ATV, especially on a slope. This ATV is equipped with front and rear axle parking brake. Front Axle Parking Brake: Apply the front brake lever and push down the lock button to apply the parking brake. Squeeze the front brake lever to release the parking brake. -
Page 19: Choke Lever
CHOKE LEVER Starting a cold engine requires a richer air-fuel mixture. Move the choke lever all the way up when starting a cold engine. Once the engine is warmed up return the choke lever all the way down in the running position. Choke Lever NOTICE For maximum engine life, never accelerate hard when the engine is cold or choke lever is in the... -
Page 20: Fuel Tank Capacity
FUEL TANK CAPACITY Gasoline and gasoline vapors are extremely flammable. To avoid fires, explosions and to reduce the risk of injury when refueling, follow these instructions. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. -
Page 21: Fuel Tank Cap
FUEL TANK CAP Remove the fuel tank cap by turning it counter clockwise. Turn the fuel tank cap fully clockwise to make sure it is securely closed Your ATV’s engine has been designed to use regular unleaded gasoline with a pump octane number of 91 or higher. -
Page 22: Fuel Cock/Fuel Valve
FUEL COCK/ FUEL VALVE FUEL COCK/ FUEL VALVE The fuel cock/valve supplies fuel from the tank to the carburetor. The fuel cock/valve lever positions are explained as follows and shown in the illustrations. FUEL OFF Arrow mark positioned over “OFF” position. Fuel is off and fuel will not flow to the carburetor. Always turn the fuel valve to the"‘OFF" position and allow the engine to idle until it burns remaining fuel in the line when the ATV is being stored. -
Page 23: Seat
SEAT To Remove Seat To remove the seat, pull the seat lock lever(#1) backward and then pull up the seat. The seat lock is located under the seat in the back of the ATV. To Install Seat Insert tab(#3) on the front of the seat into the seat holder(#2) and push down on the seat at the rear. Make sure that the seat is securely installed in place and will not move during operation. -
Page 24: Battery & Location
BATTERY 1. Battery Straps 5. Tool Kit 2. Battery 5Amp 6. Starter Relay Battery Removal 3. Fuse Box 10Amp 4. CDI box 1. Make sure the ignition switch is set to the "OFF" position. 2. Remove seat 3. Disconnect the negative cable from the battery by unscrewing battery terminal bolt. 4. -
Page 25: Battery Charging & Changing Fuse
BATTERY CHARGING 1. Before charging the battery, set ignition key to the" OFF" position. 2. Remove seat. 3. Attach battery charger clamps to battery terminals. 4. Connect low-voltage battery charger to AC outlet. Use GFI AC Type outlet if possible for additional electrical safety. 5. -
Page 26: Pre-Ride Safety Checks
PRE-RIDE SAFETY CHECKS Inspect the ATV prior to each use to ensure it is in a safe operating condition. Always follow the inspections, procedures and schedules described in the Owner’s Manual. Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment failure. - Page 27 ITEM ROUTINE PAGE Throttle Lever • Make sure that operation is smooth. Lubricate cable and lever housing if necessary. • Check lever free play, and adjust if necessary. Control Cables • Make sure that operation is smooth. Lubricate if necessary. Drive Chain •...
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Page 28: Front & Rear Brakes
FRONT & REAR BRAKES BRAKE OPERATION Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brake pads for wear. THROTTLE LEVER Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. If throttle is not operating properly DO NOT START ENGINE. -
Page 29: Tire Wear Limits And Chassis Fasteners
TIRES Check tire pressure with tire gauge to make sure that both front tires and rear tires are equally inflated and meet the recommended PSI specifications. All Tao Motor ATVs are installed with tubeless, low-pressure ATV valved tires. TIRE WEAR LIMIT When the tire groove decreases to 3mm (0.12 in) due to wear, replace the tire. -
Page 30: Starting Engine
STARTING ENGINE (COLD) Set the parking brake. (The engine can be started only when the front / rear brake lever is applied.) Turn the fuel valve lever to the "ON" position. Turn the ignition key to the "ON" position. Set "RUN" position on main switch. Set gear box to neutral position. -
Page 31: Engine Break-In
ENGINE BREAK-IN Proper engine break-in will increase the lifespan of your Coleman ATV. The engine break-in period is the initial 20 hours of operation. You should avoid maintaining a constant engine RPM and do not operate your ATV above 1/2 throttle during the break-in period. -
Page 32: Parking, Accessories & Modifications, Rear Cargo Rack
PARKING When parking the ATV: first apply the brake lever, stop the engine, apply the parking brake, and then turn the fuel valve to “OFF” position. Never park the ATV on hills that are too steep to walk up easily. ACCESSORIES &... -
Page 33: Gear Selector Lever
GEAR SELECTOR LEVER This ATV is equipped with a 2 gear transmission gearbox, The gear shift lever is located on the left side of the ATV. When changing the transmission gear position, first apply the brakes to come to a complete stop, before moving the lever to the desired position. -
Page 34: Throttle Cable & Throttle Cable Adjustment
THROTTLE CABLE Throttle cable inspection Inspect throttle cable for excessive wear, kinking or fraying. Ensure cable moves freely. NOTE The throttle cable must be replaced if any signs of wear, fraying or other damages found. THROTTLE CABLE ADJUSTMENT Check throttle lever free-play, adjust if necessary. NOTE Please check with Tao Motor dealer if throttle cable adjustment can not be adjusted properly. -
Page 35: Hydraulic Brakes
BRAKES Replacement of brake components requires professional knowledge. Brake service should be performed by a Coleman Service center Operating with improperly adjusted brakes could lead to a loss in braking ability and an accident. The brakes can be very hot after prolong use of the vehicle and can cause burns. Wait for the brake to cool down. HYDRAULIC BRAKES New brakes will not perform to their maximum efficiency until after their initial brake-in is complete. - Page 36 Have your authorized Coleman service center inspect brakes system for wear or damage. NOTICE If any problem is found concerning the brake system contact your Coleman service center for service . Recommended Brake Fluid Always use recommended brake fluid DOT 4 or 3. Brake Fluid Level Brake fluid reservoir is located on the the handlebar above brake lever on the left &...
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Page 37: Engine Idle Adjustment
ENGINE IDLE ADJUSTMENT If it is necessary to adjust the carburetor idle screw due to changed outside environmental conditions, to adjust carburetor idle screw as follows; Apply parking brake. Warm up the engine by running the vehicle. Adjust the carburetor idle screw until the desired idle RPM is reached. Turning the idle screw in (clockwise) to raise RPM. Turning the screw out (counterclockwise) will lower RPM. -
Page 38: Adjusting Suspension Spring Preload
Increased spring tension will stiffen the ride. Decreasing spring tension will soften the ride. The suspension was pre-set at the factory, but can be adjusted with a special NOTICE suspension adjustment tool available for purchase at Coleman Powersports. 1. Spring Preload Adjustment Ring 2. Position Indicator... -
Page 39: Maintenance
MAINTENANCE Due to the nature of the adjustments marked with a √ on the following chart, it is CAUTION recommended that service be performed by an authorized Service Center • Perform maintenance more often if you use your ATV under severe conditions, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components. -
Page 40: Getting To Know Your Atv
GETTING TO KNOW YOUR ATV... - Page 41 This ATV is intended for use by operators 10 years of age and older. Adult supervision is required while a child operates any ATV. Do not operate this ATV or allow anyone else to operate it without proper Instruction. The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.
- Page 42 Never carry a passenger. Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV. You could have an accident, resulting in severe injury or death to you and/or your passenger. The long seat is to allow the operator to shift position as needed during operation.
- Page 43 Protective clothing Protective Goggles Protective Gloves Protective Boots Protective Helmet Do not operate after or while consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming alcohol or drugs could seriously affect your judgment, cause you to react more slowly, and affect your balance and perception.
- Page 44 DURING RIDING Always keep your feet on the foot boards during operation; otherwise, they may contact the rear wheels. Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV. If you remove a foot from a foot board, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
- Page 45 Never operate this ATV on any public street, road or highway, even a dirt or gravel one. You could collide with another vehicle. 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.
- Page 46 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on thea ATV. DO NOT use the flag pole bracket as a trailer hitch. You could collide with another vehicle if operating in off-road areas where you cannot easily be seen.
- Page 47 STEERING YOUR ATV To achieve maximum traction while riding off road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily.
- Page 48 Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. Do not attempt to climb hills until you have mastered basic maneuvers on fl t ground. Always check the terrain carefully before attempting any hill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control.
- Page 49 Stalling, rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning. If you cannot control the ATV, dismount immediately on the uphill side. DOWNHILL RIDING When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible.
- Page 50 WATER CROSSINGS The ATV can be used to cross slow moving, shallow water of up to a maximum of 11 cm (3 in) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV.
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Page 51: Specification Chart
SPECIFICATION CHART ENGINE Fuel Tank ............... 0.58 Gal (2.2L) Type ............... Single-Cylinder Four-Stroke, Engine Oil ............SAE 15W40 ................. Air-Cooled, Automatic Climbing .............. ≥12° ................. Centrifugal Clutch Acceleration Noise Level ........ ≤80dB Displacement ..........120CC Recommended Tire Pressure ......5 PSI Bore X Stroke .......... -
Page 52: Maintenance Chart
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM • For ATVs not equipped with an odometer follow the month maintenance intervals. • For ATVs 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 53 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY WHICHEVER COMES FIRST Month CHECK OR km (mi) 1300 2500 2500 5000 MAINTENANCE JOB (200) (800) (1600) (1600) (3200) ITEM Hours Air Filter Element • Clean and replace if necessary. Every 20-40 hours (more often in wet or dusty areas) Front Brake* •...
- Page 54 GENERAL MAINTENANCE AND LUBRICATION CHART CONTINUED WHICHEVER COMES FIRST INITIAL EVERY Month CHECK OR km (mi) 1300 2500 2500 5000 MAINTENANCE JOB (200) (800) (1600) (1600) (3200) ITEM Hours Wheel Hub • Check for looseness or damage, and replace if necessary. ...
- Page 55 GENERAL MAINTENANCE AND LUBRICATION CHART CONTINUED WHICHEVER COMES FIRST INITIAL EVERY Month CHECK OR km (mi) 1300 2500 2500 5000 MAINTENANCE JOB (200) (800) (1600) (1600) (3200) ITEM Hours Moving Parts and • Lubricate Cables* • Check operation and correct if necessary. Throttle Lever ...
- Page 56 PERIODIC MAINTENANCE RECORD MAINTENANCE SERVICING DATE SERVICING DEALER OR PERSON REMARK INTERVAL PERFORMED...
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Page 57: Engine Oil
ENGINE OIL The engine oil level should be checked before each ride. In addition, always follow the maintenance schedule for oil changes as shown in the maintenance schedule. Your new vehicles engine comes with shipping oil, shipping oil must be changed before the engine NOTE is started for the first time. - Page 58 To change the engine oil 1. Place the ATV on a level surface. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase.
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Page 59: Cleaning Air Filter Element
CLEANING AIR FILTER ELEMENT The air filter element should be serviced at the intervals specified in the periodic maintenance and lubrication chart. Clean and replace as needed. Clean and replace air filter more frequently if used in dusty or dirty areas. Never use low-flash-point solvents or gasoline to clean the air filter element because the engine could catch fire or explode. -
Page 60: Spark Plug
SPARK PLUG Checking the spark plug The spark plug is an important engine component, which is easy to check. The spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. To remove the spark plug 1. -
Page 61: Drive Chain & Adjustment
DRIVE CHAIN Checking Drive Chain Slack The drive chain slack should be checked before each ride. How to check for drive chain slack; 1. Place the ATV on a level surface. 2. Move the ATV back and forth to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. - Page 62 DRIVE CHAIN ADJUSMENT To adjust the drive chain slack 1. Loosen axle carrier/housing bolts. 2. For all Tao Motor models equipped with chain tensioner, always do the following; lift and hold the chain tension off the chain to release chain tension until the chain adjustment is completed. Carrier Housing Bolts...
- Page 63 To tighten drive chain, 1. Loosen the chain adjuster nut(#1) on the back side of the carrier/housing. 2. Tighten the chain adjuster nuts(#2) to move the carrier/housing forward. 3. When proper chain slack is achieved tighten chain adjuster nuts (#1,3). To loosen drive chain, 1.
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Page 64: Lubricating Pivoting Joints
LUBRICATING PIVOTING JOINTS Pivot joints must be lubricated at intervals specified in the periodic maintenance and lubrication chart. Hight quality heavy duty grease must be used for long life of components. Extreme pressure and water resistant grease is recommended. This REX ATV has multipliable grease nipples located in front and rear pivoting arms and on the steering shaft. For Lubricating grease nipple, use an automotive grease gun. -
Page 65: Cleaning Spark Arrester
CLEANING SPARK ARRESTER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Unscrew the 3(4mm) allen bolts (#4) securing the muffler end cap to muffler by using a 4mm allen socket wrench. 2. Unscrew the 3 Phillips screws (#5) securing spark arrester to muffler. 3. -
Page 68: Commonly Asked Questions
COMMONLY ASKED QUESTIONS What kind of oil do I use? 15W-40 4-Stroke ATV Conventional Oil for Wet Clutch System. Can I use Synthetic Oil ? Yes: 10W-40 4-Stroke ATV Full Synthetic Oil for Wet Clutch System. How much oil do I use? Less than one quart around 0.8 US qt or 0.8 liters. -
Page 69: Coleman Powersports Limited Warranty
The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 90 days 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 70 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 71 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.
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Page 72: Emission Control System Warranty
EMISSION CONTROL SYSTEM WARRANTY Below is the emission control system warranty printed in the owner’s manual, the copy of the owner’s manual is available upon your request. YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board, the U.S. Environmental Protection Agency, and Tao Motor Inc. (hereinafter “Tao Motor” are pleased to explain the emission control system warranty on your 20 Model Year ATV. - Page 73 You are responsible for presenting your vehicle to the Tao Motor’s dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As the vehicle owner, you should be aware that Tao Motor may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modific tions.
- Page 74 To find a local dealer or a service shop in your area, please call 888-908-3816 or E-mail service@taomotor.com. If no Tao Motor Inc. dealers or contracted service shop is available in your area, repairs may be performed at any available service establishment, or by any individual, using any replacement part.
- Page 75 B. No express emission control system warranty is given by us except as specifically set orth herein. Any emission control system warranty implied by law,including any warranty of merchantability or fitness or a particular purpose, is limited to the express emission control system warranty terms stated in this warranty.
- Page 76 POWERSPORTS...
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Questions and answers
My 125 ex quad will not start - NO SPARK. The quad was running fine, I stopped the quad near my KIA Sorrernto and used the remote start for the Sorrento. A short time later, I tried to start the quad with no success (no spark). Is it possible the remote stop on the quad was activated by my KIA remote start? If so, how do I reset the quad remote stop?