1. Manuals
  2. Brands
  3. Crossfire Manuals
  4. Offroad Vehicle
  5. TERRITORY 500 2000
  6. User manual

Crossfire TERRITORY 500 2000 User Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
CROSSFIRE
TERRITORY 500
USER MANUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TERRITORY 500 2000 and is the answer not in the manual?

Questions and answers

Related Manuals for Crossfire TERRITORY 500 2000

Summary of Contents for Crossfire TERRITORY 500 2000

  • Page 1 CROSSFIRE TERRITORY 500 USER MANUAL...
  • Page 2 Owner Manual...
  • Page 3 Owner Manual INTRODUCTION Congratulations on your purchase of the HS500ATV-4/HS700ATV-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 Curve speed must be smaller than 30km/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 Throttle Lever 4-14 Location of the Warning and Speed Limiter 4-15 Specification Labels Front Brake Lever 4-17 Brake Pedal and Rear Brake Safety Information Lever 4-17 Drive Select Lever 4-18 Description and Vehicle Fuel Tank Cap 4-18 Identification Identification Number Records Seat 4-19...
  • 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 Be Careful Where You Ride...
  • 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 8-39 Lubrication Chart Checking the Rear Brake Pads 8-39 Panel Removal and Installation Checking the Brake Fluid Level...
  • Page 9 Owner Manual Fuse Replacement 8-50 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: Location Of The Warning And Specification Labels

    Location of the Warning and Safety Labels LOCATION OF THE WARNING AND SPECIFICATION LABELS ② ⑫...
  • Page 11 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 12 Location of the Warning and Safety Labels ④ ⑤ ⑥...
  • Page 13 Location of the Warning and Safety Labels ⑦ ⑧...
  • Page 14 Location of the Warning and Safety Labels ⑨ ⑪ ⑫ ⑩...

  • Page 15: 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 16 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 17 Safety Information Always follow proper procedures for turning as described in this manual. Practice turning  at low 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 18 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 19 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 slowly.  Always use the size and type tires specified in this manual. ...
  • Page 20 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 21 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 22: Description And Vehicle Identification

    Description and Vehicle Identification...

  • Page 23: Identification Number Records

    Description and Vehicle Identification Identification number records Vehicle identification number Record the key identification number, vehicle The vehicle identification number is stamped identification number model label into the frame. information in the spaces provided for assistance when ordering spare parts from a dealer or for reference in case the vehicle is stolen.

  • Page 24: Control Functions Main Switch

    Control Functions CONTROL FUNCTIONS The engine can be started only at this position and the headlights and taillight come Main switch 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 25: Indicator And Warning Lights

    Control Functions Indicator and Warning Lights 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. Four-wheel locked showing light Fault indicator light of EPS system High-Range Indicator Light “H”...

  • Page 26: Use Of Eps System

    Control Functions This indicator light comes on when the drive is out. Continuous use while the light is select lever is in the “R” reverse position. on may cause damage to the engine. High beam indicator The light being on means headlight is at high Coolant Temperature Warning Light “...
  • Page 27 Control Functions monitors working condition of EPS system. Check the meter. If fault indicator light of  Fault can be displayed by fault indicator light EPS system does not be lit, ECU can be and fault indicator of EPS system, so the for regular use.

  • Page 28: Speedometer Unit

    Control Functions  a speedometer (which shows the speed) Speedometer Unit  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 29: Clock Time Adjustment

    Control Functions then to the hours meter; then it starts the displayed mileage from miles cycle over. kilometers. The odometer displays the total distance Clock time adjustment traveled by the ATV. The tripometer records Press the left button and hold for three distances for a specific trip and can record seconds and the clock goes into the hour distances from 0 through 999.9 miles.

  • Page 30: Differential Gear Lock Indicator

    Control Functions high speed, adjust settings yellow 4WD selector buttons are pressed in “2WD/UNLOCK” and there are no symbols indicating the “4WD” function has been in either of the 4WD indicators. activated. This position also indicates that Riding an ATV while the differential the 4WD is NOT locked.

  • Page 31: Fault Code Indicator

    Control Functions The description for the fault codes are shown CAUTION: If the display indicators flash or the 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 32: Handlebar Switches

    Control Functions Light switch “ ” Handlebar switches /OFF/ Set the switch to “ ” to turn on the low beam and the taillight. Set the switch to “ ” to turn on the high beam and the taillight. Set the switch to “OFF” to turn off all the lights.
  • Page 33 4-10 Control Functions especially in an emergency. The engine will Start switch “ ” The starter motor cranks the engine when not start or run when the engine stop switch this switch is pushed. is set to “ ”. Horn switch Press this switch, horn rings.
  • Page 34 Control Functions 4-11 a differential gear lock switch “LOCK”/ On-Command four-wheel drive and “4WD”. differential gear lock switches Select the appropriate drive according to terrain and the conditions. G Two-wheel drive (2WD): Power is supplied to the rear wheels only. Four-wheel drive (4WD): Power is ...
  • Page 35 4-12 Control Functions On-Command Four-Wheel-Drive Switch WARNING “2WD/4WD” POTENTIAL HAZARD Changing from 2WD to 4WD or from 2WD to 2WD-Differential UNLOCK, or vice-versa while the vehicle is moving. WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD- Differential UNLOCK some circumstances.
  • Page 36 Control Functions 4-13 indicator will come To lock the differential gear in 4WD, make multi-function display. sure the On-Command four-wheel-drive To change from 4WD to 2WD switch is set to “4WD”, stop the ATV, move stop the vehicle, and then set the switch to the lever to position (b), and then set the “2WD”。the 4WD indicator will go out in the switch to “LOCK”.

  • Page 37: Throttle Lever

    4-14 Control Functions Regulate the speed of the machine by varying the throttle position. Because the the differential is locked, so it takes throttle is spring-loaded, the machine will more effort to turn the vehicle. The decelerate, and the engine will return to an amount of effort required is greater the idle any time the hand is removed from the faster you go.

  • Page 38: Speed Limiter

    Control Functions 4-15 it returns to the idle position as soon as the Speed limiter lever is released. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the WARNING adjusting screw limits the maximum engine POTENTIAL HAZARD...

  • Page 39: Front Brake Lever

    4-16 Control Functions Front brake lever The front brake lever is located on the right WARNING handlebar. Pull it toward the handlebar to POTENTIAL HAZARD apply the front brake. Improper adjustment of the speed limit-ere and throttle. WHAT CAN HAPPEN throttle cable could...

  • Page 40: Drive Select Lever

    Control Functions 4-17 Drive select lever The drive select lever is used to shift your machine into the low, high, neutral, reverse and park positions. (Refer to pages 6-2—6-4 for the drive select lever operation.) 1. Brake pedal 1. Drive select lever Parking brake lever...

  • Page 41: Fuel Tank Cap

    4-18 Control Functions Fuel tank cap SEAT Remove the fuel tank cap by turning it To remove the seat, pull the seat lock lever counterclockwise. upward and pull up the seat at the rear. 1.Seat 2.Seat lock lever Fuel tank cap To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.

  • Page 42: Storage Compartment

    Control Functions 4-19 When storing the owner’s manual or other NOTE: Make sure that the seat is securely filed. documents in the storage compartment, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the storage compartment.

  • Page 43: Front Carrier

    4-20 Control Functions Front carrier Rear carrier Rear carrier Maximum load limit: Front carrier Maximum load limit: 35kg(77lb) 20kg(44lb) 1. Rear carrier Front carrier...

  • Page 44: Front And Rear Shock Absorber Adjustment

    Control Functions 4-21 Front and rear shock absorber adjustment The spring preload can be adjusted to suit rider’s weight and tiding concisions. NOTE: When adjusting the rear shock absorbers, the mar wheels need to be removed. (See pages 8-47 — 8-48 removal installation procedures.) 1.

  • Page 45: Auxiliary Dc Jack

    4-22 Control Functions Standard position: B WARNING A- Minimum (soft) POTENTIAL HAZARD E- Maximum (hard) Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting.
  • Page 46 Control Functions 4-23 suitable work lights, radios, etc. insert the accessory power plug into the The auxiliary DC jack should only be used jack. when the engine is running. Auxiliary DC jack 1. Auxiliary DC jack cap Maximum rated capacity for the auxiliary 1.
  • Page 47 4-24 Control Functions 4. When the auxiliary DC jack is not being used, cover it with the cap. CAUTION: Do not use accessories requiring move  than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If accessories are used without the ...

  • Page 48: 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 3 brake fluid if necessary. 8-41-8-43 ● Check for proper operation, condition and free play. Parking brake ●...

  • Page 49: 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 50 Pre Operation Checks out to make sure they are working properly. If Brake fluid level Check the brake fluid level. Add fluid if the brakes do not provide proper braking necessary. (See pages 8-39—8-41.) performance, inspect the brake pads for wear.(See page 8-38-8-39.) Recommended brake fluid: DOT 3 WARNING...

  • Page 51: Fuel

    Pre Operation Checks Your engine has been designed to use Fuel 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 52 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 53: 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 54: Differential Gear Oil

    Pre Operation Checks to bring the level up to maximum level mark. Differential gear oil 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 55: Throttle Lever

    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 56: Tires

    Pre Operation Checks Tires WARNING 3. Tire pressure below the minimum specified could cause the tire to dislodge from the rim POTENTIAL HAZARD under severe riding conditions. Operating this ATV with improper tires, or with improper or uneven tire pressure. 4.

  • Page 57: Tire Wear Limit

    5-10 Pre Operation Checks the second reading. Dust or dirt in the gauge Tire wear limit could cause the first reading to be incorrect. When the tire groove decreases to 3 mm Set pressure with tires cold. (0.12 in) due to wear, replace the tire. tire pressures following...

  • Page 58: 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. controls. WHAT CAN HAPPEN 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 59: Starting A Warming Engine

    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 one dealer to inspect the To get maximum engine life, always warm up respective electric circuit.
  • Page 60 Operation completely shifted into position. Shifting: Neutral to High and High to 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 61 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 62: 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 63 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 64: Parking

    Operation Parking When parking, stop the engine and shift the rocks or other objects. brave select lever into the park position, then Do not park the ATV at all on hills that are so steep you could not walk up them easily. turn the fuel cock to the “OFF”...

  • Page 65: 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 66 Operation Do not exceed the maximum tongue weight. Loading 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 67 6-10 Operation going. Drive more slowly than you would without a WARNING 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 68: Your Vehicle

    Your Vehicle begin to ride, be sure you have read this DRIVING YOUR VEHICLE 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 69 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 70 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 71: 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 72 Your Vehicle Do not operate after consuming alcohol HOW TO AVOID THE HAZARD or drugs. 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 73 Your Vehicle Pre-operation checks Always perform the pre-operation checks WARNING listed on page 5-1 before riding for safety and POTENTIAL HAZARD proper care of the ATV. Operating this ATV after consuming alcohol or WARNING drugs. WHAT CAN HAPPEN POTENTIAL HAZARD Could seriously affect your judgment.
  • Page 74 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 75: Speed Limiter

    Your Vehicle Speed limiter 1. Locknut 2.Adjusting screw For riders less experienced with this model, Loading and accessories 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 76: 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 77 7-10 Your Vehicle Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING 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 re-duce Increases...

  • Page 78: Modifications

    Your Vehicle 7-11 Modifications Exhaust system The exhaust system on the ATV is very hot WARNING 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 79: Be Careful Where You Ride

    7-12 Your Vehicle BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. HOW TO AVOID THE HAZARD 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 80 Your Vehicle 7-13 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 81 7-14 Your 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. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 82 Your Vehicle 7-15 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 83 7-16 Your Vehicle When riding in an area where you might not easily be seen, such as desert terrain, mount WARNING 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 84 Your Vehicle 7-17 not ride in 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 85: Turning Your Atv

    7-18 Your Vehicle or 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”...
  • Page 86 Your Vehicle 7-19 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 87 7-20 Your Vehicle 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 88: Climbing Uphill

    Your Vehicle 7-21 CLIMBING UPHILL Use proper riding techniques to avoid vehicle WARNING 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 89 7-22 Your Vehicle 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 90 Your Vehicle 7-23 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 91 7-24 Your Vehicle 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 92 Your Vehicle 7-25 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 93: Riding Downhill

    7-26 Your Vehicle When this ATV is in 4WD or 4WD-LOCK, all RIDING DOWNHILL 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 94 Your Vehicle 7-27 appear. 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.

  • Page 95: Crossing A Slope

    7-28 Your Vehicle balance, gradually steer again in the CROSSING A SLOPE Traversing a sloping surface on your ATV direction you wish to travel. requires you to properly position your weight WARNING 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 96: Crossing Through Shallow Water

    Your Vehicle 7-29 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 97 7-30 Your Vehicle 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 98 Your Vehicle 7-31 the ATV in fresh water if it has been operated in salt water or muddy conditions. Air filter case check hose CAUTION: 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 99: Riding Over Rough Terrain

    7-32 Your Vehicle 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 100: Sliding And Skidding

    Your Vehicle 7-33 Avoid jumping the ATV as loss of control and SLIDING AND SKIDDING damage to the ATV may result. Care should be used when riding on loose or WARNING slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could POTENTIAL HAZARD lead to an accident.
  • Page 101 7-34 Your Vehicle 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 102 Your Vehicle 7-35 2．If your ATV begins to tip while turning: ● Lean more into the turn to regain balance. practicing at low speeds and on level, ● 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 103 7-36 Your Vehicle ● 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 104: Periodic Maintenance And Adjustment

    Periodic Maintenance and Adjustment Owner’s manual and tool kit Periodic Maintenance And Adjustment You are recommended to put this owner’s Periodic inspection, adjustment manual in the vinyl bag and always carry it in lubrication will keep your machine in the the storage box.
  • Page 105 Periodic Maintenance and Adjustment manual is intended to provide you, the owner, WARNING with necessary information completing your preventive POTENTIAL HAZARD maintenance and minor repairs. The tools Operating this with improper provided in the Owner’s tool kit are sufficient modifications. for this purpose, except that a torque wrench WHAT CAN HAPPEN is also necessary to properly tighten nuts and...

  • Page 106: 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 107: 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 108 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 109: 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 110 Periodic Maintenance and Adjustment pull upward as shown. 1. Panel D 1.Panel A 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 111 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 112 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 113 8-10 Periodic Maintenance and Adjustment 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 114 Periodic Maintenance and Adjustment 8-11 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 115 8-12 Periodic Maintenance and Adjustment 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 116: Efi System

    Periodic Maintenance and Adjustment 8-13 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 117 8-14 Periodic Maintenance and Adjustment 500: 700: 1. oxygen sensor assy 2. oxygen sensor threaded sleeve 3. exhaust Pipe 1. oxygen sensor assy 2. oxygen sensor threaded sleeve 3. exhaust Pipe...
  • Page 118 Periodic Maintenance and Adjustment 8-15 1. ECU 1. fuel injector 2. water temperature sensor 1. high voltage wire 2.ignition signal plug 3. intake air temperature sensor/ pressure sensor 3. ignition coil...
  • Page 119 8-16 Periodic Maintenance and Adjustment Idle speed stepper motor To stabilize the idle speed Fuel injector Inject the fuel into the cylinder Intake air temperature sensor Inspect engine intake temperature, according to the temperature, ECU will automatically adjust the fuel injection volume. Air intake pipe pressure sensor For testing the negative pressure of the air 1.

  • Page 120: Efi System Inspection

    Periodic Maintenance and Adjustment 8-17 Water temperature sensor EFI System inspection testing cooling water temperature, according to the temperature difference, If the EFI system has failure, the meter will ECU will automatically revise fuel injection display the appropriate failure code, you can volume, to ensure the smooth operation of also use the special "EFI system failure the engine all the time.

  • Page 121: Engine Oil And Oil Filter Cartridge

    8-18 Periodic Maintenance and Adjustment Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart.
  • Page 122 Periodic Maintenance and Adjustment 8-19 To change the engine oil (with or without oil filter cartridge replacement) 1. Remove panel F. (See page 8-11 for panel removal and installation procedures.) 2. Start the engine, warm it up for several minutes, and then turn it off. 3.
  • Page 123 8-20 Periodic Maintenance and Adjustment NOTE: NOTE: Skip steps 5-9 if the oil filter cartridge is not An oil filter wrench is available at a nearby being replaced. dealer. Remove panels D and E. (See pages 7. Apply a light coat of engine oil to the 8-6-8-7 and 8-11 for panel removal and O-ring of the new oil filter cartridge.
  • Page 124 Periodic Maintenance and Adjustment 8-21 filter wrench, and then tighten it to the specified torque with a torque wrench. 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 125: Final Gear Oil

    8-22 Periodic Maintenance and Adjustment Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a dealer check and repair the ATV. Replacing the final gear oil 1. Place the ATV on a level surface. 2.

  • Page 126: Differential Gear Oil

    Periodic Maintenance and Adjustment 8-23 amount of the recommended oil. Differential gear oil Recommended oil: Checking the differential gear oil 1. Place the ATV on a level surface. SAE 80 API GL-4 Hypoid gear oil 2. Remove the differential gear oil filler bolt Oil quantity: and check the oil level.
  • Page 127 8-24 Periodic Maintenance and Adjustment CAUTION: Be sure no foreign material enters the differential gear case. 3. Install the differential gear oil filler bolt, and then tighten it to the specified torque. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.3m·kgf, 17ft·lbf) 1.

  • Page 128: Cooling System

    Periodic Maintenance and Adjustment 8-25 reservoir when the engine is cold, as the Recommended oil: coolant level will vary with engine SAE 80 API GL-4 Hypoid gear oil temperature. Oil quantity: NOTE: 0.28 L (0.25 Imp qt, 0.3 US qt) The coolant should be between the minimum and maximum level marks.
  • Page 129 8-26 Periodic Maintenance and Adjustment NOTE: If water is added, have a dealer check the antifreeze content of the coolant as soon as possible. The radiator fan operation is completely automatic. It is switched on or off according to the coolant temperature in the radiator. 1.

  • Page 130: Changing The Coolant

    Periodic Maintenance and Adjustment 8-27 Changing the coolant WARNING POTENTIAL HAZARD Removing the radiator cap when the en-gone 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 131 8-28 Periodic Maintenance and Adjustment 4. Remove the front carrier and panel C. from the coolant reservoir. (See pages 8-9 for removal and installation procedures.) 1. Consider reservoir drain hose 9. After draining the coolant, thoroughly flush 1. Radiator cap the cooling system with clean tap water.

  • Page 132: Axle Boots

    Periodic Maintenance and Adjustment 8-29 11. Install the coolant reservoir hose. 12. Pour the recommended coolant into the CAUTION: reservoir to the maximum level mark, and Hard water or salt water is harmful to the then install the reservoir cap and panel D. engine.

  • Page 133: Spark Plug Inspection

    8-30 Periodic Maintenance and Adjustment If any damage is found, have them replaced Spark plug inspection by a dealer. Removal 1. Remove panel A. (See pages 8-6—8-7 for panel removal and installation procedures.) 2. Remove the spark plug cap. 1.Front axle boot (×2 each side) 1.
  • Page 134 Periodic Maintenance and Adjustment 8-31 Instead, take the ATV to a dealer. You should 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 plug with the specified plug.

  • Page 135: Air Filter Elements Cleaning

    8-32 Periodic Maintenance and Adjustment grime from the threads. the correct torque is 1/4 to 1/2 turn past 3. Install the spark plug and tighten it to the finger tight. Have the spark plug tightened to specified torque. the specified torque as soon as possible. 4.
  • Page 136 Periodic Maintenance and Adjustment 8-33 1. Holder (×5) 2. Air filter case cover 1. Air filter case check hose 1. Remove the seat. (See page 4-19 for seat removal and installation procedures.) 2. Remove the air filter case cover by unhooking the holders.
  • Page 137 8-34 Periodic Maintenance and Adjustment 5. Wash the air filter element gently but thoroughly in solvent. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode.
  • Page 138 Periodic Maintenance and Adjustment 8-35 7. Inspect the air filter element and replace it 11. Install the air filter case cover and be sure if damaged. to connect the hose. 8. Apply roam air filter oil or other quality 12. Install the seat. foam air filter oil to the air filter element.

  • Page 139: Spark Arrester Cleaning

    8-36 Periodic Maintenance and Adjustment air to enter, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance possible engine overheating. Spark arrester cleaning Be sure the exhaust pipe and muffler are 1.

  • Page 140: V-Belt Cooling Duct Check Hose

    Periodic Maintenance and Adjustment 8-37 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. 1.

  • Page 141: Valve Clearance Adjustment

    8-38 Periodic Maintenance and Adjustment 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 142: Front Brake Pad Check

    Periodic Maintenance and Adjustment 8-39 1. Brake pad a. Brake pad thickness 1. Locknut 2. Adjusting bolt NOTE: a. Throttle lever free play The wheels need to be removed to check the brake pads. (See pages 8-47 — 8-48 for Front brake pad check removal and installation procedures.) Check the brake pads for damage and wear.

  • Page 143: Checking The Brake Fluid Level

    8-40 Periodic Maintenance and Adjustment 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 144: Brake Fluid Replacement

    Periodic Maintenance and Adjustment 8-41 Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance. 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 145: Front Brake Lever Free Play

    8-42 Periodic Maintenance and Adjustment Front brake lever free play The front brake lever should have a free play WARNING of zero mm (zero in) at the lever end. If not, POTENTIAL HAZARD have a dealer check the brake system. Operating with improperly serviced or Adjusted brakes.

  • Page 146: Adjusting The Brake Pedal

    Periodic Maintenance and Adjustment 8-43 1. Loosen the locknut. dealer to make that adjustment. NOTE: When adjusting the urgent brake lever free play:  Be sure not to step on the brake pedal.  Make sure the brake pedal does not move.

  • Page 147: Adjusting The Rear Brake Light Switch

    8-44 Periodic Maintenance and Adjustment WARNING POTENTIAL HAZARD Operating with improperly serviced 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 Distance between brake pedal and footrest and that the free play is correct.

  • Page 148: Cable Inspection And Lubrication

    Periodic Maintenance and Adjustment 8-45 light comes on just before braking takes 1. Rear brake light switch effect. If necessary, adjust the brake light 2. Adjusting nut switch as follows. 3. Install the panel. 1. Remove panel B. (See page 8-8 for panel removal and installation procedures.) Cable inspection and lubrication 2.

  • Page 149: Lubricating The Brake Levers And Brake Pedal

    8-46 Periodic Maintenance and Adjustment Recommended lubricant: The chain and cable lube or SAE 10W/40 motor oil Lubricating the brake levers and brake pedal Lubricate the pivoting parts. NOTE: To access the brake pedal pivot, remove panel B. (See page 8-8 for panel removal and installation procedures.) Recommended lubricant: Lithium-soap-based grease...

  • Page 150: Rear Knuckle Upper And Lower Pivot Lubrication

    Periodic Maintenance and Adjustment 8-47 1. Upper knuckle 2. Lower knuckle Rear knuckle upper and lower pivot Recommended lubricant: lubrication Lithium-soap-based grease Lubricate the knuckle upper and lower pivots with a grease gun. Wheel removal 1. Loosen the wheel nuts. 2.

  • Page 151: Wheel Installation

    8-48 Periodic Maintenance and Adjustment 1. Arrow mark 1. Nut (×4) Wheel installation 1. Install the wheel and the nuts. NOTE: The arrow mark on the tire must point toward the rotating direction of the wheel. Tapered nuts are used for both the front and rear wheels.

  • Page 152: Battery

    Periodic Maintenance and Adjustment 8-49 2. Lower the ATV so that the wheel is on the ground. WARNING 3. Tighten the wheel nuts to the specified POTENTIAL HAZARD torque. Failure handle batteries battery electrolyte carefully. Wheel nut torque: WHAT CAN HAPPEN Front: 55 Nm (5.5m·kgf, 40ft·lbf) You could be poisoned.

  • Page 153: Battery Maintenance

    8-50 Periodic Maintenance and Adjustment Battery maintenance and the switch of the circuit in question. Then, install a new fuse of the specified amperage. 1. When the machine is not used for a month Turn on the main switch. If the fuse or longer, remove the battery and store it in a immediately blows again, consult a dealer.

  • Page 154: Replacing A Headlight Bulb

    Periodic Maintenance and Adjustment 8-51 Specified fuses: CAUTION: Main fuse: 30 A To prevent accidental short-circuiting, turn off Speedometer unit the main switch when checking or replacing Signaling system fuse a fuse. Four-wheel drive fuse: Auxiliary DC jack fuse: ECU: Headlight fuse: Replacing a headlight bulb Backup fuse:...
  • Page 155 8-52 Periodic Maintenance and Adjustment 2. Remove the headlight bulb holder cover 4. Remove the defective bulb by pulling it by pulling it off. out. WARNING POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable.

  • Page 156: Headlight Beam Adjustment

    Periodic Maintenance and Adjustment 8-53 6. Install the bulb holder by pushing it in and turning it clockwise. CAUTION: 7. Install the bulb holder cover and the cover Do not touch the glass part of the headlight at the rear of the headlight. bulb to keep it free from oil, otherwise the transparency of the glass;...

  • Page 157: Tail/Brake Light Bulb Replacement

    8-54 Periodic Maintenance and Adjustment 1. Tail/brake light bulb holder 1. Headlight beam adjusting screw 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.

  • Page 158: Check And Solution To Common Problems In Vehicle

    Periodic Maintenance and Adjustment 8-55 Check and solution to Common Problems in Vehicle Here you can see some tables on the common problems which may come up when you are driving a ATV, which will help to solve these problems. To repair a ATV requires technical skills, if you cannot fix it up yourself , please contact your dealer.
  • Page 159 8-56 Periodic Maintenance and Adjustment Table1:Check and Solution of Common Problems in Appearance parts and impact fittings. Problems Solutions 1.Covers are cracked up when go acrossing the field. Covers are cracked up when go acrossing the 2.Change for new plastic covers. field.
  • Page 160 Periodic Maintenance and Adjustment 8-57 ： Check and Solution of Common Problems in Brake System . Table 2 Problems Solutions 1.Check if the handle of parking brake ruturn to its position. 2.Check if the brake discs are deformed. Brake system is locked 3.Check if the calipers' hydraulic cylinders get stuck, or the fixing parts of calipers are deformed.
  • Page 161 8-58 Periodic Maintenance and Adjustment Problems Solutions Front or rear brake 1.Check if the brake discs are deformed. system makes affricate 2.Check if the calipers' hydraulic cylinders get stuck, or the noise, or the brake discs fixing parts of calipers are deformed. go .
  • Page 162 Periodic Maintenance and Adjustment 8-59 Table 3: Check and Solution of Common Problems in Electrical System Problems Solutions 1.Check if the headlight switch functions well. Lamps don't work. 2.Check if the wires are broken. 3.Check if the lamps or bulbs are broken. 1.Check if the control switch on meter board works well.
  • Page 163 8-60 Periodic Maintenance and Adjustment Problems Solutions 1.Check if the switch is broken. Start switch on meter 2.Check if the wire is broken. board won't work 3.Check if the ECU in electrical injection system is broken.
  • Page 164 Periodic Maintenance and Adjustment 8-61 Table 4: Check and Solution of Common Problems in Running System Problems Solutions 1.Check the fix screws connecting steering rod to steering stem and knuckle to find out if they are loose or broken Swing clearance of stee- 2.Check the bulds on the ends of steering rod to find out if ring wheel is too big they are broken...
  • Page 165 8-62 Periodic Maintenance and Adjustment 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. Rear wheels shake 3.Check the inner splines of rear wheel hubs and outer seriously in running.
  • Page 166 Periodic Maintenance and Adjustment 8-63 Problems Solutions 1.Check if overloaded. Shock absorbers beco- 2.Check if the springs are two soft after after long time me soft and not comfort- running. table in running. 3.Check if the shock absorbers lose their damping force in their travel.
  • Page 167 8-64 Periodic Maintenance and Adjustment Table5: Check and Solution of Common Problems in Engine System Problems Solutions 1.Check the battery voltage for Within specified value 2.Check the rectifier output voltage for within specified Idle speed is not stable value 3.Check MEUI for failure 1.Check if there is one cylinder not working.
  • Page 168 Periodic Maintenance and Adjustment 8-65 Problems Solutions Engine is difficult to start 2.If the temperature is under -18℃,have the vehicle placed at low temperature in warmer place for start. 1.Check the cooling fin of radiator for blocked by soil or dirt 2.Check the speed sensor of radiator for damage and Check fan for failure Coolant boils...
  • Page 169 8-66 Periodic Maintenance and Adjustment Problems Solutions 6.Check if the ignition signal is in good condition 7.Check if the air cleaner is blocked Engine can not start 8.Check if the oil circuit is smooth 9.Check if the exhaust system is blocked 1..
  • Page 170 Periodic Maintenance and Adjustment 8-67 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 171: Cleaning And Storage Cleaning

    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 172: Storage

    Cleaning and Storage chamois, clean towel or soft absorbent clothe. WARNING 6. Clean the seat with vinyl upholstery POTENTIAL HAZARD cleaner to keep the cover pliable and glossy. Operation with wet brakes after washing. 7. Automotive type wax may be applied to all WHAT CAN HAPPEN painted and chrome plated surfaces.
  • Page 173 Cleaning and Storage prepare for storage as follows: the cylinder wall with oil. 1. Fill the fuel tank with fresh fuel and add 3. Lubricate all control cables. the specified amount of Fuel Stabilizer and 4. Block up the frame to raise all wheels off Conditioner or an equivalent product.
  • Page 174 Specification 10-1 Model HS500ATV-4/HS700ATV-4 Dimensions: Overall length 2,250mm (88.6in) Overall width 1,210mm (47.6in) Overall height 1,225mm (48.2in) Seat height 880mm (34.6in) Wheelbase 1,365mm (53.7in) Ground clearance 260mm (10.2in) Minimum turning radius 3,200mm (126.0in) Basic weight: With oil and full fuel tank 370kg (816 lb) /390 kg (860 lb) Engine: Engine type...

  • Page 175: Specifications

    10-2 Specifications Model HS500ATV-4/HS700ATV-4 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 176 Specification 10-3 Model HS500ATV-4/HS700ATV-4 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) Air filter:...
  • Page 177 10-4 Specifications Model HS500ATV-4/HS700ATV-4 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° Trail 26 mm (1.0 2 in) Tire:...
  • Page 178 Specification 10-5 Model HS500ATV-4/HS700ATV-4 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 Rear brake Type Dual disc brake...
  • Page 179 10-6 Specifications Model HS500ATV-4/HS700ATV-4 Electrical: Ignition system Generator system A.C. magneto Battery type YTX20L-BS or GSTX20L-BS Battery capacity 12 V, 21 Ah or 12V,18Ah Headlight type: Krypton bulb Bulb voltage, wattage ×quantity: 12 V, 35 W / 35 W×2 Head light Tail/brake light 12 V, 5 W / 21 W×1 Indicator light:...
  • Page 180 Specification 10-7 Model HS500ATV-4/HS700ATV-4 Fuses: Main fuse: 30 A Speedometer unit Signaling system fuse Four-wheel drive fuse: Auxiliary DC jack fuse: ECU: Headlight fuse: Backup fuse: 5A /10A/15A...
  • Page 181 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 182 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 183 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 184 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The U.S. Environmental Protection Agency and Hisun Motors Corp., U.S.A. (hereinafter “HISUN”) are pleased to explain the emission control system warranty on your Off-Road vehicle. New off-road motor vehicles must be designed, built and equipped to meet U.S.
  • Page 185 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement replaced by HISUN. This is your EMISSION CONTROL SYSTEM WARRANTY. NOTICE! Use of this vehicle in any type of competitive event completely and absolutely voids this and all other warranties offered by HISUN. OWNER’S WARRANTY RESPONSIBILITIES As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.
  • Page 186 Hisun Motors Corp., U.S.A. Emission Control System Warranty Statement 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 187 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System YOUR WARRANTY RIGHTS AND OBLIGATIONS Hisun Motors Corp., U.S.A. warrants that each new off-road vehicle: A. is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and B.
  • Page 188 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System II. Limitations This Emission Control System Warranty shall not cover any of the following: A. Repair or replacement as a result of (1) accident, (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...
  • Page 189 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System C. Any vehicle equipped with an odometer or hour meter on which the odometer mileage or hour meter reading has been changed so that actual mileage cannot be readily determined. III.
  • Page 190 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System B. No express emission control system warranty is given by HISUN except as specifically set forth herein. Any emission control system warranty implied by law, including any warranty of merchantability or fitness for a particular purpose, is limited to the express emission control system warranty terms stated in this warranty.
  • Page 191 Hisun Motors Corp., U.S.A. Limited Warranty on Emission Control System performance and durability may be used in the performance of any maintenance or repairs by the owner. However, HISUN is not liable for these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual.

This manual is also suitable for:

Hs500atv-4 2000Hs700atv-4 2000

Table of Contents