Coleman ATV260 Owner's/Operator's Manual
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Coleman ATV260 Owner's/Operator's Manual

Coleman ATV260 Owner's/Operator's Manual

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WARNING：Read
this Manual , and
any Supplements
Carefully
Before Operating
Vehicle.
Assembly
Operation
Maintenance
THIS VEHICLE IS
FOR OFF-ROAD
USE ONLY
THIS VEHICLE IS
NOT DESIGENED
FOR USE ON
RENTAL TRACKS
OR RACING
BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR MUST
UNDERSTANDED
MANUFACTURED TO MEET SPECIFICATIONS FOR USE ON PUBLIC ROADS,
STREETS, HIGHWAYS, AND THOROUGHFARES AND HAVE READ AND HAVE AN
UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND
SAFE OPERATION, AS WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE
AND ALL OTHER PORTIONS OF VEHICLE.
OWNER'S/OPERATOR'S
MANUAL
ATV260/ATV300
THAT
THIS
VEHICLE
USA
WAS
NOT
DESIGENED
PN:F010203A07
OR

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Summary of Contents for Coleman ATV260

  • Page 1 Carefully Before Operating Vehicle. Assembly Operation Maintenance THIS VEHICLE IS FOR OFF-ROAD USE ONLY ATV260/ATV300 THIS VEHICLE IS NOT DESIGENED FOR USE ON RENTAL TRACKS OR RACING BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR MUST UNDERSTANDED THAT THIS...

  • Page 2: Table Of Contents

    CONTENTS 1. INTRODUCTION 2. UNDERSTANDING WARNING 3. SAFETY WARNING 4. DAILY PRE-RIDE INSPECTION 5. OPERATION WARNING 6. V.I.N 7. CONTROL AND FUNCTIONS 8. STARTING THE ENGINE 9. VEHICLE BREAK-IN PERIOD 10. RIDING GEAR 11. CARRYING LOADS 12. RIDING 13. CVT SYSTEM 14.

  • Page 3: Introduction

    1. Introduction Congratulations on the purchase of your ALL Terrain Vehicle (ATV). We take pride in offering you this product engineered and manufactured to the highest performance and quality standards. We are sure that you will enjoy superior levels of performance, reliability, riding comfort, and safety.
  • Page 4 Practice Responsible ATV Riding Make sure that you understand and follow all local, state/province, and federal/national riding laws and requirements. Remember……Respect your vehicle, respect the environment and respect the property of others. You are responsible for your safety and the safety of others around you when you ride!
  • Page 5 AN ATV CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. SERIOUS INJURY OR DEATH can result if you do not follow these instruction.
  • Page 6  Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.  Never operate on excessively rough, slippery or loose terrain.  Always follow proper procedures for turning as described in this manual.
  • Page 7  Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.  Always be careful of skidding of sliding. On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

  • Page 8: Understanding Warning

    2. UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY: not a toy. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BERORE OPERATION. KNOW YOUR VEHCLE BEFORE YOU BEGING RIDING! Read this manual thoroughly referring to the various areas which are being discussed on your machine. Operating this vehicle carries with it responsibilities for your personal safety, the safety of others, and the protection of our environment.
  • Page 9 2. UNDERSTANDING WARNINGS SAFETY ALERT WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. Read all WARNINGS in this manual care fully. Follow their instructions to remain safe. The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol.
  • Page 10 3.SFETY WARNING NOTE： Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your dealer for a replacement. NOTE: No.1 、2、7、11、13 ONLY FOR 4WD No.11 ONLY FOR 504WD...

  • Page 11: Safety Warning

    3.SAFETY WARNING...

  • Page 17: Daily Pre-Ride Inspection

    4. DAILY PRE-RIDE INSPECTION WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is improper working order each time you ride.

  • Page 18: Operation Warning

    5. OPERATION WANINGS WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course.
  • Page 19 5. OPERATION WANINGS WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and /or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 20 5. OPERATION WANINGS WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement.
  • Page 21 5. OPERATION WANINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 22 5. OPERATION WANINGS WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions;...
  • Page 23 5. OPERATION WANINGS WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. 5. OPERATION WANINGS...
  • Page 24 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 25 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 26 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 practiced the skills necessary to control the ATV on such terrain.
  • Page 27 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills...
  • Page 28 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. NOTE: A special technique is required when braking as you go downhill.
  • Page 29 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill. Apply the brakes.
  • Page 30 WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 31 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 operating the ATV through water which exceeds the recommended maximum depth in this manual.
  • Page 32 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tier pressure, may cause loss of control, and increases the risk of an accident.
  • Page 33 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV, Cargo should be properly distributed and securely attached, Reduce speed when carrying cargo or pulling a trailer.

  • Page 34: V.i.n

    WARNING After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. WARNING Safe operation of this ride active vehicle requires good judgment and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death.

  • Page 35: Control And Functions

    record these numbers from your ATV in the spaces provided. 1. Frame VIN (found on the lower tight side of the frame tube) 2. Engine Serial Number (Left front side of engine crankcase) Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank and having it cut by mating it with your existing key.
  • Page 36 Electrical Switches 1. Main Switch -This key switch must be turned clockwise to the “on” position to start the engine. 2. Hazard Light Switch –When the switch is pushed to “ “ , the four signal lights are on and the buzzer is sounding. 3.
  • Page 37 Light Switches and Indicator Lights WARNING This ATV is not equipped with highway approved lighting. This ATV is designed for off – road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
  • Page 38 1.Neutral indicator light High beam indicator light Turn indicator light Reverse indicator light Speedometer .6 Coolant temperature meter 7 Engine rpm meter 8、9 The odometer 10 Engine working hour counter 11 2WD/4WD indicator km/ mile selector B: hour / distance selector 7.
  • Page 39 WARNING Do not start or operate an ATV with sticking or improperly operation throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death. Always contact your dealer for service repairs whenever throttle problems arise.
  • Page 40 reservoir of hand brake is located on the left side of the handlebar. The reservoir of foot brake is located under the seat. The fluid should be kept between the maximum and minimum marks. CAUTION Once a bottle of brake fluid is opened, use what is necessary and discard the rest.
  • Page 41 Operating the ATV with a spongy brake lever can result in loss of braking. Loss of braking could cause an accident. 7. CONTROL AND PARTS FUNCTIONS Setting the Parking Brake 1. Squeeze the left hand brake lever two or three times and hold 2.
  • Page 42  Always block the downhill side of the wheels if leaving the ATV on a hill or park the ATV in a side hill position. WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated.
  • Page 43 on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes inoperative. IF the rear wheels slide, reduce brake pedal pressure to brake the rear wheels without skidding.
  • Page 44 seen through it, and should be maintained between the indicated “max” and “min” marks on the reservoir. 7. CONTROL AND PARTS FUNCTIONS Automatic Transmission Gear Selector Operation The transmission gear selector is located on the right side of the vehicle. The transmission selector lever has four positions: high forward;...
  • Page 45 a lower gear. 7. CONTROL AND PARTS FUNCTIONS Engine Cooling System Coolant Level The recovery bottle, located under the seat, must be maintained between the minimum and levels indicated on the recovery bottle. The engine coolant level is controlled or maintained by the recovery system.
  • Page 46 NOTE: Always follow manufacturer’s mixing recommendations for the freeze protection required in your area. 7. CONTROL AND PARTS FUNCTIONS Cooling System WARNING Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.
  • Page 47 Using a funnel, slowly add coolant as necessary through the radiator filler neck. 7. CONTROL AND PARTS FUNCTIONS Fuel and Oil system WARNING Gasoline is highly flammable and explosive under certain conditions.  Always exercise extreme caution whenever handling gasoline. ...
  • Page 48 7. CONTROL AND PARTS FUNCTIONS Fuel and Oil System Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’s Manual for tank capacity. Use regular unleaded gasoline. The fuel valve is located on the left side of the front fender and has three positions: OFF: For vehicle storage and whenever transporting.
  • Page 49 7.CONTROL AND PARTS FUNCTIONS Oil System The oil tank is located on the right side of the engine . To check the oil: 1. Set machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3.
  • Page 50 7.CONTROL AND PARTS FUNCTIONS 4 Wheel Drive System (4WD) 4 wheel drive ATVs are equipped with a manual shift. The selector is located on the right side of the vehicle directly under the gear selector. The selector lever has two positions: 2WD; 4WD.
  • Page 51 NOTE: The heavy steering of the 4WD is normal. 4 Wheel Drive System (ELECTRIC SHIFT) 1. Electric 2WD- 4WD Shift Some model is equipped with an electric shift. CAUTION: Always shift as the vehicle stop. NOTE: When shift 2WD/ 4WD, the mechanics in the front gear box maybe still engaged/ disengaged, the mechanics would finally disengaged/ engaged when rides on a hard surface or rides in reverse.
  • Page 52 will stay in 4WD position but 4WD mechanics maybe still disengaged. Always apply throttle gently and let the wheels move slightly to allow the 4WD mechanics finally engage. The 4WD indicator on the speedometer will come on when 4WD engaged. 7.CONTROL AND PARTS FUNCTIONS WARNING：...

  • Page 53: Starting The Engine

    If the tires on this 4WD ATV are more than 50% worn, fitting only one new tire may also affect the road handling. In this case, it is recommended that 4 new original tires are fitted. NOTE: Use 4WD only for necessary, this will result in less fuel consuming and longer life for the machine.
  • Page 54 CAUTION This ATV only equipped with an electric start system. If the battery is under charging, the ATV will not run. 9. VEHCLE BRESK-IN PERIOD The break-in period for your new ATV is defined as the first 50 hours of operation. No single action on your part is as important as a proper break in period.

  • Page 55: Riding Gear

    5. Perform regular checks on fluid levels, controls and all important areas on the vehicle as outlined earlier on the daily pre-ride inspection checklist found in”4.daily pre-ride inspection”. 6. Don’t pull loads. 10. RIDING FEAR Safe Riding Gear Always wear clothing suite to the type of riding you are doing ATV riding requires special protective clothing which will make you fell more comfortable and reduce chances of injury.
  • Page 56 Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed(1/3 on the front and 2/3 on the rear ) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
  • Page 57 To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below:  REDUCE SPEED AND ALLOW GREATED DISTANCE FOR BRAKING WHEN CARRYING CARGO.  CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack.

  • Page 58: Riding

     Do not use safety chain for towing. 12. RIDING WARNING The engine rpm limiter will work at 7500rpm, this may cause excessive fuel to build in the exhaust, and ignited by the catalyst muffler, RESULT MUFFLERS OVERHEATING AND FIRE RISK. Always reduce throttle when the engine reach top rpm, avoid the engine popping.
  • Page 59 WARNING You must inspect you ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. See“4.DAILY PRE-RIDE INSPECTION” 1. Sit upright with both feet on footrests and both hand on the handlebars.
  • Page 60 Making turns Practice making turns at slow speeds This ATV is equipped with a solid rear axle which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheels when turning and the inside tire must slip traction slightly.
  • Page 61 Riding on slippery surfaces Whenever riding on slippery surface such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids.
  • Page 62 WARNING Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills (15%maximum). 2.
  • Page 63 Sidehilling your ATV is one of the most dangerous types of riding and should be avoided. If you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring you upper body weight toward the hill while keeping your feet on the footrests.
  • Page 64 Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer you weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs.
  • Page 65 If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1. Stop and lock the parking brake while maintaining body weight uphill.
  • Page 66 Your ATV can operate through water up to maximum recommended depths is 8 inch. Before fording steams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4.
  • Page 67 CAUTION If you ATV becomes immersed,take it to your dealer before starting the engine.Major engine damage can result if the maching is not thoroughly inspected. If it is impossible to take it to a dealer before starting, follow thee steps outlined below. ...
  • Page 68 Keep Alert! Lock ahead and learn to read the trail as you ride.Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs,rocks and low hanging branches. WARNING Not all obstacles are visible.Travel with caution on trails.Severe injury or death can vehicle comes in contact with a hidden obstacle.
  • Page 69 Backing your ATV can be dangerous! could hit an obstacle or person behind you; or the vehicle could tip over rearward on a steep incline causing severe injury or death. Backing up 1. Avoid backing up on steep inclines. 2. Always back slowly. 3.
  • Page 70 12. RIDING Parking on an incline Whenever the vehicle is parked 1. Turn the engine off. 2. Place the transmission in gear. 3. Set the parking brake. 4. Shut off fuel supply. 5. Avoid parking on an incline.If it is neceddary to park on an incline,always block the rear wheels on the down hill side as shown above.

  • Page 71: Cvt System

    13. CVT SYSTEM CVT System WARNING The CVT system rotates at high speeds, creating large amounts of force on clutch components. However, as the owner you have the following responsibilities to make sure this system remains safe:  Do not modify any component of the CAT system. Doing so may reduce its strength so that a failure may occur at high speeds.
  • Page 72 13. CVT SYSTEM CVT System On this ATV, the approximate gear ratio difference between high and low range is 1:2.05.This difference in gearing affects the operation of the CVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed. By switching to low range while operating at low ground speeds, the air temperature in the clutch will be reduced.
  • Page 73 13. CVT SYSTEM When To Use Low Range The following lists provide a guideline for when to use low range rather than high. Low Range  Basic operation at speeds less than 7 MPH (11km/h)  Heavy pulling  Riding through rough terrain (swamps, mountains, etc.)at low ground speeds High Range: ...

  • Page 74: Battery

    14. BATTERY Battery WARNING Whenever removing the battery, disconnect the negative (back) cable first. When reinstalling the battery, connect the negative (back) cable last or explosive situation could result causing serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
  • Page 75 14. BATTERY Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red(positive) battery cable next. 5.
  • Page 76 14. BATTERY 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion.

  • Page 77: Exhaust System

    15. EXHAUST SYSTEM SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! CAUTION: Exhaust system components are very hot during and after use of ATV.  Do not tough exhaust system components. Serious burns can result. Be especially careful when traveling through tall grass. The potential for fire exists.

  • Page 78: Maintenance

    Catalyst There is catalyst inside the muffler on all Europe models and some U.S. models. WARNING The engine rpm limiter will work at 7500rpm, this may cause excessive fuel to build in the exhaust, and ignited by the catalyst muffler, RESULT MUFFLERS OVERHEATING AND FIRE RISK.
  • Page 79 safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart on the following pages. Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently.
  • Page 80 Coolant/Level Daily Daily Replace engine coolant Inspection Every one year Air Box Sediment Daily Daily Drain deposits whenever  Tube visible Headlamp Daily Daily Check operation daily; Inspection apply dielectric grease connector when replaced Tail lamp inspection Daily Daily Check operation daily; apply dielectric grease to socket when replaced ...
  • Page 81 Base Fasteners only) General Lubrication 50 hrs Lubricate all fittings,  months pivots, cables, etc. 16. MAINTENANCE Item Hours When Remarks Check Level Daily; Break  Engine 30 hrs 3 months in Service at 1 month. Oil-Level/Change Change oil more often in cold weather use.
  • Page 82 Coolant strength 100 hrs 6 months Inspect strength seasonally Shift linkage 50 hrs 6 months Inspect, adjust Drive belt 50 hrs 6 months Inspect, replace if necessary Steering 50 hrs 6 months Inspect daily, lubricate  Rear Axle 50 hrs 6 months Inspect bearings, Lube ...
  • Page 83 16. MAINTENANCE Item Hours When Remove Radiator 100 hrs 12 months Inspect/clean external surface Cooling System 50 hrs 6 months Inspect/replace if hoses necessary Spark arrestor 10 hrs monthly Clean out-replace if necessary...
  • Page 84 Clutches (drive and 25 hrs 3 months Inspect, clean Driven) Engine mounts 25 hrs 3 months Inspect Valve clearance 100 hrs 12 months Inspect/adjust Shift selector box 200 hrs 24 months Change grease every (H/L/R/N) two years Brake fluid 200 hrs 24 months Change every...
  • Page 85 3.Transmissi See “16.MAI- Change on Oil 80W/90GL5 NTENANCE/TRAN annually or at 100 hours MISSION LUB” 4.Rear Gear See “16.MAI- Change case oil 80W/90GL5 NTENANCE/Rear annually or Gear case at 100 hours Lubrication” 5.Front Gear See “16.MAI- Change case oil 80W/90GL5 NTENANCE/Rear annually or Gear...
  • Page 86 pivot Shaft pivot shaft and or50hours grease with grease gun 7.Steering Grease Locate fitting on Every 3 months  Post Bushings pivot shaft and or50hours grease with grease gun 8.Front Wheel Grease Inspect Semi-annually  bearings replace bearings if necessary 9.Tie rods Grease Locate fittings...
  • Page 87 16. MAINTENANCE...
  • Page 88 16. MAINTENANCE Lubrication Recommendations  12.Rear Axle Grease Locate fittings Every Bearing and grease months or50hours  13. Swing Grease Locate fittings Monthly or 20 and grease hours Bearing  14. Throttle Grease M Grease, inspect Monthly or 20 Cable and replace it if hours necessary...
  • Page 89 16. MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work： Maintenance Servicing Servicing Remark Interval Date Dealer or Performed person First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs...
  • Page 90 16. MAINTENANCE WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit.
  • Page 91 16. MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Wheel Nut Torque Specifications Bolt Size Specification Front M10X1.25 20Ft.Lbs 27N.m Rear M12X1.25 50Ft.Lbs 69N.m Rear(ALUMINUM 69Ft.Lbs 95N.m WHEEL) M12X1.25 NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Dealer.
  • Page 92 16. MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Rear Spring Adjustment Air Filter Service 1. Remove seat. 2. Release clips and remove Cover.
  • Page 93 tighten clamp or filter damage may occur. 16. MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable.
  • Page 94 16. MAINTENANCE Front Brake WARNING Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.
  • Page 95 friction material is worn to 3/64”(1mm).(A) 16. MAINTENANCE Rear and Auxiliary Brake Rear Brake The rear brake is a hydraulic disc type brake which is activated by brake lever on handlebar (also the foot pedal on the side of the right floorboard) which activates the front brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear...
  • Page 96 16. MAINTENANCE Carburetor/ Engine Idle RPM Adjustment If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running the vehicle approximately five minutes. 2.
  • Page 97 16. MAINTENANCE Spark Plugs Inspect:  Insulator ① Abnormal color: Replace. Normal color is a medium- To-light tan color.  Electrode ② Wear/damage:Replace. Clean: Standard spark plug  Spark plug DR8EA(NGK) (with spark plug cleaner or wire brush) ③ Gap:0.6-0.7mm Measure: ...
  • Page 98 16. MAINTENANCE Oil and Filter Change The recommended oil change interval is 30 hours, or every 3 mouths, whichever comes first. Suggested break in oil change is at 20 hours, or one mouth, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions, and cold weather riding.
  • Page 99 7. Reinstall drain plug and torque to 14ft.Ibs (19N.m) 16. MAINTENANCE Transmission Lubrication The transmission fill plug is located on the right side of the machine. The transmission lubricant level should be checked monthly or 20 hours, whichever comes first. Transmission oil should be changed annually.
  • Page 100 16. MAINTENANCE Transmission Oil Changing Procedure 1. Remove the four screws on the footwall and gently pull outward for access. 2. Remove fill plug. 3. Remove transmission drain plug located on the bottom left hand side and drain the oil. Catch and discard used oil properly.
  • Page 101 16. MAINTENANCE Rear Gearcase Lubrication Which the ATV on the a level surface, remove fill plug and visually inspect the lubricant level through the fill hole(1).Lubricant should be kept even with the center of the drill point (2) approximately 1 5/8” (41mm) below the top of the fill hole.
  • Page 102 16. MAINTENANCE WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tire will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation.
  • Page 103 16. MAINTENANCE Wheel Installation 1. With the transmission in gear and the parking brake locked, place th wheel in the correvt position on the wheel hub. Be sure the valve stem is toward the outside and totation arrows on the tire point toward rotation.
  • Page 104 16. MAINTENANCE Headlight Lamp Replacement WARNING Keep your headlights and taillights clean. Poor light while riding can result in an accident causing severe injury or death. CAUTION Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
  • Page 105 16. MAINTENANCE Lamp Replacement A.Headlight Lamp Relpacement (FOR O5) 1. Use bulb 12V 35W/35W. 2. Remove the cover 1. 3. Dismantle the basis of the light. 4. Replace the bulb with a new one (12V 35W/35W), locating it properly and securely. 5.
  • Page 106 16. MAINTENANCE Taillight /Brakelight Lamp Replacement If the taillight / brakelight does not work the lamp may need to be replaced. 1. Remove the lens. 2. Remove lamp and replace it with recommended lamp. 3. Test the taillight/ brakelight to see that it’s working .
  • Page 107 16. MAINTENANCE Cleaning Your ATV Keeping your ATV clean will extend the life of various components. Washing Never use a high pressure type car wash system, it can damage to the wheel bearings, transmission seals, body panels, brakes and warning labels, and water might enter the engine or exhaust system.
  • Page 108 16. MAINTENANCE Storage Tips CAUTION Do not start the engine during the storage period. This will disturb the protective film created by fogging. Cleaning——Clean the ATV thoroughly. Fuel——Turn the fuel valve to “OFF” and drain the carburetor bowl completely. Oil Add and Filter Change——Warm the engine and change oil and filter.
  • Page 109 16. MAINTENANCE Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn off the engine and remove the key. 2. Turn the fuel valve to off. 3. Be certain the fuel cap, oil cap, and seat are installed correctly.

  • Page 110: Troubleshooting

    17. TROUBLESHOOTING Issues of Improper Operation driven clutch (CVT) Burning Possible Causes Solutions Loading the ATV into a Shift transmission to Low Range during pickup or tall trailer when in loading of the ATV to prevent belt burning high range. Starting out going up a When starting out on an incline, use low steep incline...
  • Page 111 17. TROUBLESHOOTING Battery Wane Possible Causes Solutions Starting a faulty engine for See”8.STARTING THE ENGINE” long time And check the fuel/ air/ ignition/ compression system Let the main switch (key) When stopping the engine turn off on while parking the ATV the main switch (key) off at once WARNING This ATV only equipped with an electric start system.
  • Page 112 17. TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. Adjustment and replacement must be done by your dealer.
  • Page 113 17. TROUBLESHOOTING IGNTION SYSTEM Battery Ignition system Improperly charged battery Faulty igniter unit Faulty battery Faulty pick up coil Fuse Broken magneto Burnt out, improper connection woodruff key Spark plug Switch Improper plug gap Faulty main switch Worn electrodes Faulty “ENGINE STOP” Wire between terminals broken switch Improper heat range...
  • Page 114 17. TROUBLESHOOTING POOR MEDIUM AND HIGH SPEED PERFORMANCE Carburetor Air cleaner Improperly adjusted fuel level Clogged air cleaner element Clogged main nozzle Clogged or loose pilot jet POOR SPEED PERFORMANCE Ignition system Compression system Dirty spark plug Worn cylinder Improper heat range Worn or seized piston ring Faulty igniter unit Cylinder head gasket broken...
  • Page 115 17. TROUBLESHOOTING OVER HEATING OR OVER-COOLING OVER HEATING OVER-COOLING Ignition system Cooling system Improperly spark plug gap Faulty thermostat Improper spark plug heat rang Faulty thermo switch Faulty ignitor unit Fuel system Improper carburetor setting Improper fuel level adjustment Clogged air cleaner element Compression system Heavy carbon deposit build-up Improperly adjusted valve timing...
  • Page 116 17. TROUBLESHOOTING FAULTY CLUTCH WHEN ENGINE RUN, ATV DOES NOT RUN V belt POOR SPEED PERFORMANCE V-belt Worn/bent/slipping Worn Cam, slider Oil V belt Worm/damaged Compression spring Roller weight  Worn/improper operation Damage Gears Primary/secondary/sheave Damage CLUTCH SLIPPING CVT SYSTEM Clutch weight spring Uncorrect Primaty Clutch Position Uncorrect engine mount...

  • Page 117: Tools

    18. Tool...

  • Page 118: Specification

    19. SPECIFICATION Capacities Fuel capacity 12.5L Engine Oil Capacity 1.4L Ground Clearance 183mm Height 1170mm Length 2096mm Width 1170mm Seat height 865mm Wheel Base 1265mm Turn Radius 3277mm Dry Weight 280kg Front Rack 18kg Rear Rack 36kg Load Capacity(Combined Rider& Payload) 150kg Tongue Weight 11kg...
  • Page 119 19. SPECIFICATION Engine ATV260 ATV300 170MM 4Stroke, Single 173MM 4Stroke, Single Engine Type Cylinder, SOHC Cylinder, SOHC Bore x Stroke 70mmX66.8mm 72.5mmX66.8mm Displacement 257cm 275cm Starter System Electric Starter Engine Cooling Liquid-Cooled Lubrication System Wet Sump Carburetor CVK30 Ignitions T.C.I Spark Plug Type DR8EA（NGK）...
  • Page 120 20. WIRNING DIAGRAM...

This manual is also suitable for:

Atv300

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