LONCIN LX500ATV Owner's Manual
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LONCIN LX500ATV Owner's Manual

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OWNER S MANUAL
READ THIS MANUAL CAREFULLY
IT CONTAINS IMPORTANT SAFETY INFORMATION.
MINIMUM
RECOMMENDED
OPERATOR AGE:
This vehicle is sold for OFF-ROAD USE ONLY. Before
operating this vehicle, read all the instructions for safe
assembly and operation as well as the instructions
governing the engine and other portions of the vehicle.
Pay close attention to all caution and warning labels on
the ATV.
'
LX500ATV
1st Edition 2007
16

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  • Page 1 OWNER S MANUAL LX500ATV 1st Edition 2007 READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION. MINIMUM RECOMMENDED OPERATOR AGE: This vehicle is sold for OFF-ROAD USE ONLY. Before operating this vehicle, read all the instructions for safe assembly and operation as well as the instructions governing the engine and other portions of the vehicle.
  • Page 2 IMPORTANT NOTICES IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle. AGE RECOMMENDATION The minimum recommended age for this ATV model is 16 Children under age 16 should never operate Vehicle.
  • Page 3 IMPORTANT NOTICES The saf ety alert symb ol m eans ATTENTION! Become alert your safety is involved. Indicates a strong possibility that WARNING serious injury or death may result if instructions are not followed. Indicates special precautions that must be take to avoid damage to the machine.
  • Page 4 IMPORTANT NOTICES PREFACE Congratulations on your purchase of this ATV. We take pride in a worldwide reputation for quality-in research, design, production and service. For replacement parts and accessories, we recommend genuine manufactory products. They've been specially designed for your vehicle and manufactured to meet manufactroy's demanding standards.

  • Page 5: Table Of Contents

    CONTENTS CONTENTS LOCATION OF THE WARNING ....AND SPECIFICATION LABELS ..... . SAFETY INFORMATION DESCRIPTION AND MACHINE IDENTIFICATION ..IDENTIFICATION NUMBER RECORDS ...
  • Page 6 CONTENTS ....ACCESSORY SOCKET SEAT 4 20 ....PRE-OPERATION CHECKS ....FRONT AND REAR BRAKES ........FUEL ....
  • Page 7 CONTENTS .... Loading and Operational Guidelines ......ACCESSORIES 7 10 ......MODIFICATIONS 7 11 ......No Modifications 7 12 ..
  • Page 8 CONTENTS FRONT BRAKE LEVER ....FREE PLAY ADJUSTMENT . 8 26 ADJUSTING THE REAR BRAKE LEVEL AND ......BRAKE PEDAL 8 27 .

  • Page 9: Location Of The Warning

    & WARNING SPECIFICATION LABELS LOCATION OF THE WARNING AND SPECIFICATION LABELS Warning information Anyone who rides the vehicle should read and under stand this information before riding. They contain im portant information for safe and proper operation of your ATV. The labels should be considered as permanent parts of the vehicle.
  • Page 10 & WARNING SPECIFICATION LABELS LOAD LIMIT Maximum Load Limit 45 Kg 100 lbs WARNING NEVER CARRIER PASSENGER ON THIS CARRIER LOAD LIMIT MAXIMUM LOAD LIMIT 90 Kg 198 lbs...
  • Page 11 & WARNING SPECIFICATION LABELS WARNING Exceeding vehicle towing limit could lead to an accident. Reduce speed when towing a trailer. Read owner's manual for details. MAXIMUM TOWING CAPACITY: 550kg (1212lbs) TONGUE WEIGHT: 15kg (33lbs) WARNING Improper ATV use can result in SEVERE INJURY or DEATH.
  • Page 12 & WARNING SPECIFICATION LABELS DRIVE SELECT LEVER Å Read Owner s Manual carefully before operating Å ATV must be stopped before shifting select lever Å Shifting info or from reverse or park is impossible without applying rear brake Å Before shifting, you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed.
  • Page 13 & WARNING SPECIFICATION LABELS WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. WARNING Operating this ATV if you are under the age of 16 increases your changes of severe injury or death.

  • Page 14: 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. An accident 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 15 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 16 SAFETY INFORMATION Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed.
  • Page 17 SAFETY INFORMATION 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. Never operate an ATV in fast flowing water or in water d e e p e r t h a n t h a t r e co m m e n d e d in t h is m a n u a l.
  • Page 18 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 19 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 machine in an area with adequate ventilation.

  • Page 20: Identification Number Records

    & DESCRIPTION MACHINE IDNTIFICATION DESCRIPTION AND MACHINE IDENTIFICATION Identification number records Record the key identification number, vehicle identifica tion number and model label information in the spaces provided for assistance when ordering spare parts from a LONGTING dealer or for reference in case the vehicle is stolen.
  • Page 21 & DESCRIPTION MACHINE IDNTIFICATION ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase. 1 ENGINE SERIAL NUMBER...

  • Page 22: Parts Location 3

    & DESCRIPTION MACHINE IDNTIFICATION PARTS LOCATIONS 1. Rear shock absorber spring preload adjusting ring 2. Spark arrester 3. Storage compartment and tod kit 4. Air filter case 5. Front brake fluid reservoir 6. Front shock absorber spring preload adjusting ring 7.
  • Page 23 & DESCRIPTION MACHINE IDNTIFICATION 10. Radiator cap 11. Drive select lever 12. Fuel tank cap 13. Fuel cock 14. Battery 15. Fuses 16. Engine oil dipstick 17. Recoil starter 18. Coolant reservoir 19. Drive select lever box check hose 20. V-belt cooling duct check hose 21.
  • Page 24 & DESCRIPTION MACHINE IDNTIFICATION NOTE The machine you have purchased may differ slightly from those shown In the figures of this manual.

  • Page 25: Control Functions

    CONTROL FUNCTION CONTROL FUNCTION IGNITION SWITCH Functions of the respective s w it c h p o s i t i o n s a r e a s follows: "OFF" position: The ignition circuits and headlight electrical circuits are switched off. The turning lights and beacon can come 1 Ignition Switch on at this position.
  • Page 26 CONTROL FUNCTION 1 Left turn light indicator 2. Low-range indicator light “L” 3. High-range indicator light “H” 4. Neutral indicator light “N” 5. Reverse indicator light “R” 6. Park indicator light “P” 7 Right turn light indicator 8 High Beam Indicator 9 Differential gear lock indicator light ( )/( ) 7 Turn Light Indicator...

  • Page 27: Instruments And Indicator

    CONTROL FUNCTION INSTRUMENTS AND INDICATORS 1 Four-wheel-drive indicator “ ”/“ ” Speedometer Indicator 3. Coolant temperature warning light 4.Hour meter 5. Odometer/Tripmeter 6. Fuel meter ." " SELECT Button " " 8. REST Button Four-wheel-drive indicator “ ”/“ ” This indicator comes on when the “2WD”/“4WD” switch is set to the “4WD”...
  • Page 28 CONTROL FUNCTION 4 .Hour meter " ." " ." A Push the buttons at the same time to set the display to the hour mode. B Set the hours by pushing the “SEL ” Button. " . " C Set the minutes by pushing the RES button "...

  • Page 29: Handlebar Switch

    CONTROL FUNCTION HANDLEBAR SWITCHES Light Switch 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 (1 Light Switch taillight. 2 Start Button Set the switch to “...

  • Page 30: Engine Stop Switch

    CONTROL FUNCTION If the starter switch is pushed with the ignition switch "ON" and the engine stop switch “ ”, the starter motor will be activated but the engine will not start. To start the engine, be sure to position the engine stop switch at “...

  • Page 31: Horn Button

    CONTROL FUNCTION Horn Button When the ignition switch is ON, push the horn button and it will sound. Turn Signal Switch Use the turn signal switch 5 Horn Button wh il e t u r n i n g t o a n o t h e r 4 Turn Signal Switch d i r e c t i o n o r s h i f t i n g t o another lane.

  • Page 32: On Command Four Wheel Drive And Differential

    CONTROL FUNCTION On-Command four-wheel drive and differential gear lock switches 1 On Command four wheel drive switch " "/" " 2 Differential gear lock switch “LOCK " /" " This ATV is equipped with an On-Command four-wheel drive switch “2WD”/“4WD” and a differential gear lock switch “LOCK”/“4WD”.
  • Page 33 CONTROL FUNCTION 4WD-LOCK, or vice-versa while moving may ca use une xpecte dly ha ndle differently. This could distract the operator and increase the risk of losing control and an accident. HOW TO AVOID THE HAZARD Always stop the ATV before changing from 2WD to 4WD or from 4WD to 4WD-LOCK, or vice-versa.
  • Page 34 CONTROL FUNCTION To lock the differential gear in 4WD, make sure the On- Command four-wheel-drive switch is set to “4WD”, stop the ATV, move the lever to position b , and then set the switch to “LOCK”. When the differential gear is locked, the differential gear lock indicator (“DIFF.LOCK”) light will come on along with the indicator “...

  • Page 35: Throttle Lever

    CONTROL FUNCTION ● Riding before the differential gear lock is properly engaged (e.g., when the indicator light is flashing) will cause the engine speed to be Limited until engagement is complete. Throttle lever 1. Lever Once the engine is running, movement of the throttle lever will increase the engine speed.

  • Page 36: Speed Limiter

    CONTROL FUNCTION POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident. HOW TO AVOID THE HAZARD Check the operation of the throttle lever before you start the engine.

  • Page 37: Brake Lever

    CONTROL FUNCTION rake lever 1. Brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. rake pedal 1. Brake pedal The brake pedal is located on the right side of the machine Push down the pedal to apply the rear brake.

  • Page 38: Drive Select Lever

    CONTROL FUNCTION Using the parking brake when you have to start the engine or park the machine, especially on a slope. Apple the parking brake lever and push down the lock plate to apply the parking brake. Squeeze the parking brake lever to release the parking brake.

  • Page 39: Recoil Starter

    CONTROL FUNCTION The drive select lever is used to shift your machine into the low, high, neutral, reverse positions. (Refer to page 6-4 for the drive select lever operation.) Recoil starter 1. Recoil starter The recoil starter is on the left side of the ATV. It is used to start the engine when the battery is low.

  • Page 40: Fuel Tank Cap

    CONTROL FUNCTION Fuel tank cap 1. Fuel tank cap R e m o v e t h e f u e l t a n k c a p b y t u r n i n g i t counterclockwise.

  • Page 41: Starter Choke

    CONTROL FUNCTION RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this position. THEN FILL THE FUEL TANK AT THE FIRST OPPORTUNITY. After refuelling, return the fuel cock lever to the “ON” position. RES Position Starter choke Starting a cold engine...

  • Page 42: Trailer Hitch

    CONTROL FUNCTION TRAILER HITCH The trailer hitch is located on the rear axle housing. To use the hitch, you will need proper size ball as specified by t he trailer manufacturer. To attach the ball and 1 Trailer Hitch properly hook up a trailer, follow the trailer manufacturer's instructions.

  • Page 43: Shock Absorber Adjustment

    CONTROL FUNCTION FRONT CARRIER Maximum Load Limit: 45 Kg (100lb) REAR CARRIER Maximum Load Limit: 90 Kg (198lb) SHOCK ABSORBER ADJUSTMENT The spring preload can be adjusted to suit the rider's weight and riding conditions. Adjust the spring preload as follows: Å...

  • Page 44: Accessory Socket Seat

    CONTROL FUNCTION POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident. HOW TO AVOID THE HAZARD Always adjust the shock absorbers on the left and right side to the same setting.

  • Page 45: Pre-Operation Checks

    PRE-OPERATION CHECKS PRE OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE Å Check operation, free play, fluid level and fluid leakage Å FRONT BRAKE Fill with DOT 4 brake fluid if necessary Å Check operation condition and free play REAR BRAKE Å...

  • Page 46: Front And Rear Brakes

    PRE-OPERATION CHECKS FRONT AND REAR BRAKES Brake Levers And Brake Pedal Check for correct free play in the front brake lever. If the free play is incorrect, have a LONGTING dealer adjust it. Check for correct free play in the brake lever and brake pedal.

  • Page 47: Fuel

    PRE-OPERATION CHECKS WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes.

  • Page 48: Gasohol

    PRE-OPERATION CHECKS NOTE Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. Your ATV S engine has been designed to use regular unleaded gasoline with a pump octane number of 86 or higher, or research octane number of 91 or higher.

  • Page 49: Engine Oil

    PRE-OPERATION CHECKS 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 over filled, fuel could spill out due to heat from the engine. HOW TO AVOID THE HAZARD Do not overfill the fuel tank.

  • Page 50: Final Gear Oil

    PRE-OPERATION CHECKS 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” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CON SERVING II”...

  • Page 51: Fittings And Fasteners

    PRE-OPERATION CHECKS FITTINGS AND FASTENERS Always check the tightness of chassis fittings and fasten ers before a ride. Take the machine to a LONGTING dealer or refer to the Service Manual for correct tightening tor que. LIGHTS Check the headlight and tail/brake light to make sure they are in working condition.
  • Page 52 PRE-OPERATION CHECKS Chongqing Longting Power Equipment Co this model. Other tire combinations are not recom mended. SIZE TYPE Front Tubeless 25X8 12 Rear 25X10 12 Tubeless 2.The tires should be set to the recommended pressure: Recommended tire pressure : FRONT 32 35 kpa, (0.

  • Page 53: How To Measure Tire Pressure

    PRE-OPERATION CHECKS HOW TO MEASURE TIRE PRESURE NOTE Use the low-pressure tire gauge. (Tool kit) The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.

  • Page 54: Operation

    OPERATION OPERATION WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD Read the Owner's Manual carefully. If there is a control or function you do not understand, ask your LONTING dealer.
  • Page 55 OPERATION 1. Set the parking brake. 2. Turn the fuel lock to "ON". 3. Turn the main switch to "ON" position and the engine " " stop switch to " RUN" 4. Shift the transmission into neutral. NOTE Å When te transmission is in neutral, the neutral indicator light should come on.

  • Page 56: Using The Recoil Strater

    OPERATION NOTE Å If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt.

  • Page 57: Starting A Warm Engine

    OPERATION To start the engine without the electric starter 1. Follow steps 1 through 5. 2 . W i t h t h e t h r o t t l e c l o s e d t u r n in g s t a r t e r g r i p counterclockwise to unlock and grasp the starter grip firmly, then pull it out slowly until it seats lightly.
  • Page 58 OPERATION NOTE Before shifting, you must stop the ATV and return the throttle lever to the closed position, otherwise the transmission may be damaged. 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2.

  • Page 59: Engine Brake In

    OPERATION WARNING POTENTIAL HAZARD Improperly operating in revere. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

  • Page 60: Parking

    OPERATION 1. 0~10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation. Vary the speed of the machine from time to time. Do not operate it at full throttle position. 2.
  • Page 61 OPERATION PARKING ON A SLOPE WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines. If you must park on an incline, place the machine transversely across the incline, put the ATV in low gear apply the...

  • Page 62: Accessories - Loading

    OPERATION ACCESSORIES Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. Å Choose only accessories designed for your ATV. Your LONGTING dealer has a variety of genuine LONGTING accessories.
  • Page 63 OPERATION ÅNever exceed the weight limit shown. An overloaded ATV can be unstable. Å Maixmum Loading Limit Å Vehicle loading limit (total weight of cargo, rider and accessories, and tongue weight): 220 Kg (485 lb) Å Front Carrier: 45 Kg (100 lb) Å...
  • Page 64 OPERATION OPERATION ÅAvoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. 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.

  • Page 65: Riding Your Atv

    RIDING YOUR ATV RIDING YOUR ATV...

  • Page 66: Getting To Know Your Atv

    RIDING YOUR ATV WARNING Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is mainly for utility use, but may aslo be used for recreation. This section, riding your ATV, provides general ATV riding instructions for recreational riding.
  • Page 67 RIDING YOUR ATV WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN This risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

  • Page 68: Apparel

    RIDING YOUR ATV Continued H O W A V O I D T H E HAZARD A child under 16 should never operate an ATV with engine size greater than 90cc. APPAREL WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved motorcycle helmet, eye protection and protective clothing.
  • Page 69 RIDING YOUR ATV Continued Operating without protective clothing increases your chances of severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly. You should also wear: eye protection(goggles or face shield) gloves boots long-sleeved shirt or jacket...

  • Page 70: Pre-Operation Checks

    RIDING YOUR ATV This machine is designed to carry operator and cargo only -passengers prohibited. WARNING This is just for basic style not for EC style POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV.
  • Page 71 RIDING YOUR ATV WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect to your ATV each time you use it to make sure the ATV is in safe operating condition.

  • Page 72: Speed Limiter

    RIDING YOUR ATV Do not operate at speeds too fast for your skills or the conditions. WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident.

  • Page 73: Loading And Accessories

    RIDING YOUR ATV LOADING AND ACCESSORIES Load Limits There are limits to how much weight can be carried on your ATV. NOTE: The following weight limits apply to standard equipment only. Modifying your ATV, using nonstandard equipment or riding on terrain that is not flat and smooth could further reduce these limits.

  • Page 74: Accessories

    RIDING YOUR ATV 1. Never ride with a passenger. 2. Do not tow another vehicle. 3. Make sure all cargo is secured before riding. 4. Allow extra room for starting, stopping and turning whenever you carry cargo or pull a trailer. 5.

  • Page 75: Modifications

    RIDING YOUR ATV Always follow the loading instructions above, plus the following: 1. Carefully inspect the accessory to make sure it does not block any lights, reduce ground clearance, or limit suspension travel, steering travel, or other controls. 2. Make sure the accessory does not interfere with your ability to shift body position on the seat or operate hand and foot controls.

  • Page 76: No Modifications

    RIDING YOUR ATV No Modifications Modifying this ATV or removing original equipment may render the vehicle unsafe or illegal. Spark arresters and mufflers are required in most areas. Don't modify your exhaust system or emission control system components. Remember, excessive noise bothers everyone and creates a bad image for off-road vehicles.
  • Page 77 RIDING YOUR ATV BE CAREFUL WHERE YOU RIDE This machine is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATV are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 78 RIDING YOUR ATV Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. 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 a dirt or gravel one.
  • Page 79 RIDING YOUR ATV 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 machine to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 80 RIDING YOUR ATV WARNING POTENTIAL HAZARD F a i lu r e t o u s e e x t r a c a r e w h e n o p e r a t i n g o n excessively rough, slippery or loose terrain.

  • Page 81: For Off-Road Use Only

    RIDING YOUR ATV Whe n riding in an a re a where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other...
  • Page 82 RIDING YOUR ATV Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, shifting procedure and turning techniques in this areas before trying more difficult terrain.

  • Page 83: During Operation

    RIDING YOUR ATV Do not shift gears without releasing the throttle. Damage to the engine or drive train may occur. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down, shift to a lower gear. Ensure that the engine has sufficiently slowed before engaging a lower gear.
  • Page 84 RIDING YOUR ATV WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
  • Page 85 RIDING YOUR ATV Avoid wheelies and jumping. You may lose control of the ATV or overturn. 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.

  • Page 86: Turning Your Atv

    RIDING YOUR ATV TURNING YOUR ATV To achieve maximum traction while riding off road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning.
  • Page 87 RIDING YOUR ATV This procedure should be practiced at slow speed many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV may continue to go straight. If the ATV doesn't turn, come to a stop and then practice the procedure again.

  • Page 88: Sliding And Skidding

    RIDING YOUR ATV Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident.
  • Page 89 RIDING YOUR ATV With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that slidin g mane uve rs sh ould always b e avo ide d on extremely slippery surfaces such as ice, since all control may be lost.

  • Page 90: Climbing Uphill

    RIDING YOUR ATV CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill.
  • Page 91 RIDING YOUR ATV WHAT CAN HAPPEN Could cause loss of control or cause the ATV to over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill.
  • Page 92 RIDING YOUR ATV If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill.
  • Page 93 RIDING YOUR ATV If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side.
  • Page 94 RIDING YOUR ATV Turn the ATV around and remount, following the procedure described in the Owner's Manual. If the hill is not too steep and you have good footing, you may be able to walk the ATV back down the hill. Make sure your intended path is clear in case you lose control of the ATV .
  • Page 95 RIDING YOUR ATV 7 31...

  • Page 96: Riding Downhill

    RIDING YOUR ATV RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight choose a low gear which will allow the engine compression to do most of the braking for you.

  • Page 97: Crossing A Slope

    RIDING YOUR ATV Avoid going down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance.
  • Page 98 RIDING YOUR ATV If your ATV does begin to tip over, gradually steer in the downhill direction if there are no obstacles in your path. As you regain proper balance, gradually steer again in the direction you wish to travel. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills.

  • Page 99: Riding Over Rough Terrain

    RIDING YOUR ATV 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. Be sure to keep your feet firmly mounted on the footboards at all time. Avoid jumping the ATV as loss of control and damage to the ATV may result.
  • Page 100 RIDING YOUR ATV 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 Owner's Manual.

  • Page 101: Parking

    RIDING YOUR ATV Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. After riding your ATV in water, be sure to drain the trappd water by removing the check hose at the bottom of the air filter case.

  • Page 102: What To Do If

    RIDING YOUR ATV WHAT TO DO IF This section is designed to be a reference guide only. Be su r e t o r e a d ea c h s ec tio n o n r id in g t e c h n i q u e s completely.
  • Page 103 RIDING YOUR ATV If you discover that the ATV is going to tip over, dismount on the uphill side. If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles. Be sure to let water drain from the ATV a n d CHECK YO U R B RAKE S F OR P ROPE R OPERATION when you come out of the water.

  • Page 104: Periodic Maintenance And Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENT PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrication will you're your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjust- ment and lubrication are explained on the following pages.
  • Page 105 PERIODIC MAINTENANCE AND ADJUSTMENT The tools in the kit are sufficient to perform routine maintenance and simple repairs. Any extensive work requiring additional tools should be performed by your authorized dealer. The tool kit includes the following items: (1) Air pressure gauge (2) Spark plug wrench (3) 13/15 mm wrench (4) Standard/Phillips screwdriver...
  • Page 106 PERIODIC MAINTENANCE AND ADJUSTMENT The service information included in this manual is intended to provide you, the owner, with the necessary i n f o r m a t i o n f o r c o m p l e t i n g y o u r o w n p r e v e n t i v e maintenance and minor repairs.

  • Page 107: Periodic Maintenance/Lubrication

    PERIODIC MAINTENANCE AND ADJUSTMENT PERIODIC MAINTENANCE/LUBRICATION...
  • Page 108 PERIODIC MAINTENANCE AND ADJUSTMENT...

  • Page 109: Panel Removal And Installation

    PRE-OPERATION CHECKS PANEL REMOVAL AND INSTALLATION The panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a panel has to be removed or reinstalled. 1 Panel A 2 Panel B 3 Panel C 1 Panel D...
  • Page 110 PRE-OPERATION CHECKS ENGINE OIL Engine Oil Level Measurement 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. To remove Panel F pull outward on the area as shown 2.
  • Page 111 NOTE The engine oil should be between the minimum and maximum level marks. 7. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 8.
  • Page 112 PERIODIC MAINTENANCE AND ADJUSTMENT 5. Remove panels D and E. 6. Remove the oil filter cartridge with an oil filter wrench. 7. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. 1 Engine oil filter cartridge 1 O Ring 8.

  • Page 113: Final Gear Oil

    PERIODIC MAINTENANCE AND ADJUSTMENT ● 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” or oils of a higher quality than specified.
  • Page 114 PERIODIC MAINTENANCE AND ADJUSTMENT 1. Final gear oil filler bolt 1. Final gear oil drain 4. Install the drain bolt and tighten it to the specified torque. 5. Fill the final gear case with the specified amount of the recommended oil. 6.

  • Page 115: Differential Gear Oil

    PERIODIC MAINTENANCE AND ADJUSTMENT Differential gear oil Differential gear oil measurement 1. Place the ATV on a level surface. 2. Remove the differential gear oil filler bolt and check the oil level. It should be up to the brim of the filler hole. If the level is low, add sufficient oil of the recommended type to raise it to the specified level.
  • Page 116 PERIODIC MAINTENANCE AND ADJUSTMENT 1. Differential gear oil drain bolt 4. Install the differential gear oil drain bolt and tighten it to the specified torque. 5. Fill the differential gear case with the recommended oil. Tightening torque: Differential gear oil drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Be sure no foreign material enters the differential gear case.

  • Page 117: Cooling System

    PERIODIC MAINTENANCE AND ADJUSTMENT Cooling system 1. Place the ATV on a level surface. 2. Check the coolant level in the coolant 1 Fanel H 1 Maximum levelmark 2 Minimum levelmark 3. If the coolant is at or below the minimum level mark, remove panel H remove the reservoir cap, add coolant to the maximum level mark, install the reservoir cap, and then install the panel.

  • Page 118: Spark Plug Inspection

    PERIODIC MAINTENANCE AND ADJUSTMENT SPARK PLUG INSPECTION The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder.

  • Page 119: Air Filter Cleaning

    PERIODIC MAINTENANCE AND ADJUSTMENT When installing the spark plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten to the specified torque. Tightening torque: Spark plug: 17.2 Nm (1.72 m.kg, 13 ft.lb) AIR FILTER CLEANING To Clean The Air Cleaner The air cleaner accumulates dust and must be cleaned...
  • Page 120 PERIODIC MAINTENANCE AND ADJUSTMENT 3. Pull the air filter element out 4. Remove the foam cover from the air filter element.. 1 Air Filter Element 2 Foam Cover 5. Tap the element lightly to remove most of the dust and dirt.
  • Page 121 PERIODIC MAINTENANCE AND ADJUSTMENT Do not twist the foam cover when squeezing it. Do not apply oil to the foam cover. Inspect the foam cover, if damage, replace it. Install the foam cover onto the air filter element. 10. Install the air filter element. 11.

  • Page 122: Air Cleaner Housing Drain Tube

    PERIODIC MAINTENANCE AND ADJUSTMENT AIR CLEANER HOUSING DRAIN TUBE The air cleaner housing drain tube should be serviced in accordance with the Maintenance Schedule. (Riding through water may require more frequent inspection.) If deposits can be seen in the drain tube, the tube must be cleaned before starting the vehicle.

  • Page 123: Idle Speed Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENT IDLE SPEED ADJUSTMENT NOTE A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.

  • Page 124: Throttle Lever Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENT THROTTLE LEVER ADJUSTMENT NOTE Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play Is 3 5 mm (0.12 0.20 in). 3.

  • Page 125: Front Brake Pad Check

    PERIODIC MAINTENANCE AND ADJUSTMENT FRONT BRAKE PAD CHECK Check the brake pads for damage and wear. If a brake pad thickness is less than 1mm(0.04 in), have a LONGTING dealer replace the pads as a set. 1. Brake pad a. Brake pad thickness Checking the rear brake pads Check the brake pads for damage and wear.

  • Page 126: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE AND ADJUSTMENT Checking the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level and replenish when necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage.
  • Page 127 PERIODIC MAINTENANCE AND ADJUSTMENT Observe these precautions: Å When checking the brake fluid level, make sure the top of the brake fluid reservoir is level. Å Use only the designated quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor brake performance.

  • Page 128: Brake Fluid Replacement

    PERIODIC MAINTENANCE AND ADJUSTMENT BRAKE FLUID REPLACEMENT Complete fluid replacement should be done only by trained our service personal. Have a our dealer replace the following components during periodic maintenance or when they are damaged or leaking. Å Replace the oil seal every two years. Å...

  • Page 129: Front Brake Lever Free Play Adjustment

    PERIODIC MAINTENANCE AND ADJUSTMENT FRONT BRAKE LEVER FREE PLAY ADJUSTMENT The front brake lever should have a free play of zero mm (zero in) at the lever end. If not, have a our dealer check the brake system. a. Front brake lever free play WARNING POTENTIAL HAZARD Operating with improperly serviced or...

  • Page 130: Adjusting The Rear Brake Level And Brake Pedal

    PERIODIC MAINTENANCE AND ADJUSTMENT Adjusting the rear brake lever and brake pedal Adjusting the rear brake lever The rear brake lever free play should be 0.5 2mm(0.02 0.08 in). 1. Loosen the locknut 2. Turn the adjusting bolt in direction a to increase free Play, and in direction b to decrease free play.
  • Page 131 PERIODIC MAINTENANCE AND ADJUSTMENT Adjusting the brake pedal The top of the brake pedal should be positioned 72 mm (2 8 in) above the top of the footrest. If not, ask our dealer to adjust It. a. Distance between brake pedal and footrest WARNING POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes.

  • Page 132: Adjusting The Rear Brake Light Switch

    PERIODIC MAINTENANCE AND ADJUSTMENT Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal and rear brake lever, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows.

  • Page 133: Cable Inspection And Lubrication

    PERIODIC MAINTENANCE AND ADJUSTMENT CABLE INSPECTION AND LUBRICATION WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury.

  • Page 134: Wheel Installation

    PERIODIC MAINTENANCE AND ADJUSTMENT 1 Wheel Nuts WHEEL INSTALLATION 1. Install the wheel and the nuts. NOTE Tapered nuts are used for both the front and rear wheels. Install the nut with its tapered side towards the wheel. The arrow mark on the tire must point toward the rotating direction of the wheel.

  • Page 135: Battery . 8

    PERIODIC MAINTENANCE AND ADJUSTMENT Lower the ATV so that the wheel is on the ground. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m-kg, 40 ft-lb) Rear: 55 Nm (5.5 m-kg, 40 ft-lb) WARNING POTENTIAL HAZARD Installing wheels improperly.

  • Page 136: Accessories 6

    PERIODIC MAINTENANCE AND ADJUSTMENT Do not attempt to remove the caps from the battery cells as this may damage the battery. Although the battery is sealed, it vents explosive gases and should be handled with appropriate care. WARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery.

  • Page 137: Battery Installation

    PERIODIC MAINTENANCE AND ADJUSTMENT Battery Removal 1. Make sure the ignition switch is OFF. 2. Remove the seat ( ) (+) 1 Battery Terminal Lead ( ) (-) Terminal Lead 3. Disconnect the negative (-) terminal lead (3) from the battery first, then disconnect the positive (+) terminal lead (2).
  • Page 138 PERIODIC MAINTENANCE AND ADJUSTMENT To replace a fuse: 1. Make sure the ignition switch is OFF. To prevent accidental short-circuiting, turn off the main switch when checking or replacing a fuse. Main Fuse 1 m ain Fuse Box Cap 1 Specified Fuse Box Cap 1 Auxiliary DC jack fuse Four-wheel drive fuse 3 Headlight fuse...
  • Page 139 PERIODIC MAINTENANCE AND ADJUSTMENT Specified fuses: Main fuse Auxiliary DC jack fuse Four-wheel drive fuse Headlight fuse: Ignition fuse: Backup fuse: Spare fuse Spare fuse WARNING POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire.
  • Page 140 PERIODIC MAINTENANCE AND ADJUSTMENT REPLACING A HEADLIGHT BULB If a headlight bulb burns out, replace the bulb as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 2. Turn the bulb holder counterclockwise to remove the defective bulb.

  • Page 141: Tail Brake Light Bulb Replacement

    PERIODIC MAINTENANCE AND ADJUSTMENT WARNING POTENTIAL HAZARD The 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 bulbtouches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it.

  • Page 142: Spark Arrester Cleaning

    PERIODIC MAINTENANCE AND ADJUSTMENT SPARK ARRESTER CLEANING Select a well-ventilated area free of combustible mater ials and make sure the exhaust pipe and muffler are cool. 1. Remove the bolts. Remove the tailpipe by pulling it out of the muffler 3.

  • Page 143: Troubleshooting

    PERIODIC MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING Although our machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a skilled technicians at a our dealership have the tools, experience, and know-how to properly service your machine.
  • Page 144 PERIODIC MAINTENANCE AND ADJUSTMENT 8 41...

  • Page 145: Cleaning And Storage

    CLEANING STORAGE CLEANING AND STORAGE CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general per formance and extend the useful life of many components. 1. Before cleaning the machine: A. Block off the end of the exhaust pipe to prevent water entry.

  • Page 146: Engine Oil 8

    CLEANING STORAGE 7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner- waxes. Many contain abrasives which may mar the paint or protective finish.
  • Page 147 CLEANING STORAGE WARNING POTENTIAL HAZARD Refueling this ATV or handling fuel improperly. WHAT CAN HAPPEN The fuel could explode or ignite. HOW TO AVOID THE HAZARD Always refuel this ATV and handle fuel in a well- ventilated area with the engine off.Do not smoke or allow flames or sparks in the area where fuel is handled.
  • Page 148 CLEANING STORAGE 3. Remove the spark plug and pour one tablespoon (15 - 20 cc)of clean engine oil into the cylinder. Operate the starter for a few seconds to distribute the oil, then reinstall the spark plug, (Make sure the engine stop switch is OFF ( ) before pressing the starter button.) 4.

  • Page 149: Specifications

    SPCIFICATIONS SPECIFICATIONS Model ATV500 Dimension: 2085mm Overall Length 1200mm Overall Width 1274mm Overall Height 877mm Seat Height 1285mm Wheel Base 280mm Minimum Ground Clearance 3000mm Minimum turning radius Basic Weight 348 KG With oil and full fuel tank Engine: Liquid cooled 4 stroke SOHC Type Cylinder arrangement...
  • Page 150 SPCIFICATIONS Model ATV 500 Carburetor Vacuum Film Piece Type Type Spark plug Type manufacturer DPR7EA 9 NGK . - . Spark plug gap 0 8 0 9mm 0 031 0 035in Transmission: V belt Primary reduction system Shaft drive Secondary reduction system V belt automatic Transmission type Left hand operation...
  • Page 151 SPCIFICATIONS Model ATV 500 Brake Dual Disc Brake Front Brake Type Right Hand Operation Single Disc Brake Rear Brake Type & Left Hand Right Foot Operation Suspension Front Double wishbone Rear Double wishbone Shock Absorber Front Spring Oil Damper Rear Spring Oil Damper Wheel Travel Front...
  • Page 152 NOISE REGULATION NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHI BITED: Some local laws and regulations prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of...

  • Page 153: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.
  • Page 154 ELECTRIC WIRING DIAGRAM ELECTRIC WIRING DIAGRAM 13 1...
  • Page 155 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER NEVER NEVER USE USE ON CARRY WITH APPROVED PUBLIC PASSENGER DRUGS OR HELMET ROADS ORALCOHOL PROTECTIVE GEAR NEVER operate : Without proper training or instruction. At speeds too fast for your skills or the conditions. On public roads-a collision can occur with another vehicle.
  • Page 156 LX 500ATV USER S MANUAL 1st Edition, September 2007...

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