Page 2 INTRODUCTION Congratulations on your purchase of the 800ATV. It represents the result of many years of experience in the production of fine sporting, touring, and pace-setting racing machines. With the purchase of this, you can now appreciate the high degree of craftsmanship and reliability. This 800ATV adopts the EFI system, enjoying the advantages of more power, less emission, higher reliability.
Page 3 IMPORTANT SAFETY INSTRUCTIONS: READ THIS MANUAL TOGETHER WITH TIPS CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS. PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV. NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.
Page 4 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: 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 IMPORTANT NOTICE The turning speed of this ATV should not exceed 25km/h. This ATV is designed and manufactured 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
CONTENTS Fault code indicator …………………4-6 LOCATION OF THE WARNING AND SPECIFICATION LABELS…………1-1 Fuel meter……………………………4-7 Left handlebar switches……………4-7 SAFETY INFORMATION……………2-1 Throttle lever ........4-13 Speed limiter…………………………4-14 DESCRIPTION AND MACHINE Front brake lever……………………4-15 rear brake pedal ……………………4-16 IDENTIFICATION…………………3-1 Identification number records………3-2 Fuel tank cap………………………4-17 Seat …………………………………4-18 Vehicle identification number………3-2 EC signs ……………………………3-3...
Page 7 PRE-OPERATION CHECKS ………5-1 Starting a warm engine………………6-2 Warming up …………………………6-2 Brake System…………………………5-3 Fuel …………………………………5-4 Engine’s turning off…………………6-2 Gasohol ………………………………5-5 Recommended procedure of turning off Engine oil…………………………… 5-6 the engine……………………………6-2 Differential gear oil ………………… 5-7 Neutral to Reverse……………………6-4 Coolant………………………………5-7 Braking………………………………6-6 Throttle lever …………………………5-9 Parking braking………………………6-7 Fittings and fasteners………………5-9 Parking on a slope……………………6-8...
Page 8 Apparel………………………………7-4 PERIODIC MAINTENANCE AND ADJUSTMENT ………………8-1 Pre-operation checks………………7-6 Speed limiter…………………………7-6 Owner’s manual and tool kit…………8-1 Loading and accessories……………7-7 Periodic maintenance chart for the During operation……………………7-8 emission control system……………8-3 No Attempting to modify your General maintenance and lubrication ATV……………………………………7-9 chart……………………………………8-4 Modifications……………………….7-10 EFI System……………………………8-5 Exhaust system ……………………7-10 EFI system examination……………8-8...
Page 9 Axle boots……………………………8-19 Lubricating the park lever and brake Spark plug inspection………………8-20 pedal…………………………………8-32 Spark plug inspection………………8-20 Rear knuckle upper and lower pivot Installation……………………………8-21 lubrication……………………………8-34 Air filter element cleaning…………8-22 Wheel removal………………………8-34 Spark arrester cleaning……………8-24 Wheel installation…………………8-35 V-belt cooling duct check hose……8-26 Battery………………………………8-36 V-belt cooling duct check hose……8-26 Battery maintenance………………8-37 Valve clearance adjustment…8-26...
Page 10 SPECIFICATIONS…………………10-1 EFI system fault code……………11-1...
Page 11: Location Of The Warning And Specification Labels
LOCATION OF THE WARNING AND SPECIFICATION LABELS...
Page 12 Read and understand all of the labels on 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 dealer.
Page 13 ⑤ ④...
Page 15: Safety Information
SAFETY INFORMATION ATV is a special vehicle, which is different from other vehicles as 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. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described.
Page 16 Never take alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts.
Page 17 or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed. Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start to go down any hill. Shift your weight backward.
Page 18 Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely 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 19 WARNING eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. Improper handling of gasoline may cause fire If gasoline spills on your clothing, change and you could be burned. your clothes. Remember: Always turn off the engine when refueling.
Page 20 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 good ventilation.
Page 21: Description And Machine Identification
DESCRIPTION AND MACHINE IDENTIFICATION...
Page 22: Identification Number Records
2. MODEL LABEL INFORMATION: NOTE: ○ The machine you have purchased may ● differ slightly from those shown in the figures of this manual. Vehicle identification number vehicle identification number Identification number records stamped into the frame. Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from...
Page 23: Model Label
NOTE: The vehicle identification number is used to identify your machine. Model label The model label is affixed to the location in the illustration. Record the information on this label in the space provided. This information will be needed to order spare parts from your dealer.
Page 24: Control Functions
CONTROL FUNCTIONS Main switch The engine can be started only in this position Switch’s functions in respective position are and the headlights and taillight come on when as follows: the light switch is on. OFF: All electrical circuits are switched off. The key can be removed in this position.
Page 25: Indicator And Warning Lights
Low-scope indicator “L” Indicator and Warning Lights This indicator light comes on when the drive select lever is in the “L” position. High-scope indicator “H” This indicator light comes on when the drive select lever is in the “H” position. Differential gear lock indicator “DIFF-LOCK”...
Page 26 comparatively high speed, adjust Neutral indicator“N” This indicator comes on when the drive “2WD/UNLOCK” switch to have the indicator select lever is in the “N” position. flash. Riding an ATV while the differential comp is working, may improve the stability and bring Reverse indicator“R”...
Page 27 Four-wheel drive indicator “ ”/ “ ” This indicator comes on when the “2WD”/ The engine may overheat if the ATV is “4WD” switch is set to the “4WD” position. overloaded. If this happens, reduce the load to specification. Coolant temperature warning indicator After restarting, make sure that the light is “...
Page 28: Speedometer Unit
Emergency indicator “ ” A speedometer unit owns: When press on the emergency switch, this a speedometer (which shows the speed) indicator is lighted up. an odometer (which shows the total distance covered) Speedometer Unit a distance table(which could clear the records, and record any new distances) rotate speed indicator (which shows the rotate speed of the engine)
Page 29: Clock Mode
“TRIP/ODO” button, and then press the Fault code indicator “TRIP/ODO” button for at least three seconds. When the EFI encounters faults, ECU will The trip meter can be used to estimate the send the fault code to the speedometer, which distance that can be traveled with a full tank of will flash on the clock.
Page 30: Fuel Meter
Fuel meter Left handlebar switches The fuel meter will indicate the fuel volume. As the fuel is running out, the indicator will flash. 1. Light switch “ / OFF/ 2. Start switch “ ” 3. Turning light switch 4. Engine stop switch “ ”...
Page 31 beam. NOTE: Set the switch to “OFF” to turn off all the See starting instructions prior to starting the lights. engine. (See P6-1—6-2) Set the switch to“ ” to turn on the little lights in the headlights and the taillights. Turning light switch Setting the switch, the turning light would NOTE:...
Page 32 this ATV. The front bridge differential comp Horn button Press this button. The horn will work. has no lock, but can automatically avoid rotating. Emergency light button Rear bridge differential comp can be locked, Press this button. The four turning lights will which can provide ATV better performance in spark continuously.
Page 33 “2WD/UNLOCK”switch “2WD/ UNLOCK”switch To control the lock of the rear bridge differential comp when the ATV is in the two-wheel drive condition. In the four-wheel drive condition, the system could not be unlocked. 1. “2WD/ “UNLOCK” switch “2WD/4WD”switch 2. Handlebar When ATV is in operation, you are not allowed to press the 2WD/4WD switch and “2WD/ UNLOCK”switch.
Page 34 2WD: UNLOCK The engine only provides power to the rear When the driving system selects “2WD”, the wheels. When the rear bridge differential engine only provide power to the rear wheels. comp is locked, the “DIFF.LOCK” will be And the rear differential comp is unlocked. lighted up.
Page 35 HOW TO AVOID THE HAZARD When 4WD is selected, the ATV goes to Always stop the ATV before changing from 4-wheel driving system. 2WD to 4WD or from 4WD to 4WD-LOCK, or When ATV adopts 4WD, the speedometer vice-versa. would indicate “ ”.
Page 36: Throttle Lever
work. “DIFF.LOCK” will spark “2WD/UNLOCK” selection continuously. Conversely, you can lock the rear bridge differential comp. WARNING POTENTIAL HAZARD When drive too fast with DIFF.LOCK. WHAT CAN HAPPEN Four wheels will move at the same speed. It is hard to make turns. And the ATV is easy to 1.
Page 37: Speed Limiter
and the engine will return to idle condition at when needed, which could cause an accident. HOW TO AVOID THE HAZARD any time the hand is removed from the throttle lever. Check the throttle lever before you starting the engine. If it does not work smoothly, check it.
Page 38: Front Brake Lever
12 mm (0.47 in). Always make sure that the throttle lever free play is adjusted to 3-5 mm (0.12-0.20 in). See page 8-27. Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to 1.
Page 39: Rear Brake Pedal
would stop the ATV. Tightly hold the bar. The Rear brake pedal The brake pedal is located on the right side of clip on the bar would get the bar stuck. The the ATV. Push down on the pedal would stop ATV could be stopped.
Page 40: Fuel Tank Cap
Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. 1. Drive select lever ．fuel tank cap 4-17...
Page 41: Seat
SEAT To remove the seat, pull the seat lock lever upward and pull up the rear part of the seat. 1. Seat holder（×2） 2. Projection（×2） Storage box 1. Seat 2. Seat lock lever The storage box is under the seat. If the manuals or other documents need to be stored in the box, make sure they are To install the seat, insert the projections on...
Page 42: Front And Rear Carrier
1. Storage box 1. Front Carrier Front & Rear Carrier Maximum load limit of front carrier: 25kg Maximum load limit of rear carrier: 30kg 1. Rear Carrier NOTE: Goods must be tied securely and placed in the middle of the carrier. Otherwise, it will 4-19...
Page 43: Front/Rear Shock Absorber Adjustment
cause imbalance, and effect driver's control of road, adjusting the shock absorber to be a the ATV. little hard. On off-road, adjusting the shock absorber to Front/rear shock absorber adjustment be a little hard. The spring preload can be adjusted to suit At full load, adjusting the shock absorber to be rider’s weight and tiding concisions.
Page 44: Auxiliary Dc Jack
Adjust the spring as follows: B- Standard position To increase the spring preload, tom the A- Minimum (soft) adjusting ring in direction (a). E- Maximum (hard) To decrease the spring preload, lure the adjusting ring in direction (b). 1. Special wrench Auxiliary DC jack The auxiliary DC jack is located at the front 1.
Page 45 DC, which can work for 1 hour. jack. The auxiliary DC jack should only be used 4. When the auxiliary DC jack is not being when the engine is running. used, cover it with the cap. 1. Auxiliary DC jack 1.
Page 46: Steering Lock
Steering Lock This vehicle is equipped with steering lock, Do not use accessories requiring move which can guard against theft while parking. than the above maximum capacity. This may overload the circuit and cause the fuse to blow. If accessories are used without the engine running or with the headlights turned on, the battery will lose its charge and engine starting may become difficult.
Page 47: 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. P5-4, P5-5 Brakes Fill with DOT 4 brake fluid if necessary. P8-38, P8-39 Check whether the brake disc plate and the brake pads are worn beyond limits. Parking Brake Check the parking brake functions normal or not.
Page 48 Fittings and fasteners Check all fittings and fasteners. P5-10 Lights and switches Check for proper operation. P5-10 Axle boots Check for damage. P8-19 Meter Check and be sure all the instruments indicate normally. Warning Lights Checking and be sure all the warning lights function normally on meter. EFI System Check the EFI fault code on meter;...
Page 49: Brake System
Brake System Disc Brake Plate Brake levers and brake pedal Checking the disc brake plates’ torn, it should Check that whether there is a free travel in be within the limit. (See page p8-28) the front brake lever or not, if not, adjust it. Check that whether there is a free travel in Brake fluid level the brake pedal or not, if not, adjust it.
Page 50: Fuel
Brake operation Fuel Test the brakes at slow speed after starting Make sure there is sufficient gasoline in the out to make sure they are working properly. If tank. the brakes do not provide proper braking Recommended fuel: performance, inspect the brake pads for wear. UNLEADED GASOLINE ONLY (See page p6-6.) Fuel tank capacity:...
Page 51: Gasohol
Your engine has been designed to use regular unleaded gasoline with a pump 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 brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
Page 52: Engine Oil
WARNING Engine oil Make sure the engine oil is at the specified POTENTIAL HAZARD level. Add oil as necessary. (See page 8-8— Improper care when refueling. 8-13.) WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up.
Page 53: Differential Gear Oil
Coolant Recommended engine oil type and Use the specialized antifreeze engine quantity: coolant. See page 10-2 Check the coolant level in the coolant reservoir when the engine is cold. (The Differential gear oil coolant level will vary with engine Make sure the differential gear oil is at the temperature.) coolant level...
Page 54 WARNING POTENTIAL HAZARD Hard water or salt water is harmful to the Removing the radiator cap when the engine engine. You may use soft water if you can not and radiator are still hot. distilled water. However, find WHAT CAN HAPPEN antifreeze coolant to replace the soft water in You could be burned by hot fluid and steam the shortest time.
Page 55: Throttle Lever
Throttle lever Idling Check to see that the throttle lever operates High idle speed will cause the engine gear correctly. It must open smoothly and spring damage. High idle speed may be caused by back to the idle position when released. the damage of throttle cable, or may be due Have a dealer repair as necessary for proper to the ECU failure.
Page 56: Tire
Tire Front 69kPa (0.70kgf/cm , 10 psi) WARNING Rear 69kPa (0.70kgf/cm , 10 psi) Check and adjust tire pressures when the POTENTIAL HAZARD tires are cold. Operating this ATV with improper tires, or Tire pressures must be equal on both sides. with improper or uneven tire pressure.
Page 57: How To Measure Tire Pressure
Before delivering to dealers from factory, the NOTE: ATV is equipped with off-road tires, which The low-pressure tire gauge is included as maximum speed for the use of “J” class. standard equipment. Make Always control the speed within 100km/h. measurements of the tire pressure and use the second reading.
Page 58: Tire Wear Limit
Tire wear limit When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. a. Tire wear limit 5-12...
Page 59: Operation
OPERATION Starting a cold engine WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating ATV without being familiar with all Freezing control cables in cold weather. WHAT CAN HAPPEN controls. WHAT CAN HAPPEN You could be unable to control the ATV, which Loss of control, which could cause an could lead to an accident or collision.
Page 60: Starting A Warm Engine
NOTE: Warming up To get maximum engine life, always warm When the gear shift is in Neutral (N), check up the engine before starting off. the “N” light on meter is lighted or not. If not, Never accelerate hard with a cold engine! please check the circuit of ATV.
Page 61 3. Wait for 3 minutes to let the fan Shifting: continues working; Neutral to High and High to Low 1. Bring the ATV to a complete stop and 4. Turn the main switch/key to “OFF”. return the throttle lever to the closed position.
Page 62: Neutral To Reverse
return the throttle lever to the idling position. Waiting for the engine speed down to 1400rpm。 2. Pressed the brake pedal. 3. Shift from neutral to reverse or from reverse to neutral and vice versa by moving the drive select lever along the shift guide.
Page 63 NOTE: WARNING When in reverse, the reverse indicator light POTENTIAL HAZARD should be on. If the light does not come on, Improperly operating in reverse. please ask a dealer to inspect the electrical WHAT CAN HAPPEN circuit. You could hit an obstacle or person behind Due to the synchronizing mechanism in the you, resulting in serious injury.
Page 64: Braking
2. Longer braking distance is needed when WARNING ATV is operated at a higher speed. POTENTIAL HAZARD 3. Longer braking distance is needed when When turning at a high speed with the the the ATV carries heavier loads. differential comp locked. 4.
Page 65: Parking Braking
Parking braking WARNING Stop the ATV with brake pedal。 ● POTENTIAL HAZARD Stop the engine. ● Shift the brave select lever into “H”, “L”, The brake becomes wet. ● and “R” position, then turn the main WHAT CAN HAPPEN switch off. ATV may lose control because of the wet Operate left handle to make parking ●...
Page 66: Parking On A Slope
2. Stop the engine. Parking on a slope 3. Shift the brave select lever into “H”, “L”, and “R” position, then turn the main WARNING switch off. POTENTIAL HAZARD 4. Operate left handle to make parking Parking on a hill or other incline. brake work and use the limit clamp the WHAT CAN HAPPEN keep the left handle jammed, parking...
Page 67: Atv Brake-In
After the break-in period, you ATV can perform in a better way. For the first three hours, if you run your engine with full throttle, the engine may overheat, which could break the oil seals ATV break-in and the driving systems. So never run your A new ATV needs the first 25 hours’...
Page 68: Engine Brakie-In
maximum) full throttle operation under load Engine break-in There is never a more important period in does not harm the engine. the life of your machine than the period Each full throttle acceleration sequence between zero and 25 hours. should be followed with a substantial rest For this reason, we ask that you carefully period for the engine by cruising at lower read the following material.
Page 69: Braking System Break-In
harm to the brake pads. 10-25 hours: Break-in is needed when replace new Avoid prolonged operation above 3/4 brake pads or the brake disc. throttle. Rev the machine freely but do not use full throttle at any time. Modifications Improper installation of accessories or modification of this vehicle may cause After break-in: changes in handling which in some...
Page 70: Loading
the cargo at the rear of the front carrier dealer. and at the front of the rear carrier. Loading Center the load from side to side. Overloading this ATV or carrying or towing Tie down cargo securely to the carriers. ●...
Page 71 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. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
Page 72: How To Ride Your Atv
HOW TO RIDE YOUR ATV safely. Getting to know you ATV Before you begin to ride, be sure you have ● This ATV is mainly for utility use, but may read this Owner’s Manual completely and also be used for recreation. This section, understand the operation of the controls.
Page 73 performance characteristics. Riding your ATV requires skills acquired through practice over a period of time. WARNING Take the time to learn the basic techniques POTENTIAL HAZARD well before attempting more difficult Operating this without proper maneuvers. instruction. WHAT CAN HAPPEN WARNING The risk of an accident is greatly increased if Not recommended for children under 16 years...
Page 74 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 your...
Page 75: Apparel
Apparel WARNING Always wear an approved motorcycle POTENTIAL HAZARD ● helmet that fits properly. Operating this ATV without wearing an You should also wear: eye protection approved motorcycle helmet, eye protection ● (goggles or face shield) 、gloves 、boots、 and protective clothing. long-sleeved shirt or jacket 、long pants.
Page 76 Do not operate after consuming Operating without eye protection can result in alcohol or drugs. an accident and increases your chances of a severe injury in the event of an accident. Operator’s performance capability ● Operating without protective clothing reduced by the influence of alcohol or increases your chances of severe injury in the drugs.
Page 77: Pre-Operation Checks
Pre-operation checks Always use the size and type tires specified in Always perform the pre-operation checks the Owner’s Manual for this vehicle on pages. listed on page 32 before riding for safety and Always maintain proper tire pressure as proper care of the ATV. described in the Owner’s Manual on page 38.
Page 78: Loading And Accessories
Loading and accessories keeps the throttle from fully opening, even when the throttle lever is pushed to the Use extra caution when riding the ATV with maximum. Screwing in the adjuster limits the additional loads, such as accessories or maximum engine power available...
Page 79: During Operation
During operation WARNING Always keep your feet on the footboards POTENTIAL HAZARD during operation. Otherwise your feet may Removing hands from handlebars or feet from contact the rear wheels. footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can re-duce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
Page 80: No Attempting To Modify Your Atv
No Attempting to modify your ATV Avoid wheelies and jumping. You may lose control of the ATV or overturn. WARNING WARNING Improper installation of accessories or Attempting wheelies, jumps, and other stunts. modification of this vehicle may could Increases chance accident, lead to an accident in some situations .
Page 81: Modifications
Modifications Exhaust system WARNING The exhaust system on the ATV is very hot during and following operation. To prevent POTENTIAL HAZARD burns, avoid touching the exhaust system. Operating this with improper Park the ATV in a place where pedestrians or modifications children are not likely to touch it.
Page 82: Pay Attention To The Road Condition
Pay attention to the road condition HOW TO AVOID THE HAZARD Know the terrain where you ride. Ride Do not operate, idle, or park the ATV in dry cautiously in unfamiliar areas. Stay alert for grass or other dry ground cover. holes, rocks, or roots in the terrain, and other Keep the engine area free of dry grass, brush, hidden hazards which may cause the ATV to...
Page 83 WARNING Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to Operating on excessively rough, slippery or changing terrain conditions when operating the loose terrain could cause loss of traction or ATV. vehicle control, which could result in an accident, including an overturn.
Page 84 When riding in an area where you might not Do not ride in areas posted “no trespassing”. easily be seen, such as desert terrain, mount Do not ride on private property without a caution flag on the ATV. DO NOT use the getting permission.
Page 85 lever to the low position “L” or the high obstacles and other riders. position “H”. Apply the throttle slowly and ● You should practice control of the throttle, smoothly. centrifugal clutch will brakes, shifting procedures, and turning engage and you will start to accelerate. techniques in this area before trying more ●...
Page 86: Turning Your Atv
quickly and easily. It is essential that this skill be learned first at low speed. Do not shift from drive position low “L” to high WARNING “H” “N” “R” or vice versa without coming to a complete stop. Damage to the engine or POTENTIAL HAZARD drive train may occur.
Page 87 As you approach a curve, slow down and This procedure should be practiced at slow begin to turn the handlebars in the desired speed many times in a large off-road area direction. As you do so, put your weight on with no obstacles.
Page 88: Climbing Uphill
while negotiating a turn, lean more to the WARNING inside. It may also be necessary to gradually The vehicle can overturn more easily on let off on the throttle and steer to the outside extremely steep hills than on level surfaces or of the turn to avoid tipping over.
Page 89 WARNING Climbing hills improperly could cause loss of control or cause the ATV to overturn. 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. Never climb hills with excessively slippery or loose surfaces.
Page 90: Crossing A Slope
WARNING ● Use proper gear and maintain steady ● speed when climbing a hill. ● If you lose all forward speed: Keep weight uphill. Apply the brakes. ● Shift to the parking position “P” after you are stopped. Crossing a slope ●...
Page 91 surfaces by pointing the front wheels slightly When crossing the side of a hill: uphill. When riding on slopes be sure not to ● Always follow proper procedures as de- make sharp turns either up or down hill. scribed in the Owner’s Manual. If your ATV does begin to tip over, gradually ●...
Page 92 descend the hill. ● When descending hills, using either brake lever or the brake pedal will brake the wheels on the downhill side. Avoid sudden application of either the front or rear brake because the wheels on the uphill side could come off the ground.
Page 93: Riding Downhill
● Use caution while descending a hill with Always follow proper procedures loose or slippery surfaces. Braking ability described in the Owner’s Manual. Avoid hills and traction may be adversely affected by with excessively slippery or loose surfaces. these surfaces. Improper braking may also Shift your weight to the uphill side of the ATV.
Page 94 downhill. Avoid sharp angles which could Avoid going down a hill at an angle that ● allow the ATV to tip or roll over. Carefully would cause the vehicle to lean sharply to choose your path and ride no faster than one side.
Page 95: Crossing Through Shallow Wat
Crossing through shallow water Owner’s Manual. The ATV can be used to cross slow moving, Remember that wet brakes may have reduced shallow water of up to a maximum of 35 cm stopping ability. Test your brakes after leaving (14 inches) in depth. Before entering the water.
Page 96 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. Also, remove the V-belt case drain plug to drain any water that may have accumulated.
Page 97: Riding Over Rough Terrain
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 times.
Page 98: Sliding And Skidding
wheels will sometimes help. ● If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
Page 99 terrain should be chosen carefully before ONCLUSION: attempting such maneuvers, since both 1. If your ATV doesn’t turn when you want it stability and control are reduced. ● Bear in mind that sliding maneuvers should ● Bring the ATV to a stop and practice the always be avoided on extremely slippery turning maneuvers again.
Page 100 recommended until you have corrected the (if there are no obstacles in your way) to slide. (See pages 7-26—7-27.) regain balance. 4．If your ATV can’t make it up a hill you are ● If you discover that the ATV is going to tip trying to climb: over, dismount on the uphill side.
Page 101: Periodic Maintenance And Adjustment
PERIODIC MAINTENANCE AND Owner’s manual and tool kit ADJUSTMENT You are recommended to put this owner’s Periodic inspection, adjustment and lubricat- manual in the vinyl bag and always carry it in the storage box. Put the owner’s tool kit and ion will keep your machine in the safest and low-pressure tire gauge in the space beside most...
Page 102 WARNING with the necessary information for complete- ng your own preventive maintenance and POTENTIAL HAZARD minor repairs. The tools provided in the Operating this ATV with improper modificati- Owner’s tool kit are sufficient for this purpose, ons. except that a torque wrench is also WHAT CAN HAPPEN necessary to properly tighten nuts and bolts.
Page 103: Periodic Maintenance Chart For The Emission Control System
Periodic maintenance chart for the emission control system NOTE: For ATVs not equipped with an odometer or stopwatch, follow the month maintenance intervals. For ATVs equipped with an odometer or stopwatch, 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 104: General Maintenance And Lubrication Chart
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 Clean. Engine oil filter ○ ○ ○ element Replace if necessary. ○ ○ Engine oil strainer ○...
Page 105: Efi System
INITIAL EVERY Whichever Month ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (200) (750) (1,500) (1,500) (3,000) (Mi) Hours Check all chassis fittings and fasteners. Fittings and ○ ○ ○ ○ ○ fastener★ Correct if necessary. Check operation. Lights and a ○...
Page 106 1. oxygen sensor 1. high voltage wire 2.ignition signal plug 3. ignition coil 2. oxygen sensor threaded sleeve 3. exhaust Pipe 1. fuel injector 2. bent pipe, inlet pipe 1.ECU 3. intake air temperature sensor/ pressure sensor 4. ducting,dampers...
Page 107 Throttle Valve To adjust the inlet airflow. Idle control stepper motor To stabilize the idle speed control Fuel Injection Tap To inject the fuel into the cylinder. Inlet temperature sensor To check the inlet temperature of the engine. 1. water temperature sensor According to temperature, ECU automatically could adjust the injection quantity.
Page 108: Efi System Examination
EFI system examination output power and the torque could be If the EFI system breaks down, the relevant adjusted by changing the injection quantity. fault code would shown speedometer, or you can examine the Water Temperature Sensor system through fault detector This sensor is used to cool the water (purchasing from your dealer).
Page 109: Checking The Engine Oil Level
intervals specified periodic maintenance and lubrication chart. Checking the engine oil level 1. Place the ATV on a level surface. 2. Start the engine to warm it up for several minutes, and then turn it off. 3. Wait a few minutes until the oil settles. 1.
Page 110: Replacing The Engine Oil (With Or Without Oil Filter Cartridge Replacement)
6. If the engine oil is at or below the minimum level mark, sufficient recommended type to raise it to the correct level. 7. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. Replacing the engine oil (with or without 1.
Page 111 torque with a torque wrench. If there is no need to replace the oil filler, skip step 4-6. 5. Apply a light coat of engine oil to the O-ring of the new oil filter. Make sure to select the proper O-ring. 1 .
Page 112: Final Gear Oil
9. Start the engine and warm it up for several 8. Fill with the specified amount of the minutes. While warming up, check for oil recommended oil. Set the dipstick and leakage. If oil leakage is found, turn the tighten it. engine off immediately and check for the cause.
Page 113 Tightening torque: Final gear oil drain bolt: 23 Nm(2.3m·kgf, 17ft·lbf) Recommended oil: SAE 90 API GL-5 gear oil Oil quantity: 1. Final gear oil filler bolt 0.25 L (0.22 lmp qt, 0.26 US qt) Be sure no foreign material enters the final gear case.
Page 114: Differential Gear Oil
7. Check for oil leakage. If oil leakage is Be sure no foreign material enters the final found, check for the cause. gear case. Differential gear oil 3. Install the differential gear oil filler bolt, and Checking the differential gear oil then tighten it to the specified torque.
Page 115: Cooling System
Oil quantity: 0.28 L (0.25 lmp qt, 0.29 US qt) Be sure no foreign material enters the differential gear case. 1. Differential gear oil drain bolt Install the differential gear oil filler bolt, and 4. Install the differential gear oil drain bolt then tighten it to the specified torque.
Page 116 coolant level will vary with engine coolant to the maximum level mark, install temperature. the reservoir cap, and then install the panel. Coolant reservoir capacity NOTE: (up to the maximum level mark): The coolant should be between the minimum 0.3 L(0.26 lmp qt, 0.31 US qt) and maximum level marks.
Page 117: Coolant Replacement
Coolant replacement prevent coolant from spilling on the footrest.) WARNING Removing the radiator cap when the engine and radiator are still hot, you could be burned by hot fluid and steam blown out under pressure. 1. Place the ATV on a level surface. 1．Trough 3.
Page 118 Coolant drain bolt: 4. Remove the coolant reservoir cap. 10 Nm(1.0m·kgf, 7.39 ft·lbf) 5. Disconnect the hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir. 8. Install the coolant reservoir hose. 9. Pour the recommended coolant into the reservoir to the maximum level mark.
Page 119: Axle Boots
Hard water or salt water is harmful to the engine. You may use soft water if you cannot get distilled water. 11. Start the engine and let it idle for several minutes. Stop the engine, and then check the coolant level in the radiator. If it is low, add 1.
Page 120: Spark Plug Inspection
Spark plug inspection Removal 1. Remove the spark plug cap. 1．spark plug wrench Spark plug inspection 1．spark plug cap The spark plug is an important engine component and is easy to be inspected. The Use the spark plug wrench in the tool kit to condition of the spark plug can indicate the remove the spark plug as shown.
Page 121: Installation
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. Specified spark plug: a.
Page 122: Air Filter Element Cleaning
3. Loosen the holder. Remove the air filter the specified torque as soon as possible. case cover. 4. Install the spark plug cap. Air filter element cleaning NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case.
Page 123 5. Remove the air filter element from its 7. Squeeze the excess solvent out of the air frame. filter element and let it dry. NOTE: Do not twist the air filter element when squeezing it. 8. Inspect the air filter element and replace it if damaged.
Page 124: Spark Arrester Cleaning
obstructions. Check the air filter element rubber joint to the carburetor and manifold fittings for an airtight seal. Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine. WARNING 1. Hose 12. Install the air filter case cover and be Never operate an engine without the air filter sure to connect the hose.
Page 125 2. Remove the tailpipe and the spark arrester cleaning by pulling it out of the muffler. 3. Tap the tailpipe lightly, and then use a wire brush to remove all carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing.
Page 126: V-Belt Cooling Duct Check Hose
NOTE: If water drains from the V-belt case after removing the plug, have a dealer inspect the ATV as the water may affect other engine parts. 1. V-belt cooling duct check hose (Left side) V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean 1．...
Page 127: Throttle Lever Adjustment
adjustment however, should be left to a 3. Tighten the locknut. professional service technician. Select lever cable adjustment This cable is set on the select lever and controled by brake pedal. Only after pressing the brake pedal, the “N” position can be changed to “R” position in the shift lever, same in reverse.
Page 128: Brake Fluid Level Checking
necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, please firstly find the reason. The rear brake fluid master cylinder reservoir is located near the brake pedal. 1.
Page 129: Brake Fluid Replacement
chemical reaction and lead to poor brake performance. 4. 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. 5. Brake fluid may deteriorate painted surfaces or plastic parts.
Page 130: Front Brake Lever Free Play
Or change these parts immediately after WARNING they are broken or leak. POTENTIAL HAZARD Operating with improperly serviced or brake lever free play Front Adjusted brakes. The front brake lever should have a free play WHAT CAN HAPPEN of zero mm (zero in) at the lever end. If not, You could lose braking ability, which have a dealer check the brake system.
Page 131: Adjusting The Rear Brake Light Switch
Adjusting the parking brake lever Adjusting the brake pedal The free play of the parking braking lever The top of the brake pedal should be should be between 0.5-1.5mm. positioned 86 mm above the top of the Loosen the locknut. footrest.
Page 132: Lubricating The Park Lever And Brake Pedal
1. Turn the adjusting nut while holding the Inspection and lubricate cable rear brake light switch in place. To make the WARNING brake light come on earlier, turn the adjusting nut in direction a. To make the brake light If the control cable protective cover damages, come on later, turn the adjusting nut in corrosion may happen.
Page 133 In order to get close to the rotating point of the brake pedal, the plastic cover should be removed Recommended lubricant: Lithium-soap-based grease 1 . Rotating point 1. Rotating point 1. Rota ng point 8-33...
Page 134: Rear Knuckle Upper And Lower Pivot Lubrication
Rear knuckle upper and lower pivot Wheel removal lubrication 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand Lubricate the knuckle upper and lower pivots under the frame. with a grease gun. 3. Remove the nuts from the wheel. 4.
Page 135: Wheel Installation
Wheel installation 1. Install the wheel and the Tapered nut 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 1. Tapered nut rear wheels. Install the nut with its tapered side towards the wheel.
Page 136: Battery
Battery WARNING This machine is equipped with a sealed-type POTENTIAL HAZARD battery. Therefore there is no need to check Improper treatment of the battery or the the electrolyte or add distilled water in the electrolyte battery. If the battery seems to have WHAT CAN HAPPEN discharged, consult a dealer.
Page 137: Battery Maintenance
Battery maintenance Fuse replacement 1. The main fuse and the fuse box are 1. When the machine is not used for a month located under the seat. or longer, remove the battery and store it in a 2. If a fuse is blown, turn off the main switch cool, dark place.
Page 138: Replacing A Headlight Bulb
Replacing a headlight bulb Specified fuses: Main fuse If a headlight bulb burns out, replace it as Headlight fuse follows. ECU fuse 1. Remove the cover at the rear of the Auxiliary DC jack fuse headlight by pulling it off Four-wheel-drive fuse Shift switch fuse Differential fuse...
Page 139 WARNING Before touching or e\removing the bulb, leave certain time to make it cold. 5. Insert a new headlight bulb into the bulb holder by pushing it in. 1. Headlight bulb holder cover 3. Remove the headlight bulb holder by Do not touch the glass part of the headlight pushing it in and turning it counterclockwise.
Page 140: Headlight Beam Adjustment
To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Do not touch the glass part of the bulb. 6. Install the bulb holder by pushing it in and turning it clockwise.
Page 141 1. Tail/brake light bulb holder 3. Remove the defective bulb from the bulb holder by pushing it inward and turning it counterclockwise. 4. Install a new bulb in the bulb holder by pushing it inward and turning it clockwise. 5. Install the bulb holder (together with the bulb). 6.
Page 142: Atv Common Fault Inspection And Measures Table
ATV common fault inspection and measures table This section provides inspection and measures table of common fault for 800ATV, it will help you use the ATV better and safer. ATV Maintenance requires special techniques. If meeting the problem which cannot be solved, please contact the dealer.
Page 143 Sheet1: Inspection and measurement table of appearance and protection parts common fault Troubles Solutions Check if the frame and supporting ear are deformed or broken. Do appropriate repair and touch-up painting Panel damaged in the Replace the plastic cover parts off-road driving Re-paste the sticker and install the warning sign by rivets.
Page 144 Braking performance 1. Check if the brake disc abrasion limit is exceeded. degradation 1. Check if the friction plate of the disc brake calipers, to see whether the abrasion limit is exceeded or be polluted by material which could reduce the frictional force like oil and so on. 1.
Page 145 Sheet3: checking methods, solution for common faults of Electrical system. Troubles Solutions Check if the function of the light switch could work. Lights not working Check if the cable be damaged. Check if the lights and bulbs be damaged. “2WD/4WD” Check if the function of control switch 2WD/4WD on Could not change into 4WD meter board is nomal.
Page 146 Sheet4: checking methods, solution for common faults of running system. Troubles Solutions Check if the fastening nut which on the shift straight rod and steering knuckle and steering stem is damaged or loosen. Steering wheel gap is too Check if the rod of the shift straight rod is damaged. large Check if the gear gap on the steering is too large.
Page 147 Check if the wheel rim is deformed. Wheel beat too much when Check if the front, rear axle is curved. moving Check if the tire is deformed. Check if overloading. Shock absorbor turn soft Check if the spring on the shock absorbor is deformed because of long and uncomfortable when time usage.
Page 148 Sheet5:checking methods, solution for common faults of engine system. Troubles Solutions With a laptop can not adjust Check if throttle cable is blocked. the idle speed Check if the ECU is damaged. check if the voltage of the battery is lower than specified value. Unstable eninge idle...
Page 149 Check if the cooling fin on the water cooler is blocked. Check if the temperature sensor on the water cooler is damaged and if Coolant boiling the cooling fan is in normal rotation. Check if the added antifreeze is according with the quality inquiry on the user manual.
Page 150: Cleaning And Storage
CLEANING AND STORAGE A . Cleaning High pressure of water will make the vechile Keep clean of the ATV not only make it hydrops, and will make the function of the appear beautiful but alsokeep its efficient brake system, seal parts of transmission and function and extend the service life of many electrical parts deteriorated.
Page 151: Storage
the surface of plastic. Keep the oil tank and oil pipe is clean and When finished, start engine, make it is in an without any oil. idle state in a few minutes at the same time. Knock down the spark plug, pull the oil SAE 10W30 or 20W40 into the spark plug hole, WARNING and reinstall the spark plug, and then roll the...
Page 152 time per month. It is strictly prohibited to storage the battery in too much warm or cold place. Checking and repairing ATV before storage.
Page 153: Specifications
SPECIFICATIONS Model 800ATV Dimensions: Overall length 2,410mm (94.8 in) Overall width 1,290mm (50.0 in) Overall height 1,240mm (52.3 in) Seat height 800mm (31.5 in) Wheelbase 1490mm (57.5 in) Ground clearance 310mm (12.2 in) Minimum turning radius 3,350mm (131.9 in) Basic weight:...
Page 154 Model 800ATV Engine oil: Type Recommended engine oil classification API Service SE, SF, SG type or higher 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 155 Model 800ATV Final gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.4 L (0.35 Imp qt, 0.42 US qt) Differential gear case oil: Type SAE80 API GL-4 Hypoid gear oil Quantity 0.10 L (0.08 Imp qt, 0.10 US qt) Radiator capacity (including all routes): 2.50 L (2.20 Imp qt, 2.64 US qt)
Page 156 Model 800ATV Transmission: Primary reduction system CVT-belt Secondary reduction system Shaft drive CVT reduction ratio 0.68-2.7 Transmission type CVT-belt automatic Operation Right hand operation Reverse gear 5.45 Sub transmission ratio 5.29 High 2.866 Chassis: Steel tube frame Frame type Caster angle 5°...
Page 157 Model 800ATV Brake: Front brake type Dual disc brake operation right hand operation Rear brake type Dual disc brake operation right foot operation Suspension: Front suspension Double wishbone Rear suspension Double wishbone Shock absorber: Front shock absorber Coil spring / oil damper...
Page 158 Model 800ATV Bulb voltage, wattage ×quantity: 12 V, 30 W / 30 W×2 Head light Tail/brake light 12 V, 5 W / 21 W×1 Indicator light: Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light High-range indicator light...

Massimo 800ATV Owner's Manual

1 Location of the Warning and Specification Labels

2 Safety Information

3 Description and Machine Identification

4 Control Functions

5 Pre-Operation Checks

6 Operation

7 How to Ride Your Atv

8 Periodic Maintenance and Adjustment

9 Cleaning and Storage

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