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FEISHEN K550ATV EEC 4x4 Owner's Manual

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WARNING: Read
this Manual, and
any Supplements
Carefully
Before Operating
Vehicle.
·Assembly
·Operation
·Maintenance
THIS VEHICLE IS
NOT DESIGNED
FOR USE ON
RENTAL TRACKS
OR RACING
BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH
OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF
ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE
OPERATION, AS WELL AS THE INSTRUCTIONS CONCERNING THE
ENGINE AND ALL OTHER PORTIONS OF VEHICLE.
OWNER'S MANUAL
EEC 4x4
K550ATV

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Summary of Contents for FEISHEN K550ATV EEC 4x4

  • Page 1 WARNING: Read OWNER’S MANUAL this Manual, and any Supplements Carefully Before Operating Vehicle. ·Assembly ·Operation ·Maintenance THIS VEHICLE IS EEC 4x4 NOT DESIGNED FOR USE ON RENTAL TRACKS K550ATV OR RACING BEFORE OPERATING THIS VEHICLE, THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION, AS WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER PORTIONS OF VEHICLE.

  • Page 2: Table Of Contents

    CONTENTS 1. INTRODUCTION----------------------------------------------------------2 2. UNDERSTANDING WARNING-----------------------------------------7 3. SAFETY WARNING-------------------------------------------------------9 4. DAILY PRE-RIDE INSPECTION--------------------------------------14 5. OPERATION WARNINGS----------------------------------------------15 6. V.I.N-------------------------------------------------------------------------29 7. CONTROL AND PARTS FUNCTIONS-------------------------------30 8. STARTING THE ENGINE---------------------------------------------- 42 9. VEHICLE BREAK-IN PERIOD----------------------------------------43 10. RIDING GEAR-----------------------------------------------------------44 11. CARRYING LOADS----------------------------------------------------45 12. RIDING--------------------------------------------------------------------47 13.

  • Page 3: Introduction

    1. INTRODUCTION Congratulations on the purchase of your All Terrain Vehicle (ATV). We take pride in offering you this product engineered and manufactured to the highest performance and quality standards. We are sure that you will enjoy superior levels of performance, reliability, riding comfort, and safety.
  • Page 4 Practice Responsible ATV Riding Make sure that you understand and follow all local, state/province, and federal/national riding laws and requirements. Remember……Respect your vehicle, respect the environment and respect the property of others. You are responsible for your safety and the safety of others around you when you ride!
  • Page 5 AN ATV CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. SERIOUS INJURY OR DEATH can result if you do not follow these instructions.
  • Page 6 accident. ·Never operate ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. ·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.
  • Page 7 If necessary, apply them lightly several times to let friction dry out the pads. ·Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

  • Page 8: Understanding Warning

    2. UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY: not a toy. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! Read this manual thoroughly referring to the various areas which are being discussed on your machine.

  • Page 9: Safety Alert

    SAFETY ALERT WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. Read all WARNINGS in this manual care fully. Follow their instructions to remain safe. The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol.

  • Page 10: Safety Warning

    3. SAFETY WARNING NOTE： Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your dealer for a replacement.

  • Page 15: Daily Pre-Ride Inspection

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

  • Page 16: Operation Warnings

    5. OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course.
  • Page 17 WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 18 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 19 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 20 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain.
  • Page 21 WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
  • Page 22 WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner’s Manual. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills.
  • Page 23 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. NOTE: A special technique is required when braking as you go downhill.
  • Page 24 WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep your weight uphill. Apply the brakes.
  • Page 25 WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 26 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operating the ATV through water which exceeds the recommended maximum depth in this manual.
  • Page 27 WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner’s Manual for this vehicle.
  • Page 28 WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
  • Page 29 WARNING After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. WARNING Safe operation of this ride active vehicle requires good judgment and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death.

  • Page 30: V.i

    6. V.I.N Record these numbers from your ATV in the spaces provided. 1. Frame VIN (found on the up right side of the frame tube) 2. Engine Serial Number (Left front side of engine crankcase) Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank and having it cut by mating it with your existing key.

  • Page 31: Control And Parts Functions

    7. CONTROL AND PARTS FUNCTIONS Electrical Switches 1. Main Switch-This key switch must be turned clockwise to the “on” position to start the engine. 2. Hazard Light Switch-When the switch is pushed to “ ”, the four signal lights are on and the buzzer is sounding. 3.
  • Page 32 Light Switches and Indicator Lights WARNING This ATV is equipped with highway approved lighting. This ATV is designed for on-road use and can be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Switches The light switch is located on the left hand handlebar.
  • Page 33 Throttle WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls. A sticking or improperly operating throttle could cause an accident resulting in severe injury or death. Always contact your dealer for service repairs whenever throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident.

  • Page 34: Front And Rear Brakes

    Front and Rear Brakes The brake fluid level should be checked before each ride. The reservoir is located under the seat. The fluid should be kept between the maximum and minimum marks. CAUTION Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid.
  • Page 35 Setting the Parking Brake 1. Squeeze and release the brake lever two or three times and hold it. 2. Push the park brake lock forward to engage the lock. Release the brake lever. 3. To release the parking brake lock, squeeze the brake lever. It will return its unlocked position.
  • Page 36 Auxiliary Brake WARNING Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward, or the rear wheels may skid and slide sideways, causing loss of control. Auxiliary brake lever Your ATV has an auxiliary brake provided brake provided as a safety feature. It is located on the left handlebar and is operated by the left hand.
  • Page 37 The brake fluid in the master cylinder, which is located on the left handlebar, should be checked before each ride. There is an indicator window on the brake fluid reservoir. This window will appear dark when the fluid level is full. When fluid needs to be added, the window will be clear.

  • Page 38: Engine Cooling System

    WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high. WHAT CAN HAPPEN The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause engine or drive train damage. HOW TO AVOID THE HAZARD Make certain the engine has sufficiently slowed before shifting to a lower gear.

  • Page 39: Cooling System

    itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. We recommend the use of a 50/50 mixture of high quality aluminum compatible anti-freeze coolant and distilled water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.
  • Page 40 Fuel and Oil system WARNING Gasoline is highly flammable and explosive under certain conditions. ·Always exercise extreme caution whenever handling gasoline. ·Always refuel with the engine stopped, and outdoors or in a well ventilated area. ·Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 41: Oil System

    Fuel and Oil System Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’s manual for tank capacity. Use regular unleaded gasoline. The fuel valve is located on the left side of the front fender and has two positions: OFF: For vehicle storage and whenever transporting.
  • Page 42 between the high and low. CAUTION Use only SAE 15W/40SG OIL. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

  • Page 43: Starting The Engine

    8. STARTING THE ENGINE Procedure for Starting a Cold Engine WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. CAUTION You must allow your vehicle adequate warm up time before operating or engine damage could result.

  • Page 44: Vehicle Break-In Period

    9. VEHICLE BREAK-IN PERIOD The break-in period for your new ATV is defined as the first 50 hours of operation. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine.

  • Page 45: Riding Gear

    10. RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

  • Page 46: Carrying Loads

    11. CARRYING LOADS Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.
  • Page 47 Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: ·REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN CARRYING CARGO. ·CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack.

  • Page 48: Riding

    12. RIDING WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. See “4. DAILY PRE-RIDE INSPECTION” 1. Sit upright with both feet on footrests and both hands on the handlebars. 2.

  • Page 49: Riding On Slippery Surfaces

    WARNING Avoid turning at sharp angles in reverse as tip over and severe injury may result. Riding on slippery surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover.

  • Page 50: Traveling Uphill

    Loss of tire traction and vehicle control can result in an accident, including an overturn. Traveling Uphill WARNING Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. Whenever traveling uphill always travel straight uphill and: 1.

  • Page 51: Side Hilling

    Side hilling Side hilling is one of the most dangerous types of riding your ATV and should be avoided. If you do enter into a situation where side hilling is necessary, always: 1. Slow down. 2. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

  • Page 52: Traveling Downhill

    Traveling Downhill Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs.

  • Page 53: Turning Around On A Hill

    Turning Around on a Hill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1. Stop and lock the parking brake while maintaining body weight uphill. 2.

  • Page 54: Crossing Streams

    Crossing Streams Your ATV can operate through water up to a maximum recommended depth (8 in.). Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4.

  • Page 55: Trail Obstacles

    CAUTION If your ATV becomes immersed, take it to your dealer before starting the engine. Major engine damage can result if the maching is not thoroughly inspected. If it is impossible to take it to a dealer before starting, follow these steps outlined below.
  • Page 56 Not all obstacles are visible. Travel with caution on trails. Severe injury or death can occur when vehicle comes in contact with a hidden obstacle. WARNING Backing your ATV can be dangerous! You should hit an obstacle or a person behind you; or the vehicle could tip over rearward on a steep incline causing severe injury or death.
  • Page 57 open throttle. Only open the throttle enough to maintain a desired speed. CAUTION Opening the throttle more than required may cause excessive fuel to build in the exhaust, resulting in engine popping and/or engine damage. Parking on an incline...
  • Page 58 Whenever the vehicle is parked 1. Turn the engine off. 2. Place the transmission in gear. 3. Set the parking brake. 4. Shut off fuel supply. 5. Avoid parking on an incline.If it is necessary to park on an incline, always block the rear wheels on the downhill side as shown above.

  • Page 59: Cvt System

    13. CVT SYSTEM CVT System WARNING The CVT system rotates at high speeds, creating large amounts of force on clutch components. However, as the owner you have the following responsibilities to make sure this system remains safe: · Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at high speeds.
  • Page 60 CVT System On this ATV, the approximate gear ratio difference between high and low range is 1:2.05. This difference in gearing affects the operation of the CVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed. By switching to low range while operating at low ground speeds, the air temperature in the clutch will be reduced.
  • Page 61 When To Use Low Range The following lists provide a guideline for when to use low range rather than high. Low Range: ·Basic operation at speeds less than 7 MPH (11 km/h) ·Heavy pulling ·Riding through rough terrain (swamps, mountains, etc.) at low ground speeds High Range: ·Basic operation at speeds greater than 7 MPH (11 km/h) ·High ground speeds...

  • Page 62: Battery

    14. BATTERY Battery WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or explosive situation could result causing serious injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

  • Page 63: Battery Removal

    Battery Removal 1. Disconnect the hold-down strap holding the electrical box and battery in position, and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5.
  • Page 64 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free of obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, severe burns could result.

  • Page 65: Exhaust System

    15. EXHAUST SYSTEM SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! CAUTION: Exhaust system components are very hot during and after use of ATV. ·Do not tough exhaust system components. Serious burns can result. ·Be especially careful when traveling through tall grass. The potential for fire exists. Spark Arrester The exhaust pipe must be periodically purged of accumulated carbon as follows: 1.

  • Page 66: Maintenance

    16. MAINTENANCE CAUTION Due to the nature of the adjustments marked with a D on the following chart, it is recommended that service be performed by an authorized dealer. ·More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 67 Item Hours When Remarks Brake System Pre-ride Pre-ride Pre-ride inspection item Auxiliary Brake Pre-ride Pre-ride Pre-ride inspection item Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection item Wheels Pre-ride Pre-ride Pre-ride inspection item Frame nuts, bolts fasteners Pre-ride Pre-ride Pre-ride inspection item Air Filter Pre-Cleaner Daily Daily...
  • Page 68 Item Hours When Remarks Engine Oil-Level/Change 30 hrs 3 months Check Level Daily; Break in Service at 1 month. Change oil more often in cold weather use. Oil Filter 50 hrs 6 months Inspect-clean Engine Breather Hose 100 hrs 6 months Inspect Carburetor Float Bowl 50 hrs...
  • Page 69 Item Hours When Remarks Radiator 100 hrs 12 months Inspect/clean external surface Cooling System Hoses 50 hrs 6 months Inspect/replace if necessary Spark Arrester 10 hrs monthly Clean out-replace if necessary Clutches (drive and 25 hrs 3 months Inspect, clean driven) Engine Mounts 25 hrs...

  • Page 70: Lubrication Recommendations

    Lubrication Recommendations Item Lube Rec Method Frequency 1. Engine Oil Add to proper level on Check level daily 15W-40SG dipstick 2. Brake Fluid DOT 3 Only Maintain level between As required; change fill lines. every two years or See “7. CONTROL” 200 hours 3.
  • Page 71 Lubrication Recommendations Item Lube Rec Method Frequency 6. Front A-arm Grease Locate fitting on pivot shaft Every 3 months or 50 Pivot Shaft and grease with grease gun hours 7. Steering Grease Locate fitting on pivot shaft Every 3 months or 50 Post Bushings and grease with grease gun hours...
  • Page 72 NOTE: 1. More often under severe use, such as wet or dusty conditions. 2. Grease: Light weight lithium-soap grease. 3. Grease M: molybdenum disulfide (MoS ) grease (water resistant).
  • Page 73 4. *When suspension action becomes stiff or after washing. 5. Hours are based on 10 mph (16 Km/h) average. Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Date Servicing Dealer or Remark Interval Performed Person First 5 Hrs 10 Hrs...
  • Page 74 WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit.
  • Page 75 The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Wheel Nut Torque Specifications Bolt Size Specification Front M10x1.25 27.4 ft. lbs. 37 Nm Rear M10x1.25 27.4 ft. lbs. 37 Nm NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Dealer.

  • Page 76: Rear Spring Adjustment

    Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension. Air Filter Service 1. Remove seat. 2. Release clips and remove cover. 3. Loosen clamp and remove filter. 4.

  • Page 77: Steering Inspection

    Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. WARNING Do not attempt to adjust the tie rod for toe alignment.

  • Page 78: Front Brake

    Front Brake WARNING Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.
  • Page 79 Rear and Auxiliary Brake Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same pedal which activates the front brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear. ·Pads should be changed when the friction material is worn to 3/64”...

  • Page 80: Spark Plugs

    Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar. 1. Slide the boots off the inline cable adjuster sleeve, loosen adjuster locknut. 2. Turn adjuster until 1/16” to 1/8” (2 to 3 mm) free play is achieved at the thumb lever.

  • Page 81: Oil And Filter Change

    Spark Plug Removal and Replacement WARNING Never attempt to remove a spark plug while the engine is warm. The exhaust system or engine could burn you causing severe injury. Remove the spark plug by rotating counterclockwise. Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. (23 Nm). Oil and Filter Change The recommended oil change interval is 30 hours, or every 3 months, whichever comes first.
  • Page 82 1. Place vehicle on a level surface; 2. Run engine two or three minutes until warm, stop engine; 3. Clean area around drain plug; 4. Place a drain pan beneath engine crankcase and remove drain plug; 5. Allow oil to drain completely; 6.

  • Page 83: Transmission Lubrication

    Oil Change 1. Position the vehicle on a level surface and remove the fill plug. 2. Place a drain pan beneath the gear case, remove the gear case drain plug (3) located on the bottom right-hand side, and drain the oil. 3.
  • Page 84 Transmission Oil Changing Procedure 1. Remove the four screws on the footwall and gently pull outward for access. 2. Remove fill plug. 3. Remove transmission drain plug located on the bottom left hand side and drain the oil. Catch and discard used oil properly. 4.

  • Page 85: Rear Gear Case Lubrication

    Rear Gear Case Lubrication Which the ATV on the a level surface, remove fill plug and visually inspect the lubricant level through the fill hole (1).Lubricant should be kept even with the center of the drill point (2) approximately 1 5/8” (41 mm) below the top of the fill hole.
  • Page 86 WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tire will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation. Important Safeguards Maintain proper tire pressure according to charts below.

  • Page 87: Wheel Installation

    Wheel Installation 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward rotation. 2.

  • Page 88: Headlight Lamp Replacement

    Headlight Lamp Replacement WARNING Keep your headlights and taillights clean. Poor light while riding can result in an accident causing severe injury or death. CAUTION Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.
  • Page 89 Taillight /Brake Light Lamp Replacement If the taillight/brake light does not work, the lamp may need to be replaced. 1. Remove the lens. 2. Remove lamp and replace it with recommended lamp. 3. Test the taillight/brake light to see that it’s working. 4.

  • Page 90: Cleaning Your Atv

    Cleaning Your ATV Keeping your ATV clean will extend the life of various components. Washing Never use a high pressure type car wash system, it can damage the wheel bearings, transmission seals, body panels, brakes and warning labels, and water might enter the engine or exhaust system.
  • Page 91 Cleaning—Clean the ATV thoroughly. Fuel—Turn the fuel valve to “OFF” and drain the carburetor bowl completely. Oil Add and Filter Change—Warm the engine and change oil and filter. Air Filter/Air Box—Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube.

  • Page 92: Trouble Shooting

    17. TROUBLE SHOOTING Issues of Improper Operation Belt Burning Possible Causes Solutions Loading the ATV into a pickup or Shift transmission to low range during loading of the ATV tall trailer when in high range. to prevent belt burning. Starting out going up a steep When starting out on an incline, use low range, or incline.
  • Page 93 Battery Wane Possible Causes Solutions Starting a faulty engine for a See “8. STARTING THE ENGINE” and check the long time. fuel/air/ignition/compression system. Let the main switch (key) on When stopping the engine, turn off the main switch while parking the ATV. (key) off at once.
  • Page 94 ·Seized or damaged piston IGNITION SYSTEM Battery Ignition system ·Improperly charged battery ·Faulty igniter unit ·Faulty battery ·Faulty pick up coil ·Broken magneto Fuse ·Burnt out, improper connection woodruff key Spark plug Switch ·Improper plug gap ·Faulty main switch ·Worn electrodes ·Faulty “ENGINE STOP”...
  • Page 95 ·Clogged fuel tank breather hole ·Improperly adjusted valve ·Clogged air cleaner element clearance ·Clogged jet ·Improperly contacted ·Improperly adjusted fuel level valve and valve seat ·Improper carburetor air vent hose ·Faulty valve timing setting Clutch ·Refer to “CLUTCH SLIPPING /DRAGGING” section Engine oil ·Improperly oil level (low or over oil level)
  • Page 96 ·Faulty thermostat ·Faulty thermo switch ·Incorrect coolant level (low coolant level) ·Faulty radiator (clogged, damage) ·Faulty radiator cap ·Impeller shaft gear malfunction (bent dowel pin, gear) ·Damaged impeller shaft ·Disconnected fan motor connector FAULTY CLUTCH WHEN ENGINE RUN, ATV DOES NOT RUN V belt POOR SPEED PERFORMANCE ·Worn/bent/slipping...
  • Page 97 ·Improper operation ·Oily or greasy brake pad ·Oily or greasy brake disc Worn guide pin groove ·Worn guide pin Clutch shoe ·Worn/bent...

  • Page 98: Ems

    18. EMS 1: Guidelines for Auto Electronic Fuel Injection System (1) Keep the wires clean. Avoid persistence of water, mud on wire connections. (2) When the ignition switch turned on, the system will begin self-checking. The EPC error indicator will be always on before the engine is started. (3) Should start the engine after 5 seconds when get the power supply, because several seconds are needed for the oil pump to set up the pressure to supply oil.

  • Page 99: Tools

    19. Tool...

  • Page 100: Specification

    20. SPECIFICATION Capacities Fuel capacity 15 L Engine Oil Capacity 1.6 L Ground Clearance 183 mm Height 1237 mm Length 2016 mm Width 1180 mm Seat height 895 mm Wheel Base 1280 mm Turn Radius 3280 mm Dry Weight 331kg Front Rack 18 kg Rear Rack...
  • Page 101 Engine Engine Type FS2V73MS 4 Stroke, V-twin, SOHC Bore x Stroke 72.5 mmx66.8 mm Displacement 552cc Starter System Electric Starter Engine Cooling Liquid-Cooled Lubrication System Wet Sump Ignitions DR8EA（NGK） Spark Plug Type Electrical Equipment Battery 12V 18AH Head Light 35W/35W Brake/Tail Light 21W/5W Reverse Indicator...

  • Page 102: Wiring Diagram

    21. WIRING DIAGRAM...

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