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Kolpin ATV-180 Owner's Manual

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Summary of Contents for Kolpin ATV-180

  • Page 2 FOREWORD Thank you for choosing the Kolpin Powersports 180 as your all-terrain vehicle (ATV). This user manual was prepared with the comfort and safety of the rider in mind. It provides all the details necessary to safely operate and maintain your vehicle. Carefully read the manual before operating your Kolpin Powersports 180cc.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION PAGE SECTION PAGE Introductory Safety Message 5-11 FEATURES & OPERATION (cont.) Seat RIDER’S SECTION Know Your Machine Exhaust Pipe/Muffler/Heat Shields Overview Photo Battery/Tool Set 38-41 Engine Stop Switch /Engine Start Switch Kick Starter Throttle Lever Adjusting the Throttle Cable Kick Starter Spark Plugs Brake Levers...
  • Page 4 Cleaning your ATV Transporting your ATV Vehicle Identification Numbers (VIN) Periodic Maintenance Schedule 96-99 Carburetor Adjustment Lubrication Recommendations Kolpin Powersports 180 Specifications Periodic Maintenance Record Troubleshooting Axle Wheel & Torque Specifications Rear Spring Adjustment Engine Air Filter Throttle Stop System...

  • Page 5: Introductory Safety Message

    !!! INTRODUCTORY SAFETY MESSAGE TO OWNERS !!! PARENTS & ADULTS MUST READ BEFORE OPERATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles.
  • Page 6 P  AY ATTENTION WHEN YOU SEE THE SYMBOLS ELOW This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. This symbol indicates a potential hazard that could result in severe injury or death. When you see this symbol on your machine or in this manual is means PAY ATTENTION! If you don’t, you could get hurt very badly or even killed.
  • Page 7  Read the Owner’s Manual and all warning labels on the ATV carefully. Follow the operating procedures described. • Training: Kolpin Powersports strongly suggests new owners call the ATV Safety Institute (ASI – a division of SVIA) to enroll in safety training or, visit their website www.ATVSAFETY.org.
  • Page 8 • Always inspect your ATV before you ride to make sure it is in safe operating condition. Follow the inspection and maintenance procedures and schedules as described in this manual. • Always wear an approved helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
  • Page 9 • 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 any hill at high speed.
  • Page 10 • Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the height of the bottom of the footrest, go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.
  • Page 11 Additional Important Information. . . The safety of our customers and the general public is the first priority at Kolpin Powersports. It is strongly recommended that consumers not install any non-Original Equipment Manufacturer (OEM) supplied equipment intended to increase speed or power on any Kolpin Powersports ATV. Do not make any other modifications intended for these purposes.

  • Page 12: Rider's Section

    Never allow your child to operate this ATV. Riders: Before you ride your new Kolpin Powersports ATV, you need to know information about how the ATV operates and most important of all, you need to know how to keep safe while operating the ATV.

  • Page 13: Overview Photo

    Front Brake Fuel Gauge OVERVIEW OF Kolpin Powersports 180 Lever Neutral Indicator Reverse Indicator Rear Brake Lever Throttle Lever Light Switch Engine Stop Switch Ignition Switch Engine Start Switch / Horn...

  • Page 14: Engine Stop Switch /Engine Start Switch

    RIDER’S SECTION KNOW YOUR MACHINE (cont.) Before you start the engine for the first time, you need to learn about the controls on your new ATV. Engine Stop Switch • The switch has to be in the position before you can start the engine.

  • Page 15: Throttle Lever

    RIDER’S SECTION KNOW YOUR MACHINE (cont.) Throttle Lever • The throttle lever is located on the right-side handlebar. It makes your ATV go forward when you press it with your thumb. • You must always make sure the throttle control does not stick before you operate your ATV.

  • Page 16: Kick Starter

    RIDER’S SECTION KNOW YOUR MACHINE (cont.) Kick Starter • If your battery is too weak to start your ATV, you can push on the kick starter with your left foot to start the engine. Review page 42 for more information on how to use the kick starter. Brake Levers •...

  • Page 17: Ignition Switch / Lights

    RIDER’S SECTION KNOW YOUR MACHINE (cont.) Ignition Switch Headlight • The key must be turned to the ON position before you push the Position starter button or use kick starter. • You should use this key to turn the engine OFF. Ignition Switch Lights Your ATV is equipped with high and low beam headlights.

  • Page 18: Pre-Ride Check

    If you have a sticky throttle, do not start the engine. You could get hurt if you ride when you have a sticky throttle. Have an adult or your local Kolpin Powersports dealer fix the throttle.  Make sure the brakes don’t stick. Check the brake levers by squeezing them toward the handlebar and then letting go.
  • Page 19 RIDER’S SECTION –PRE-RIDE CHECK (cont.)  Make sure the seat is locked back in place.  Check the gas level. Before adding gasoline to your ATV read the instructions and warnings on page 33 of this Owners Manual.  Check the engine oil level when the engine is cold. The engine is very hot after it has been running. It could burn you.

  • Page 20: Riding Rules

    RIDER’S SECTION– RIDING RULES Now you are ready to ride your new ATV. Remember that safety while you ride is the most important thing. Let’s ride!  Your ATV is made for one person. Never carry a passenger. A passenger will make the ATV harder to drive.

  • Page 21: Features & Operation

    FEATURES AND OPERATION IGNITION SWITCH • The Ignition Switch is operated with a key and must be turned to the ON position before you start the engine. • For Headlight: turn the key from the ON position to the headlight Headlight position.

  • Page 22: Engine Stop Switch

    FEATURES AND OPERATION (cont.) ENGINE STOP SWITCH • The engine will not start or run when the Engine Stop Switch is in Engine Stop Switch either position. It provides the operator with a quick way to shutdown the engine in case of stuck throttle or other emergency. •...

  • Page 23: Engine Throttle

    FEATURES AND OPERATION (cont.) • The throttle lever is located on the right-side ENGINE THROTTLE handlebar. • Pressing the throttle lever forward controls engine speed and vehicle movements. • The throttle lever is spring loaded. The engine • Do not start or operate an ATV with a speed returns to idle when the lever is released.

  • Page 24: Horn

    FEATURES AND OPERATION (cont.) HORN SWITCH To sound the horn, turn on the ignition switch and pull the horn switch Horn Button (grey Engine On / Horn switch). To sound the horn, turn on the ignition switch and pull the horn switch (grey Engine On / Horn switch).
  • Page 25 FEATURES AND OPERATION (cont.) BRAKES (cont.) Brake Lever Free Play • Check the free play of front and rear brake levers. • Use the adjustment knobs to change free play. Check the free play by measuring the travel of the front and rear brake levers from their rest position to their position when you first feel tension on the cables.
  • Page 26 FEATURES AND OPERATION (cont.) BRAKES (cont.) Auxiliary Brake Your ATV has an auxiliary brake for an added safety feature. It is located on the inside of the right floorboard (beneath the oil plug) and is operated by the right foot. Use the auxiliary brakes as a backup to the main brake system.
  • Page 27 FEATURES AND OPERATION (cont.) PARKING BRAKE The parking brake is a safety device to lock the rear brake and limit ATV movement Setting the Parking Brake • Squeeze the left-hand brake lever. • Press the parking brake lock to hold the brake lever in place. Releasing the Parking Brake •...

  • Page 28: Transmission Gear Shift Lever

    • Always lock the parking brake whenever the assure proper transmission function. Should you ATV is left unattended. experience any shifting problem, see you local Kolpin Powersports TRANSMISSION GEAR SHIFT LEVER dealer. • The transmission gear shift lever is located on the right side of the ATV.
  • Page 29 FEATURES AND OPERATION (cont.) 8. TRANSMISSION GEAR SHIFT LEVER (cont.) • Be sure the ATV is in the Neutral position before you start the engine. • If you cannot change gears, do not force gear shift lever into gear. Instead, try to change to the Neutral position first, press the throttle and then try to change gears.

  • Page 30: Cvt System

    • Routine maintenance is the responsibility of the owner. Always follow recommended maintenance procedures. See your Kolpin Powersports dealer for questions or maintenance. • The CVT housing must be securely in place during operation.

  • Page 31: Engine Air Filter

    FEATURES AND OPERATION (cont.) 10. ENGINE AIR FILTER • The engine air filter should be changed by dealer every 100 hours of operation or annually. • For more information, see page 105. If your ATV is stored/operated in salt-water areas, it must be rinsed with fresh water to prevent corrosion that can be caused by seawater.

  • Page 32: Engine Fuel & Oil Systems

    Fuel Tank FEATURES AND OPERATION (cont.) 11. ENGINE FUEL SYSTEM Fuel Tank • The fuel tank filler cap is located directly behind the handlebar (below the dash). • The capacity of fuel tank is 2.1 gallons (8 liters). • Use unleaded gasoline with an octane rating of 92 or higher. Fuel Gauge •...
  • Page 33 FEATURES AND OPERATION (cont.) 11. ENGINE FUEL SYSTEM (cont.) Gasoline is highly flammable and explosive under certain conditions. Never store ATV near products with a pilot light, such as, gas hot water heater or stoves. Always exercise extreme caution when you handle gasoline. Always refuel with the engine stopped and outdoors or in a well-ventilated area.
  • Page 34 Fuel Filter • The Kolpin Powersports 180 ATV is equipped with an in-line fuel filter. • This filter should be replaced by your dealer after every 100 hours of operation, or annually.
  • Page 35 Running the engine with low oil levels will cause the engine to overheat and seize. If the engine seizes, it will have to be rebuilt by your Kolpin Powersports dealer. • Engine repair cost resulting from damage caused by running the...

  • Page 36: Seat

    FEATURES AND OPERATION (cont.) 12. SEAT • To remove the seat, reach under the rear of the cab and pull back on the seat latch. • To replace the seat, set it in place and push down on the rear of the seat.

  • Page 37: Features & Operation (Cont.)

    FEATURES & OPERATION (cont.) 13. EXHAUST PIPE / MUFFLER / HEAT SHIELDS Heat Shields The exhaust pipe, muffler and heat shields are very hot after operation. DO NOT touch them until they have cooled. • The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

  • Page 38: Battery/Tool Set

    FEATURES & OPERATION (cont.) Tool Set Battery 14. BATTERY / TOOL SET The battery and tool set are located under the seat, attached to the rear fender by a rubber strap. Tool Set The tool set includes a spark plug tool, a screwdriver, and a tire gauge. Battery –...
  • Page 39 FEATURES & OPERATION (cont.) 14. BATTERY / TOOL SET (cont.) BATTERY (cont.) ‼ Never remove battery tops. ‼ Never attempt to add water. ‼ Never reverse leads, this could cause an EXPLOSION. ‼ Never operate this ATV without the battery cables connected and tightened.
  • Page 40 FEATURES & OPERATION (cont.) 14. BATTERY / TOOL SET (cont.) BATTERY (cont.) – Care of Terminals • Battery terminals and connections should be kept free of corrosion. • If cleaning is necessary, remove the corrosion with a stiff wire brush. •...

  • Page 41: Battery/Tool Set

    FEATURES & OPERATION (cont.) 14. BATTERY / TOOL SET (cont.) BATTERY (cont.) – Battery Fluid / Battery Removal Your Kolpin Powersports ATV is equipped with an Absorbed Glass Matte (AGM), no-maintenance battery. • DO NOT remove battery top. • DO NOT attempt to add water.

  • Page 42: Kick Starter

    FEATURES & OPERATION (cont.) 15. KICK-STARTER If the battery is too weak to start the engine, you can start the engine with the kick-starter. The kick-starter will allow the ATV to operate until repairs can be made. • Be certain the ATV is on a level surface and the parking brake is set (See page 27).

  • Page 43: Adjusting The Throttle Cable

    FEATURES AND OPERATION (cont.) Tighten Loosen 16. ADJUSTING THE THROTTLE CABLE • Check to be sure the throttle lever moves smoothly and returns on its own; if it does not, then adjust the free play of throttle. To adjust free play, loosen the nut and adjust to the proper position.

  • Page 44: Drive Chain

    FEATURES AND OPERATION (cont.) Chain 18. DRIVE CHAIN • After periods of extended operation, the drive chain will stretch and loosen. The normal chain slack should be – 1 inch (13 – 25 mm). Check the drive chain and adjust if necessary before each use. Keep the drive chain properly lubricated.

  • Page 45: Suspension

    FEATURES AND OPERATION (cont.) Front 20. SUSPENSION Adjuster Ring Front Suspension • The front R/L side suspensions can be adjusted to any of five (5) pre-load positions so they can be matched to load and riding conditions. • Always be sure to adjust both front left and front right shock absorbers to the same position.

  • Page 46: Braking Light

    FEATURES AND OPERATION (cont.) 21. BRAKE LIGHT • The brake light operates when the rear brake lever (left) is pulled. • The bulb type for the braking light is #1157 or 12V-P21/5W. Rear Brake Light.

  • Page 47: Riding & Operation Instructions

    RIDING & OPERATING INSTRUCTIONS OUTLINE: PAGE # 1) Riding Gear 2) Starting the Engine 3) ATV Break-in Period 4) Riding 5) Making Turns 6) Hauling Cargo 7) Riding on Slippery Surfaces 8) Traveling Uphill 9) Side Hill Riding 10) Traveling Downhill 11) Turning Around on a Hill 12) Crossing Streams 13) Trail Obstacles...

  • Page 48: Riding & Operating Instructions

    RIDING & OPERATING INSTRUCTIONS (cont.) P  AY ATTENTION WHEN YOU SEE THE SYMBOLS BELOW This is the safety alert symbol. When you see this symbol in this manual be alert to the potential for personal injury. This symbol indicates a potential hazard that could result in severe injury or death.
  • Page 49 RIDING & OPERATING INSTRUCTIONS (cont.) 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. Engine damage could result if you do not allow your ATV adequate warm-up time before operating Remember to perform the Pre-ride Check before riding ATV.

  • Page 50: Riding Gear

    RIDING & OPERATING INSTRUCTIONS (cont.) RIDING GEAR ATV riding requires special protective clothing and equipment to help reduce chances of injury. • Helmet – Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent severe head injury.

  • Page 51: Starting The Engine

    RIDING & OPERATING INSTRUCTIONS (cont.) STARTING THE ENGINE / Procedure for Starting a Cold Engine Set the parking brake. Push the Engine Stop Switch to Turn the ignition key to ON. Press the Engine Starter Button . NOTE: The rear brake lever must be engaged or the engine will not start.

  • Page 52: Atv Break-In Period

    ATV BREAK-IN PERIOD The break-in period for your Kolpin Powersports ATV is the time it takes for the ATV to use up the first full tank of gasoline. This break-in period is vital to the efficiency of performance and length of life of the engine.

  • Page 53: Riding

    MAKING TURNS Practice making turns at slow speeds. Kolpin Powersports ATVs are equipped with a solid rear axle that drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel and the inside tire must slip traction slightly during the turn.

  • Page 54: Hauling Cargo

    RIDING & OPERATING INSTRUCTIONS (cont.) HAULING CARGO The Kolpin Powersports 180 was designed to haul loads within a limited weight range. Never exceed the weight capacities listed in the specifications table on page 124 of this Owner’s Manual. Cargo weight should be evenly distributed (...
  • Page 55 RIDING & OPERATING INSTRUCTIONS (cont.) HAULING CARGO (cont.) • ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle. • LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

  • Page 56: Riding On Slippery Surfaces

    RIDING & OPERATING INSTRUCTIONS (cont.) 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. Slow down when entering slippery areas. Remain alert, reading the trail and avoiding quick, sharp turns that can cause skids.

  • Page 57: Traveling Uphill

    RIDING & OPERATING INSTRUCTIONS (cont.) TRAVELING UPHILL • Do not operate this ATV on hilly terrain. If you cannot avoid operating in hilly terrain, use extreme caution. Braking and handling are greatly affected. • Loss of vehicle control or overturning of the ATV could result causing sever injury or death.

  • Page 58: Side Hill Riding

    RIDING & OPERATING INSTRUCTIONS (cont.) SIDE HILL RIDING Avoid traveling across the side of a hill. In the event you do enter into a situation where side hill riding is unavoidable: Slow down. Lean into the hill transferring your upper body weight up hill while keeping your feet on the footrests. Steer slightly into the hill to maintain vehicle direction.

  • Page 59: Traveling Downhill

    RIDING & OPERATING INSTRUCTIONS (cont.) TRAVELING DOWNHILL When descending a hill: Drive directly downhill. Transfer your weight to the rear of the vehicle. Slow down. Slightly apply the front and rear brakes at the same time to help in slowing. Do not travel at excessive speeds.

  • Page 60: Turning Around On A Hill

    RIDING & OPERATING INSTRUCTIONS (cont.) 10) TURNING AROUND ON A HILL If your ATV stalls while climbing a hill, NEVER back it down the hill! Stop and lock the parking brake while maintaining body weight uphill. Shut off engine. Dismount on left or uphill side of ATV. Staying uphill, turn handlebars full left (while facing front of ATV).

  • Page 61: Crossing Streams

    RIDING & OPERATING INSTRUCTIONS (cont.) 11) CROSSING STREAMS Your Kolpin Powersports ATV can operate through water up to depths just below the footrests. Before operating through streams: Determine water depths and currents. Choose a crossing where both banks have gradual inclines.

  • Page 62: Trail Obstacles

    RIDING & OPERATING INSTRUCTIONS (cont.) 12) TRAIL OBSTACLES KEEP ALERT! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks, and low-hanging branches. Not all obstacles are visible.
  • Page 63 NOTE: Warning decals have been placed on the vehicle for the protection of the operator(s). Read and follow the instructions on each decal carefully. If any decal becomes illegible or comes off, contact your Kolpin Powersports dealer for replacement. The part number is printed on the decal.

  • Page 64: Operation Warning Decals

    OPERATION WARNING DECALS Improper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear; Never use with drugs or alcohol; Never use on public roads Never carry passengers NEVER OPERATE: • on public roads – a collision can occur; •...

  • Page 65: Operation Warning Decals

    NEVER ride as a passenger! OPERATION WARNING DECALS (cont.) Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH NO ONE UNDER 16 year of age! • Operation of this ATV by anyone under the age of 16 increases the risk of severe injury or death.
  • Page 66 • Adjust chain as figure shown. OPERATION WARNING DECALS • Inaccurate adjustment could cause (cont.) damage to the chain and adjuster. • Improper tire pressure or overloading can cause loss of control, resulting in SEVERE INJURY or DEATH. • MAXIMUM WEIGHT CAPACITY (Gross vehicle weight) including machine, driver and cargo is 680 lbs.
  • Page 67 • TO AVOID ACCIDENT OR SEVERE OPERATION WARNING DECALS INJURY, NEVER EXCEED 8 MPH (13 KM) (cont.) WHILE IN REVERSE GEAR. • Do not operate this ATV on HILLS with a grad steeper than 25 degrees. To prevent flipover when going up or down hilly terrain, use brakes and throttle gradually.
  • Page 68 OPERATION WARNING DECALS (cont.) Shift pattern: ORWARD EUTRAL EVERSE...

  • Page 69: Operation Warnings Printed In Manual

    OPERATION WARNINGS PRINTED IN THIS MANUAL POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident with severe injury or death is greatly increased if the operator does know not how to operate the ATV properly in different situations and on different types of terrain.
  • Page 70 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. Even though a child may be within the age group for which some ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and could be involved in a serious accident.
  • Page 71 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces yours ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 72 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handing and control of the ATV and may cause loss of control of the vehicle, resulting in severe injury or death.
  • Page 73 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Operating this ATV on public streets, roads, or highways. WHAT CAN HAPPEN You can collide with another vehicle, resulting in severe injury or death. HOW TO AVOID HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.
  • Page 74 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Operating this ATV Without wearing an approved helmet, eye protection And protective clothing. WHAT CAN HAPPEN Operating without an Approved helmet increases your chances of severe Head injury or death in event of an accident. Operating without eye protection can result in severe Injury in event of an accident.
  • Page 75 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Operating this ATV after consumption of alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and protection. Could cause an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD NEVER consume alcohol or drugs before or while driving this ATV.
  • Page 76 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can cause an accident, resulting in severe injury or death. HOW TO AVOID THE HAZARD Always travel at a proper speed for the terrain, visibility, operating conditions, and your experience.
  • Page 77 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of rolling the vehicle and/or causing an causing an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
  • Page 78 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increased possibility of an accident or equipment damage. Could cause an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD ♦...
  • Page 79 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot will reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident resulting in severe injury or death.
  • Page 80 OPERATION WARNINGS (cont.) 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 rolling or driver losing control of the vehicle and causing an accident resulting in severe injury or death.
  • Page 81 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause damage to terrain, or loss of vehicle control, or rolling the vehicle, or causing an accident resulting in severe injury or death.
  • Page 82 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Driver could lose control of the ATV, rolling the vehicle or causing an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD ♦ Always follow proper procedures for turning. ♦...
  • Page 83 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control, or cause ATV to overturn, .or cause an accident resulting in severe Injury or death. HOW TO AVOID THE HAZARD ♦ Always follow proper procedures for climbing hills. ♦...
  • Page 84 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn causing an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD ♦ Always follow proper procedures for going down hills as described in the Owner’s Manual.
  • Page 85 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control, or ATV to roll, or cause an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD ♦ Avoid hills with excessively slippery or loose surfaces. ♦...
  • Page 86 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could allow ATV to overturn causing an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD ♦ Maintain steady speed when climbing a hill. ♦...
  • Page 87 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly; both of which may allow the ATV to overturn causing an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
  • Page 88 OPERATION WARNINGS (cont.) 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. ♦...
  • Page 89 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator break through the ice. HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water.
  • Page 90 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Operating this ATV through deep or fast following water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident, resulting in severe injury or death. HOW TO AVOID THE HAZARD ♦...
  • Page 91 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Operating this ATV with incorrect size tires or with uneven tire pressure. WHAT CAN HAPPEN Use incorrect size tires on this ATV, or operation of this ATV with uneven tire pressure, may cause loss of control and increases the risk of an accident resulting in severe injury or death.
  • Page 92 OPERATION WARNINGS (cont.) POTENTIAL HAZARD Overloading this ATV. WHAT CAN HAPPEN Could cause changes in vehicle handling that could lead to an accident resulting in severe injury or death. HOW TO AVOID THE HAZARD ♦ Never exceed the stated load capacity for this ATV. ♦...
  • Page 93 OPERATION WARNINGS (cont.) After a rollover or an accident, have a qualified service dealer check the entire vehicle including, but not limited to, brakes, throttle and steering for possible damage. Safe operation of this rider 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 94 ATV and should be installed and used according to instructions. ♦ WARNING: Do not ride this vehicle without battery properly installed. Riding Kolpin Powersports 180cc without battery properly installed may cause short-circuit and result in shorting out electrical system causing a fire, resulting in severe injury or death.

  • Page 95: Vehicle Maintenance

    Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Kolpin Powersports and having it cut by using your existing key. The Engine Serial Number and Frame VIN are important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required.

  • Page 96: Periodic Maintenance Schedule

    Kolpin Powersports dealer perform these operations. • Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine parts available from your local Kolpin Powersports dealer. ■...
  • Page 97 VEHICLE MAINTENANCE (cont.) ► Adjustments marked with must be performed more often if ATV is under severe use, such as dirty or wet conditions. HOURS ITEM WHEN REMARKS MILES Brake System Pre-ride Pre-ride Check Operation (See pg. 108) Tires Pre-ride Pre-ride Check inflation.
  • Page 98 VEHICLE MAINTENANCE (cont.) HOURS ITEM WHEN REMARKS MILES Carburetor Float 50 hrs 6 mos Drain bowl periodically and prior to storage Bowl ■ Throttle Cable 50 hrs 6 mos Inspect- adjust, lubricate, replace if necessary; pre-ride inspection item ► Steering 50 hrs 6 mos Inspect daily, lubricate...
  • Page 99 VEHICLE MAINTENANCE (cont.) HOURS ITEM WHEN REMARKS MILES Engine Mounts 100 hrs 12 mos Inspect Spark Plug 100 hrs 12 mos Inspect-replace if necessary ■ Ignition Timing 100 hrs 12 mos Inspect and adjust as needed ■ Fuel System 100 hrs 12 mos Check for leaks at tank cap, lines, fuel valve, filter, and carburetor.

  • Page 100: Lubrication Recommendations

    VEHICLE MAINTENANCE (cont.) LUBRICATION RECOMMENDATIONS LUBRICATION ITEM RECCOMMENDATION METHOD FREQUENCY ► Engine Oil SF-SG SAE 15W-40 See page 116 Change every 6 mos., or 100 hrs. Transmission Oil SAE 85W-140 See page 115. Change annually or at 200 hrs. Drive Chain SAE 85W-140 or chain Lubricate as As required.

  • Page 101: Periodic Maintenance Record

    VEHICLE MAINTENANCE (cont.) PERIODIC MAINTENANCE RECORD Use the following chart to record periodic maintenance work: Maintenance Servicing Date Servicing Dealer Remarks Interval Performed or Person First 5 hrs. 25 hrs. 50 hrs. 75 hr. 100 hrs.
  • Page 102 VEHICLE MAINTENANCE (cont.) PERIODIC MAINTENANCE RECORD Maintenance Servicing Date Servicing Dealer Remarks Interval Performed or Person...

  • Page 103: Axle Wheel & Torque Specifications

    78 – 81 ft. lbs (108-112 Nm) NOTE: an authorized dealer must service all nuts that have a cotter pin installed. FRONT WHEEL HUB TIGHTENING Front wheel bearing tightness and spindle nut retention are critical component operations. Your authorized Kolpin Powersports dealer must perform Service work.

  • Page 104: Rear Spring Adjustment

    VEHICLE MAINTENANCE (cont.) REAR SPRING ADJUSTMENT The rear shock absorber spring is adjusted by rotating the adjuster clockwise, to one of five (5) positions, to increase spring rate or counter-clockwise to decrease spring rate. Rear Shock Absorber Spring Adjuster...

  • Page 105: Engine Air Filter

    VEHICLE MAINTENANCE (cont.) ENGINE AIR FILTER The engine air filter should be changed every 100 hours of operation, or annually (service more often if run in dusty or wet conditions). The air filter is located under the rear body. It is recommended that you have your local dealer perform this procedure.

  • Page 106: Throttle Stop System

    VEHICLE MAINTENANCE (cont.) THROTTLE STOP SYSTEM The Adjustable Throttle Stop System (throttle limiting screw) allows you to limit the speed of the vehicle according to the rider’s skill and experience. The throttle stop system controls how far the throttle opens. To adjust, loosen the jam nut, turn the screw inward to reduce speed and outward to increase speed.

  • Page 107: Steering Inspection

    CAMBER AND CASTER Not adjustable. See your dealer. TOE ALIGNMENT – SEE YOUR LOCAL Kolpin Powersports dealer. Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your local dealer. They have the training and tools to make adjustments.

  • Page 108: Brake Adjustment

    VEHICLE MAINTENANCE (cont.) BRAKE ADJUSTMENT Front Brakes Each front brake has a cable connected to the right-hand brake lever. Check the front brakes by turning the adjustment knob until free-play is in acceptable range. The acceptable range for the front brake levers’ free-play is ~ ¾...
  • Page 109 VEHICLE MAINTENANCE (cont.) BRAKE ADJUSTMENT (cont.) Rear Brakes The rear brake is operated by using the left-hand brake lever. The adjustment nut for the rear brake is beneath the brake light at the back of the ATV. To adjust free play turn the adjustment nut until you reach the proper free-play setting. Check free play by measuring the travel of the free end of the rear brake lever from its rest position to its position when you first feel tension on the cable.

  • Page 110: Brake Adjustment

    BRAKE ADJUSTMENT (cont.) Auxiliary Brake Adjustment The Kolpin Powersports 180 a rear auxiliary foot brake located at the right side of the engine assembly and is operated by the operator’s right foot. To adjust, follow the steps below. 1. Make adjustments to rear brake lever as described on page 109.

  • Page 111: Throttle Cable Adjustment

    VEHICLE MAINTENANCE (cont.) THROTTLE CABLE ADJUSTMENT • Check the throttle for smooth operation before every riding session. • Periodically check the throttle free-play. It should be kept between in. (1.5mm ~ 3.2mm). • If adjustment is required, turn the adjustment nut until the free-play reaches the acceptable limit (adjustment nut is protected by plastic sleeves, pull the sleeves back to expose the adjustment nut).

  • Page 112: Spark Plug

    SPARK PLUGS The proper spark plug for the Kolpin Powersports 180 is the NGK C7HSA or NGK CR7HSA. The spark plug gap should be between .024 ~ .028 inch (0.6 ~ 0.7 mm). An incorrect spark plug gap can cause the spark plug to foul.
  • Page 113 Spark Plug Removal and Replacement The spark plug can be removed by using the special wrench provided in the tool pouch. Remove the spark plug cap and then the spark plug by rotating counter clockwise. NEVER attempt to remove a spark plug while the engine is warm. The exhaust system or engine could burn you and cause severe injury.

  • Page 114: Atv Storage (Long-Term)

    VEHICLE MAINTENANCE (cont.) ATV STORAGE (long-term) When your ATV is to be stored for a period of more than 60 days, certain preparations should be made for the engine and fuel system to prevent rust and/or corrosion of engine parts. Supplies Needed: Vinyl &...

  • Page 115: Transmission Oil Change

    • Lubricate chain and cables with SAE 85W-140 oil or chain & cable oil. VEHICLE MAINTENANCE (cont.) TRANMSSION OIL CHANGE Change the gear oil after the first 30 hours of operation. The recommended gear oil is SAE 85W-140. Run ATV for at least five (5) minutes or until warm. Turn off unit and remove the ignition key. Place a suitable container for draining oil beneath the rear of engine.

  • Page 116: Engine Oil Change

    VEHICLE MAINTENANCE (cont.) ENGINE OIL CHANGE 1. Run unit for at least five (5) minutes or until warm. Turn Ignition Key to OFF and remove the key. 2. Place suitable container for draining oil beneath the engine. 3. Remove the engine drain plug, oil filter cap, spring and oil filter screen. Let the oil drain completely.
  • Page 117 VEHICLE MAINTENANCE (cont.) BRAKE OIL ENSURE Check the brake oil tank. If the brake oil to reduce under the limit. You must to fill the brake oil until upper limit. Be careful the brake oil when to topple into the oil tank to avoid the oil to sprinkle Under limit...
  • Page 118 VEHICLE MAINTENANCE (cont.) TIRE / TIRE PRESSURE / TIRE INSTALLATION • ATV tires can become distorted by over-inflation. (Ballooning, stretching of rubber and fiber cords). • Once a tire has been over-inflated it will not return to its original size. •...

  • Page 119: Tire/Tire Pressure/Wheel Installation

    ATV Model Tire Size Wheel Nut Torque Front Rear Front Rear Kolpin Powersports 21x7-10 21x10-8 28 ft lbs 180cc WHEEL INSTALLATION: Lock the parking brake; 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 forward rotation.

  • Page 120: Drive Chain Inspection & Adjustment

    VEHICLE MAINTENANCE (cont.) TIRE / TIRE PRESSURE / TIRE INSTALLATION (cont.) WHEEL REMOVAL PROCEDURE: Stop the engine and lock the parking brake. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. Remove the wheel nuts and remove the wheel.
  • Page 121 VEHICLE MAINTENANCE (cont.) DRIVE CHAIN INSPECTION AND ADJUSTMENT (cont.) The normal chain slack should be kept between ~ 1 in. (13 mm ~ 25 mm) Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result.

  • Page 122: Brakelight Lamp Replacement

    VEHICLE MAINTENANCE (cont.) BRAKELIGHT LAMP REPLACEMENT If the brake light does not work the bulb may need to be replaced. From the rear of the brake light, remove two screws holding lens cover in place and remove lens cover. Remove bulb and replace it with the recommended bulb #1157 or 12V-P21/5W . Test the brake light to see if it is working.

  • Page 123: Cleaning Your Atv

    Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your Kolpin Powersports dealer for replacement. Waxing Your ATV can be waxed with any non-abrasive past wax.

  • Page 124: Carburetor Adjustment

    VEHICLE MAINTENANCE (cont.) TRANSPORTING Whenever the ATV is to be transported the following measures should be taken. Turn the fuel valve OFF (if so equipped). Be certain the fuel cap and seat are installed correctly. Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope. Always lock the parking brake.
  • Page 125 Overland ATV 180 Specifications ITEM Kolpin Powersports 180 Air Cooled, 4-Stroke ENGINE TYPE DISPLACEMENT 169 cc BORW STROKE 61x57.8 mm 9.4:1 COMPRESSION RATIO MAX. TORQUE 9.15 Nm @ 6250 rpm STARTING Electric w/Kick Start Backup Oil Injection / 1 quart (1 liter)

  • Page 126: Troubleshooting

    TROUBLESHOOTING Procedures The following information is provided to help you identify probable questions you may have about the operation of your ATV. See your dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Plug No Spark to...
  • Page 127 TROUBLESHOOTING (cont.) ENGINE STOPS OR LOSES POWER Engine No Fuel Spark Plug Overheated Fouled Clean Oil Cooler Replenish Fuel Air Filter Screen Clogged Fuel Vent Exhaust Clean Engine Line Kinked Restricted Exterior Or Plugged Contact your Contact Your Water in Fuel Dealer Dealer...

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