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Craftsman 108.27807 Operator's Manual

All terrain vehicle 300 electric start engine 2 wheel or 4-wheel drive automatic transmission.
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Operator's Manual
ALL TERRAIN VEHICLE
Craftsman 300 Electric Start Engine
2 Wheel or 4-Wheel Drive
Automatic Transmission
Model Number: 108.27807
WARNING
Before operating this vehicle, the owner and each operator must:
• Understand that this vehicle was not designed or manufactured to
meet specifications for use on public roads, streets, highways, and
thoroughfares.
• 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 the vehicle.
• View "Operations and Safety" video.
• Be at least 16 years of age.
For answers to your questions about this product, call:
1-800-643-7332
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
8 a.m.– 5 p.m. ET, Mon – Fri
PN 83155

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   Summary of Contents for Craftsman 108.27807

  • Page 1

    Operator’s Manual ALL TERRAIN VEHICLE Craftsman 300 Electric Start Engine 2 Wheel or 4-Wheel Drive Automatic Transmission Model Number: 108.27807 WARNING Before operating this vehicle, the owner and each operator must: • Understand that this vehicle was not designed or manufactured to meet specifications for use on public roads, streets, highways, and thoroughfares.

  • Page 2: Table Of Contents

    Table of Contents Page Section 1. Introduction 2. Understanding Warnings 3. Safety Warnings 4. Warning Decals 5. Daily Pre-Ride Inspection 6. Operation Warnings 7. Vehicle Identification 8. Basic System Functions 9. Starting the Engine 10. Vehicle Break-in Period 11. Riding Gear 12.

  • Page 3: Introduction

    ATV. Please be certain that any accessory added has been approved by Manco (the manufacturer of this Craftsman ATV). Contact Manco Customer Service at 1-800-643-7332 or 1-260-432-1596. Practice Responsible ATV Riding Make sure that you understand and follow all local, state/province, and federal riding laws and requirements.

  • Page 4: Understanding Warnings

    2. Understanding Warnings ATTENTION: Read and understand warnings and owner’s manual before operation. This is an adult vehicle only— it is not a toy. 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 carefully.

  • Page 5: Safety Warnings

    3. Safety Warnings AN ATV 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, if you fail to take proper precautions. Know your vehicle before you begin riding! Read this manual thoroughly prior to operating your vehicle.

  • Page 6

    Always be alert to changing terrain conditions when operating the ATV. • Never operate on excessively rough, slippery or loose terrain. • Always follow proper procedures for turning as described Section 12 “Riding – Making Turns”. Practice turning at low speeds before attempting to turn at faster speeds.

  • Page 7

    • Wet brakes may have reduced stopping ability. Test your brakes after leaving water. 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.

  • Page 8: Warning Decals

    4. Warning Decals Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event that any decal becomes illegible or comes off, contact 1-800-643-7332. NOTE: Illustrations used in this manual are for general representation only. Your model may differ.

  • Page 12

    Refer to Page 13...

  • Page 13: Emission Control Information

    Emission Control Information: EMISSION CONTROL INFORMATION IMPORTED BY Sunright International of America, Inc. HANGSU LINHAI POWER MACHINERY GROUP ENGINE DISPLACEMENT: 275cc MAXIUM BRAKE HORSEPOWER: ENGINE FAMILY: THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE THIS VEHICLE CONFORMS TO US ENVIRONMENTAL PROTECTION AGENCY REGULATIONS APPLICABLE TO 2006 MODEL YEAR ALL-TERRAIN VEHICLES AND IS CERTIFIED TO 1.5 GM/KM HC+NO ENGINE FAMILY EXHAUST EMISSION STANDARDS.

  • Page 16: Daily Pre-ride Inspection

    5. 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 17: Operation Warnings

    6. Operation Warnings WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete a certified training course.

  • Page 18

    WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and /or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.

  • Page 19

    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 operating this ATV.

  • Page 20

    WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain ATV. WHAT CAN HAPPEN Increases the possibility of 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 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 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 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. HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting large hills.

  • Page 23

    WARNING POTENTIAL HAZARD Stalling, rolling backwards, or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed, keep weight uphill and apply the brakes.

  • Page 24

    WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance or skidding or sliding out of control.

  • Page 25

    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 tires specified in Section 21 “System Specifications”...

  • Page 26

    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 before you are sure the ice is thick enough and sound enough to support the machine and its operator, as well as the force that is created by a moving vehicle.

  • Page 27: Vehicle Identification

    7. Vehicle Identification Record these numbers from your ATV in the spaces provided. 1. Frame VIN (found on the left side, below engine, by rear swing arm) Engine Serial Number (left front side of engine crankcase) The vehicle VIN and engine serial numbers are important for model identification when registering your vehicle, obtaining insurance, or whenever replacement parts are required.

  • Page 28: Basic System Functions

    Remove the spare key and store in a safe place. Your key can only be duplicated by obtaining a key blank and having it cut by mating it with your existing key. Record key number in space below. Key Number 8.

  • Page 29

    Pictures are for Reference Only Main Switch – This key switch must be turned clockwise to the “on” position to start the engine. Hazard Light Switch (when equipped) – When the switch is pushed to “ “, the four signal lights are on and the buzzer is sounding. Engine Start Button –...

  • Page 30

    Light Switches and Indicator Lights WARNING This ATV is NOT equipped with highway-approved lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

  • Page 31: Throttle Lever

    Throttle WARNING Do not start or operate an ATV with sticking or improperly operating throttle control. A stuck or improperly operating throttle could cause an accident resulting in injury or death. Always contact your dealer for service repairs whenever throttle problems arise.

  • Page 32: Setting The Parking Brake

    Front and Rear Brake Control WARNING Never operate the ATV with a spongy feeling brake lever. Operating the ATV with a spongy brake lever can result in loss of braking. Loss of braking could cause an accident. Front and Rear Brake Control Lever The front and rear brake control is located on the left handlebar and...

  • Page 33

    return to its released position. Important Safeguards • The parking brake may relax when left on for a long period time. This could cause an accident. • Do not leave the vehicle on a hill depending on the parking brake for more than five minutes.

  • Page 34

    Master Cylinder 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 (1) on the top of the master cylinder. This window will appear dark when the fluid level is full.

  • Page 35: Engine Cooling System

    is a torque converter belt used to drive the transmission. NOTE: There extend belt life, use low forward gear in heavy pulling situations and in situations when you are operating below 7mph (11km/h) for extended periods of time. Engine Cooling System Fill Location Coolant level –...

  • Page 36

    Pressure Cap Fuel System WARNING • Gasoline is highly flammable and explosive under certain conditions. • The engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects or other reproductive harm. CAUTION: Alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage.

  • Page 37

    The fuel tank filler cap (1) is located directly behind the handlebar. Refer to Section 19 “Specifications” for tank capacity. Use regular unleaded gasoline. The fuel valve selector is located on the left side of the front fender and has three positions: OFF: For vehicle storage and whenever transporting.

  • Page 38: Oil System

    Oil System CAUTION Use only SAE 15W/40 OIL. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. The oil fill is located on the right side of the engine. To check the oil: 1. Set machine on a level surface. 2.

  • Page 39: Starting The Engine

    CAUTION: To engage or disengage the 4WD drive system, stop the vehicle and with the engine idling, move the lever to desired position. Shifting while the vehicle is moving or the rear wheels are spinning could cause transmission and drive system damage.

  • Page 40

    neutral. Press the engine start button. NEVER press the engine start button for more than 5 seconds at a time or you can flood the engine. 4. If the engine does not start, turn the key switch off, wait 15 seconds and repeat steps 3 and 4 two more times.

  • Page 41: Vehicle Break-in Period

    10. Vehicle Break-in Period CAUTION Do not operate at full throttle or high speeds for extended periods during the break-in period. Excessive heat can build up and cause damage to close fitting engine parts. CAUTION: Speed adjustment should be limited during the break-in period to a top speed of 25 MPH.

  • Page 42: 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 Section 5 “Daily Pre-Ride Inspection” 1. Sit upright with both feet on footrests and both hand on the handlebars. 2.

  • Page 43: Traveling Uphill

    Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

  • Page 44: Side Hilling

    Side Hilling WARNING Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. Side hilling your ATV is one of the most dangerous types of riding and should be avoided.

  • Page 45: Turning Around On A Hill

    Turning Around On A Hill WARNING Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death. 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.

  • Page 46

    4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal. NOTE: After running the vehicle in water, it is critical your machine is serviced as outlined in the maintenance chart in Section 17 “Maintenance”. The following areas need special attention: engine oil, transmission oil, rear gear case, and all grease fittings.

  • Page 47: Trail Obstacles

    Trail Obstacles WARNING Not all obstacles are visible. Travel with caution on trails. Severe injury or death can occur if vehicle comes in contact with a hidden obstacle. 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.

  • Page 48: Parking On An Incline

    Backing up 1. Avoid backing up on steep inclines. 2. Always back up slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while operating in reverse. 6.

  • Page 49: Carrying Loads

    13. Carrying Loads WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Never exceed the load weights specified in Section 21 “Specifications” of this manual. Overloading or incorrect positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.

  • Page 50: Cvt System

    • Always attach a tow load to the hitch point designated for your ATV. • The vehicle should never exceed 10 mph (16km/h) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

  • Page 51: Battery

    When To Use Low or High Range The following lists provide a guideline for when to use low range or high range during operation of your vehicle. Low Range • Basic operation at speeds less than 7 MPH (11km/h) • Heavy pulling •...

  • Page 52: Replenishing The Battery Fluid

    Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. To refill use only distilled water. Tap water contains minerals which are harmful to a battery.

  • Page 53: Exhaust System

    Battery Installation 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte;...

  • Page 54: Maintenance

    laws apply on federal lands. A spark arrester for the muffler is available by contacting Manco Customer Service at 1-800-643-7332 or 1-260-432-1596. The exhaust pipe must be periodically purged of accumulated carbon as follows: Remove the arrester screw (1) located on the bottom of the muffler, pull out the spark arrester (2) (the mesh).

  • Page 55

    Maintenance Table Codes (See illustrated parts list for view of mentioned ATV parts.) – Due to the nature of these adjustments, items marked with this symbol are recommended for repair or replacement by an authorized service center. Call 1-800-643-7332 for service. •...

  • Page 56

    Item Hours When Remarks Code Brake pad wear 10 hrs Monthly Visually Inspect periodically Rear Gear case Oil 100 hrs Monthly Check monthly and • change annually Front Gear case Oil 100 hrs Monthly Check monthly and • (Only for 4WD) change annually Engine Cylinder 25 hrs...

  • Page 57: Lubrication Recommendations

    Item Hours When Remarks Code Radiator 100 hrs 12 months Inspect/clean external surface Cooling System 50 hrs 6 months Inspect/replace if hoses 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 58

    Item Lubricant / Fluid Method Frequency Code 7. Steering Grease Locate fitting on pivot Every 3 months • Post Bushings shaft and grease with or 50 hours grease gun D 8. Front Wheel Grease Inspect and replace Semi-annually • Bearings bearings if necessary 9.

  • Page 60

    Periodic Maintenance Record Use the following table to record periodic maintenance work. Maintenance Service Service Interval Date Dealer Remarks First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs...

  • Page 61: Handlebar Adjustment

    Handlebar Adjustment WARNING Improper adjustment of the handlebars or incorrect torque 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. Your ATV has handlebars which can be adjusted for your personal fit. Remove the handlebar cover.

  • Page 62: Front Wheel Hub Tightening

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. An authorized service center must perform service work. Call 1-800-643-7332 for service. Front Rear Flange nuts: Install with flat side Tapered Nuts: Install with tapered against wheel.

  • Page 63: Steering Inspection

    Steering Inspection The steering assembly of the ATV 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. Toe Alignment Check WARNING Do not attempt to adjust the tie rod for toe alignment.

  • Page 64: 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 of 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 65

    NOTE: Since this is a rear brake only, it will not be as effective as the hand brake, which brakes all 4 wheels simultaneously. Carburetor/ Engine Idle RPM Adjustment If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1.

  • Page 66: Spark Plugs

    Spark Plugs Inspect the following: 1. Insulator (1) for abnormal color. Normal color is a medium to light tan. Replace if necessary. 2. Electrode (2) for wear/damage. Replace or clean spark plug with spark plug cleaner or a wire brush. Standard spark plug: 3.

  • Page 67: Radiator Coolant Level Inspection

    1. Place vehicle on a level surface. 2. Run engine for 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 68

    transmission oil reservoir. 2. Remove fill plug. 3. Remove the transmission drain plug located on the bottom left hand side and drain the oil. Catch and discard used oil properly. 4. Clean and reinstall the drain plug torque to 14 ft.lbs. (20Nm) 5.

  • Page 69: Rear Gear Case

    Front Gear Case Rear Gear Case Wheel Safeguards WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires, or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation.

  • Page 70: Wheel Installation

    Wheel Removal Procedure 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. The stand must be sturdy enough to safely support the weight of the ATV.

  • Page 71: Indicator Lamp Replacement

    Headlight / Tail Light / Brake Light 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.

  • Page 72: Storage

    Washing WARNING Never use a high-pressure type car wash system, it can cause damage to the wheel bearings, transmission seals, body panels, brakes, warning labels, and water might enter the engine or exhaust system. The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water.

  • Page 73

    • Turn off the engine. • Change oil and screen as described in Section 17 “Maintenance – Oil and Oil Screen Change”. FUEL SYSTEM CAUTION: It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor, fuel filter, fuel hose or tank during storage. Also, alcohol blended fuels (called gasohol or using ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage.

  • Page 74: Troubleshooting

    prevent condensation, and may promote corrosion and oxidation. CAUTION: Never cover ATV with engine and exhaust areas still warm. 19. Troubleshooting NOTE: The following table does not cover all the possible causes of trouble. It should be helpful, however, as a general guide to troubleshooting. Where applicable refer to the relative procedure in this manual for inspection, adjustment and replacement of parts.

  • Page 75

    PROBLEM CAUSE CORRECTION 11. Dirty air filter. 11. Clean/replace air filter. 12. Dirty fuel filter. 12. Contact 1-800-643-7332. 13. Water in fuel. 13. Empty fuel tank and Will not start carburetor, refill tank with (continued) fresh fuel and replace fuel filter.

  • Page 76

    PROBLEM CAUSE CORRECTION filter, refill with fresh fuel. 9. Loose or damaged 9. Contact 1-800-643-7332. Poor speed wiring. performance 10. Carburetor out of 10. Contact 1-800-643-7332. (Continued) adjustment. 11. Engine valves out of 11. Contact 1-800-643-7332. adjustment. 1. Incorrect coolant 1.

  • Page 77: Tools

    20. Tools included with ATV Spark Plug Wrench Open End Wrench (8, 10 mm) Open End Wrench (12, 14 mm)

  • Page 78: System Specifications

    21. System Specifications Capacities Fuel capacity 12.5L / 3.3gal Engine Oil Capacity 1.4L / 1.7qt Ground Clearance 183mm / 7.2in Height 1170mm / 46in Length 2096mm / 82.5in Width 1170mm / 46in Seat height 865mm / 34in Wheel Base 1265mm / 49.8in Turn Radius 3277mm / 129in Dry Weight...

  • Page 79

    Engine ATV300 Engine Type 4Stroke, Single Cylinder, SOHC Bore x Stroke 70mm X 66.8mm Displacement 275cc Starter System Electric Start Engine Cooling Liquid-Cooled Lubrication System Wet Sump Carburetor CVK30 Ignitions T.C.I Spark Plug Type DR7EA (NGK) Electrical Equipment Battery 12V 14AH Head light 35W / 35W Brake/ Tail Light...

  • Page 80: Wiring Diagram

    22. Wiring Diagram...

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