Manual: Brief introduction
The full name of ATV is All-Terrain vehicles.200(EC)ATV is newlymanufactured by our
industries (group) cO.,Ltd ..
200(EC)ATV embodies the experience and essence of world motorcycletechnology. It adpots
single-cylinder four-stroke air -cooled engine newly developed by ourcompany,and employs
the devices ofcarburetor carburetor, wet automatic centrifugal clutch, five-speed shifting, through
driving, reversedriving hand pulled recoil starter and electric-starter in combination, CDIelectric
19nition,pressuresplash lubrication system, etc, which are good in performance. This ATV isnovel
and bright indesign, having moved, streamlined model and luxury decorationdesign, And it meet
the nationalstandard in noise anddirt drainage ,especially it embodiesthe great power, reliability,
endurance, beingan ideal transportation facility for ATV funs.
The correct operation andmaintenance are the prerequisites at your safety riding of the
ATV,and also can reduce the fault of the ATV and keep its bestperformance. So please read
thismanual! to understand its basic operation, repair and maintenance methods .Theinformation contained herein all relates to the ATV of the current design andis subject to changes by
our company according to the demands of market and users without notice.if you have any
questions.Please consult with our motorcycle dealer .We are welcome foryou precious advice
and suggestions. Our company has established many service centers(stations, points),with specially
·trained technical personnel In operation and maintenance ,pleasecontact with our motorcycle dealer and service center(stations, points).Ourcompany consistently adheres to the
principle of quality first, users upmost, reputation foremost andbe ready to provide youwith high quality service.
IMPORTANT INFORMATION FOR OPERATION
WARNING Injun; or death could be result from failure to follow WARNING instructionswhen you are operating inspecting or repairing the ATV.
CAUTION A CAUTION indicates special precautions that must be taken toavoid
damage to the ATV.
NOTE A NOTE provides information can make your operation in the ATVeasier
or clearer.
Content
Safetyinformation ......................................... 1
Descriptionand machine identification .......... 1
Control functions ........... ....... 3
Mainswitch ........ ........... . ....... 3
Indicatorlights ............... .. ........ 3
Handlebarswitches..... . ........... 3
Start switches ...... ........................... 3
Lightswitches. . . .............. ,, 4
Throttlelever . ............ . .....................4
Speedlimiter ................................................ 5
Front brake lever .. ,,,...... . .. 5
Rear brake pedal and lever ........................... 5
Parking brake .. .................. . 6
Shiftpedal ......... .. ... 7
Drive select lever ... ...............7
Recoil starter................. ............. 7
Fueltank cap .... ............. 7
Fuel cock ................ 8
Seat............. ................. 8
Storagebox. .......... 9
Front carrier .. .............. .9
Rearcarrier ............ .. ..................9
Rearshock absorber .......... . .9
Spring preload adjustment ...... ............ 9
Pre-operationcheckes ... ............. 10
Frontand rear brakes.. ............. 10
Fuel ............ .......................... 11
Engineoil. ................. .......... ..... 11
Lubrication oil of gear case .... .. . ............ 11
Throttle lever .. .............. ............... 11
Fittings and Fasteners .. ................ 12
Lights.......... ....... .......... 12
Switches.... ............ 12
Battery..........12
Tires... ..........12
Howto measure tire pressure ... .......... 12
Tire wear limit ........... 13
Operation..... ..................................14
Startingan engine .... ..................................... 14
Startinga cold engine ................................... 14
Startinga warm engine .......... .............14
Prewarming..... ........................ 14
Drive Select lever operation
andreverse driving........................................ 15
Shifting . ............. 15
Tostart out and accelerate ........... ............. 16
To decelerate ........... 16
Enginebreak-in .. ............ 16
Accessories.................. , 17
Loading... ............... 17
Ridewith care ............... 18
Speedlimit valve .............. 19
Exhaustsilencer ..... ...................... 19
Turning.......... .......... 20
Climbingslope.......... .......... 21
Ridingdownhill .......... .......... 22
Crossing depression ............ 22
Crossingthrough shallow water .......... 22
Ridingover rough terrain .......... .......... 23
Slipping.......... ............ 23
Periodicmaintenance and adjustment .......... .......... 24
Operationmanual and tool kit .......... 24
Periodicmaintenance / Lubrication ...... ..............,25
Engine oil .............. ....... .............. 27
Lubricationoil of gear case ................ 29
Replaceof lubrication oil of gear case.............. 29
Sparkplug inspection .............. .......................... 30
Airfilter cleaning ....... ..............31
Carburetoradjustment ...... ................. 32
Idlespeed adjustment .... ...............32
Valveclearance adjustment ..............32
Throttle lever adjustment .... ............... 32
Frontand rear brake shoe inspection................ 33
Front brake lever free play adjustment ................ 33
Rearbrake adjustment .... ..............34
Clutchadjustment ..... ..............36
Cable inspection and lubrication..............36
Brake and shift pedal / brake lever lubrication
Steering vertical tube lubrication ..................36
Wheel removal .... .............. ..............36
Wheel installation . .............. .............. 37
Fuse replacement ... .............. ................ 38
Replacing the headlight bulb .. ..............38
Spark arrester cleaning .. .............. 39
Cleaningand storage .. ............................40
Cleaning. .............. .............. 40
Storage,.. .............. ..............41
Main data and specification.............. ................. 42
Maintenance record.............. ............... 44
Electric wiring diagram . ................ 45
SAFETY INFORMATION
This operation manual includes important
safety and maintenance information. When re-selling the ATV TO THE NEXT BUYER, the
operation manual should be passed on together
with it because the next useralso need
the manual .Please read the manual carefully
before driving the new .If failed to conform
the requirements described in the manual, lt
will be easy to cause injuries and deaths.
WARNING
• Read this manual carefully and follow
the operating procedures and methods described
in this manual.
• Never operate an ATV without proper
training or instruction .
• A child under 16 years old should never
operate an ATV, Never allow drive of an ATV
by an individual person if he or she does not
have the abilities to operate it safely .
• Always avoid driving an ATV on any
paved surfaces, including sidewalks,
driveways, parking lots and streets .
• Never operate an ATV in any public
street, road Or highway, even a dirt or gravel
one.
• Never drive an ATVwithout wearing an
approved motorcycle helmet that fits
properly, You should also wear eye protection
(goggles or face shield), gloves, boots, long-sleeved
shirt or jacket, and long pants.
• Never consume alcohol or drugs before
or while operating this ATV.
• Never operate at speeds too fast
always drive at low speed on dusty surface.
• Always inspect your ATV each time you
use it to makesure it is in safe operating
condition. Always follow the inspection and
maintenance procedures and schedules described in this manual
• Always keep both hands on the
handlebars and both feet on the footboards
of the ATV during operation.
• Never operate on excessively rough,
slippery orloose terrain unless you have
learned and d practiced the skills necessary
to control the ATV on such terrain. Always be
especially cautious on these kinds of terrain.
• Always follow proper procedures for
turning as described in this manual-. Practice
turning at low speeds before attempting to
turn at faster speeds, Do not turn at excessive speed.
• Never drive the 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 starting up
any hill. Never climb hills with excessively slippery or loose surfaces.Shift your weigth
forward. Never open the throttle suddenly or
make sudden gear changes. Never go over
the top of a hill at high speed.
• Alwaysfollow proper procedures for going
down hills andfor braking on hills as described
in thismanual. check the terrain
carefullybefore starting down any hill .Shift your
weightbackward. Never go down a hill at high
speed . Avoidgoing down a hill at an angle that
would causethe vehicle to lean sharply to one
side. Go straight down the hill where possible.
• Always follow proper procedures for
crossing the side of a hill as described in this
manual. Avoidhills with excessively slippery or
loosesurfaces. shift your weight to the uphill
side of theATV. Never attempt to turn the ATV
around on anyhill until you have mastered the
turningtechnique described in this manual on
level ground .Avoid crossing the side of a
steep hill ifpossible.
• Avoid crossing the steep hills.
• Always use proper procedures if you
stail or rollbackwards when climbing a hill. To
avoid staling,use proper gear and maintain
a steady speedwhen climbing a hill. If you stall
or rollbackwards, follow the special procedure
for brakingdescribed in this manual.
• Always checkfor obstacles before operating
in a new area.Never attempt to operate
over large obstacles,such as large rocks
or fallen trees. Always follow proper procedures
when operatingover obstacles as
described in this manual.
• Always be careful when skidding or
Sliding. Learnto safely control skidding or
sliding bypracticing at low speeds and on level.
smooth terrain. On extremely slippery surfaces,
such as ice, goslowly and be very cautious in
order to reduce the chance of skidding or sliding out of control.
• Never operate an ATV in fast flowing
water or in water deeper than that recommended in this manual. Rememberthat wet
brakes may have reduced stopping ability.
Test your brakes after wiping water away, if
necessary, apply them several times to let
fricting dry out the linings,
• Always be sure there are no obstacles
or people behind you when operating in
reverse. When it is safe to proceed in reverse,
go slowly. Always use the size and type tires
specified in this manual. Always maintain
proper tire procedure as described in this
manual.
• Never modify an ATV through improper
installation or use of accessories
• Never exceed the stated load capacity
for an ATV. Cargo should be properly distributed
and securely attached .
• Reduce speed and follow instructions
in this manual for carrying cargo or pulling a
trailer. Allow greater distance for braking .
• Improper handing of gasoline can cause
fire and can cause injuries and deaths and
other serious accident So do not refuel right
after the engine has been running and is still
every hot .Never refuel while smoking .or while
in the vicinity of sparks ,open flames ,or other
sources of ignition, when transporting the
machine in another vehicle, be sure it is kept
upright and that the fuel cock is in
the "OFF” position, otherwise fuel may leak out
of the carburetor or fuel tank.
• Starting or running the engine in a
closed area will cause the breakdown .And exhaust fumes are poisonoususand may cause loss
of consciousness and death within a short time, Always operate yourmachine in an area with
adequate ventilation.
DESCRIPTION AND MACHINE IDENTIFICATION
1.Front wheel
2.HeadUght
3.Driveselect lever
4.Shiftpedal
5,Fuelcock
6.Recollstarter
7.Starter(choke)
8.Taillight
9.Rear wheel
10.Rear carrier
11.Sparkarrester
12.Seat
13,Fueltank cap
14.Brakepedal
15.Frontcarrier
16.Rear brake lever
17.Parkingbrake
18Main switch
19,Throttle lever
20.Front brake lever
21Handlebar switch
Themachine you have purchased may differ
slightlyiron those shown [n the figures of this manual
forprogress or other change.
identification numbers Record
Whenordering spare parts from a our dealer or for reference in case the vehicle isstolen Record,
vehicleIdentification number in the spaces provided for assistance.
1. VEHICLEIDENTIFICATION NUMBER:
Vehicle identification number
Thevehicle identification number is stamped on crosstube Of pedestal.
.2.
CONTROL FUNCTIONS
Main switch
Functionsof the respective switch positions are
asfollows:
ON:
Enginecan be started only at this position and
theheadlight and taillight come on when the light
switchis on,
OFF:
All electrical circuits are switched off, The key
can be removed In this position,
Indicator lights
Reverseindicator light “R”
Thisindicator light comes on when the transmission
isin reverse, The light is blue In color.
Neutral indicator light " N "
Thisindicator light comes on when the transmission
isin neutral.
High beam indicator light
Thislight is yellow in color .It comes on when
thehead light and high beam light is on.
Handlebar switches
Engine stop switch
Makesure that the engine stop switch is in
the position. Theengine stop switch
controlsIgnition and can be used at all times to
stopthe engine, especially in an emergency. The
enginewill not start or run whenthe engine stop
switchis turned to ,
Start switch
Thestarter motor cranks the engine when this
switchis pushed.
Seestarting instructions prior to starting engine
(seepage for details).
Ifthe starter switch is pushed with the
·3·
1.Neutralindicator light "N"
2.Reverseindicator light “R"
3.Hightbeam indicator light
1.Lights switch
2.Enginestop switch
3.Startswitch
mainswitch " () " and the engine stop
switch"CO” ,the starter motorwill be activated
butthe engine will not start. To start the engine ,be
sureto set the engine stop switch at "??",
Lights switch "LlGHTS”
,Turn the switch to “D" for the low beam and
taillight.
Turnthe switch to ”D" tor the highbeam
andtaillight
Throttle lever
Oncethe engine is running ,movement of the
throttlelever will increase the engine speed. Adjust
thespeed of the machine by changing the throttle
position.Because the throttle is spring-Ioaded, the
machinewill decelerate, and the engine will return
toan idle any time the hand is removed from the
throttlelever, Before starting the engine ,check the
throttleto be sure it is operating smoothly.Make
sureIt returns to the idle position as soonas the
leverIs released.
Checkthe operation of the throttle lever before
startingthe engine. lf it does not work smoothly, check
-4-
forthe cause. Correct the problem before riding the
ATV.Consult a Our dealer if you can't find or solve the
problemyourself.
1. Throttle lever
Speed Limiter
Thespeed Limiter keeps the throttle from fully
opening,even when the throt1le lever is pushed to
the maximum, Screwing in the adjusting screw limits
themaximum engine power available and decreases
themaximum speed of the ATV.
1.Locknut2.Adjusting Screw
a.12mm(047in)
CAUTION
Donot turn the speed adjusting screw out more
than12mm.Always make sure the throttle lever free
playis adjusted to 3·5 mm.
Front brake lever
Thefront brake lever is located on the right
handlebar.Pull it toward the handlebarto apply the
frontbrake.
Rear brake pedal and lever
Thebrake pedal is located on the right side of
·5-
themachine and the brake lever is located on the left
handlebar,Pull the lever toward the handlebar or tread
slowthe pedal to apply the rear brake.
Parking brake
Whenyou have to start the engine or park the
machine,especially on a slope, use the parking brake
1. Rear brake pedal
Applythe rear brake lever and push down the
lockplate to apply tile parking brake, squeeze the
rearbrake lever to release the parking brake.
CAUTION
theATV could start moving unexpectedly if the
parkingbrake is out of function before starting the
engine.This could cause loss ofcontrol or a collision.
Thebrakes could overheat if you ride the ATV
withoutreleasing the parking brake. You could lose
brakingperformance which could cause an accident
.Youcould also wear out the brakes prematurely.
1. Rear brake lever 2,Lock plate
1.Lockplate
-6-
HOW TO AVOID THE HAZARD
Alwaysset the parking brakebefore starting the
engine.Always be sure the parking brake have been
releasedbefore you begin to ride.
Shift pedal
Thismachine is equipped with a constant mesh
5-speedtransmission .The shift pedal is located on
theleft side of the engine. Neutral is at the bottom
position.
Drive select lever
Thedrive select lever is used for driving the machine
eitherforward or in reverse. Refer to page for
driveselect lever operation.
Shiftpedal N. Neutral
1.Drive select lever
2.Hand start lever
Recoil starter
Firmly grasp the handle and pullslightly up to
engagement can be felt. Then pullforcefully , being
careful not to pull the rope allthe way out
CAUTION
Don't start the engine innon-neutral or without
setting the parking brake system.
Put the transmission in neutraland set the parking
brake before starting the engine.
Fuel tank cap
Remove the fuel tank cap byturning it counterclockwise
·7·
Fuel cock
Thefuel cock supplies fuel from the fuel tank to
thecarburetor,
OFF:
Itthe lever is in this position ,fuel will not flow.
Alwaysturn the lever to this position when the engine
isnot running
Fuel tank cap
ON:
Iftl10 lever is in this position, fuel flows to the
carburetor. Normal riding isdone with the lover in
this position,
RES:
Thisindicates reserve. If you run out of fuel while
riding.turn the lever to this position. After refueling,
returnthe fuel cock lever to the "ON” position.
Seat
Toremove the seat, pull the seat lock lever upward and pull up the seat at the rear.
Toinstall the seat, insertthe lobes on the frame
andpush down the seat at the rear, you should pay
i. Seatlocklever
-8-
attentionto make sure that the seat is securelyfitted.
Storage box
Maximumload limit: 2kg
Front carrier
Maximumload limit 30kg
Rear carrier
Maximumload limit 60kg.
Rear shock absorber
Thespring preload can be adjusted to suit the
rider'sweight and riding Conditions.
Spring preload adjustment
Toincrease the spring preload. turn the adjuster
indirection@.To decrease the spring preload.run
theadjuster In direction@.
Standardposition:6
A·Minimum (Soft)
E:·Maximum(Hard)
-9-
PRE·OPERATION CHECKS
Before using this machine, check tile following points'
Inspectthe ATV each time you use it to make
surethe ATV Is In safetyoperation condition.
Followthe Inspection and maintenance procedures
andschedules described in the Operation Manual.
Frontand rear brakes
Alwayscheck the brakes at the start of every
side.Do not ride the ATV if youfind any problem with
thebrakes. lf a problem cannot be corrected bythe
adjustmentprocedures. Provided in this manual, have
the ATV Inspected by aour dealer.
1.Brakelevel and brake pedal
Checkfor correct free play in the brake levers
andbrake pedal, If the free play is incorrect adjust it
see pages.
Checkoperation of the levers and pedal They
shouldmove smoothly and there should be a firm
feelingwhen the brake is applied, If not ,have the
machineinspected by a our dealer.
2. Brakeoperation
'10-
Testthe brakes at slow speed after starting out
tomake sure they are working properly. lf the brakes
donot provide proper braking performance, inspect the brakes for wear. See page.
Fuel
Makesure there is sufficient gasoline in the tank.
Recommendedfuel; unleaded fuel
Fueltank capacity:
Total:12L
Reserve:1.6L
Unleadedfuel will give a longer spark plug life
andreduce maintenance cost. lf unleaded gasoline
isnot available, the leaded regular gasoline can be
used.
CAUTION
Fuelcan spill, causing a fire and severe injury.
Fuelwill expand when it heats up if the fuel tank
isoverfilled ,fuel could spill out due to heat from the
engine or the sun .So, do not overfillthe fuel tank ,Be
careful.Not to spill fuel, especially on the engine or
exhaustpipe. wipe up any spilled fuel immediately.
Besure the fuel lank cap is closed securely, Do not
refuelright after the engine has been running and is
stillvery hot.
'Engine oil
Makesure the engine oil is at the specified level.
Addoil as necessary.(See page)
Recommendedoil
SAE20W40
SAE10W30
SAE5W30
Recommendedengine oil classification:
SE,SF,SG,type or higher.
Oilquantity:
Periodicoil change:1.5L
Withoil filter replacement:1.6L
Totalamount:1.8L
Lubricationoil of gear case
Makesure the lubrication oil of gear case is at
thespecified level. Add oil as necessary.(see page
fordetails’),
Recommended oil
SAE80API GL Hypoid gear oil
Throttlelever
Checkto see that throttle lever operates correctly.
It mustopen smoothly and spring back to idle position
-11-
whenreleased. Repair as necessary for proper
operation.
Fittings and Fasteners
Alwayscheck the tightness of chassis fittings
andfasteners before a ride. Refer to the Service.
Manualfor correct tightening torque.
Lights
Checkthe headlight and taillight to make sure
theyare in working condition. Repair as necessary
forproper operation.
Switches
Checkthe Operation of the headlight switch,
enginestop switch and any other switches. Repair
asnecessary for properoperation.
Battery
'Thebattery is an enclosed one and unnecessary to fill water(see page)
·Don’t take off the closing bolt when charging.
Whencharging, please obey the charging current and time as shown on the followingtable,
Chargecriteria: Charge the battery with ten percent
ofcapacity of battery for 5 to 10 hours, or quickly
chargethe battery with 2A to 3A for 2 hours.
Tire
Thesize and type (in low pressure condition) of
hollow tire used for 250ATV arelisted below
Front wheel Rear wheel
'-'..
Size AT23X7-10 AT22 x 10-10
Type zherig xin or wuxi Zheng xin or wuxi
Warning
Useof improper tires on this ATV, or operation
of this ATV with improper tire pressure may increase
yourrisk of accident
Use of improper tires on this ATV, or operation
ofthis ATV with improper tire pressure may cause
lossof control.
Payattention to choose the Size and type of
usedtire according to the description in the above
chartand make sure that the tire pressure isnormal.
2.Thetires should be set tothe recommended
pressure,
Front20 KPa ( O.20kgf/cm~2,2.8pai)
Rear25 KPa (O.25kgf/cm~2,3.6pai)
Checkand adjust tire pressure when the tires
arecold.
TirePressure below the minimum specified
couldcause the tire to dislodge from the rim under
severeriding conditions, the following are minimums:
Front17 KPa (O.17kgf/cml)
Rear22 KPa (O.22kgf/cmt )
Higherpressures may cause the tires to burst.
Inflationcould cause the tires to burst
Howto measure tire pressure
-12-
Usethe low-pressure tiregauge
Caution:
Thelow-pressure tire gauge isincluded as
standardequipment. conduct two measurements if
thetire pressure and use the second reading Dust
or dirt in the gauge would cause theFirst reading to
be incorrect.
Setpressure when tires are in cold and set tire
pressuresto the condition following specifications
Tirewear limit
Whenthe tire groove decreases to 3mm due to wear
a.3mm(o.12in)
-13-
OPERATION
WARNING
Neveroperate ATV until you are familiar with all controls.
Readthe operation Manual carefully. If there is a controls or function you do notunderstand ,ask your our
dealer'.
WARNING
Neverride the ATV in cold weather, always make sure all control cables work smoothlybefore you begin
ridding.Please read the engine brake-in section before you operate ,the engine at firsttime.
Starting a cold engine:
1.setthe parking brake.
2.Turnthe fuel lock to "ON" and the engine stop switch to" () ",
4.Shiftthe transmission into neutral.
WARNING
Theengine can be started in any gear ifthe fear brake lever is applier. However, it isrecommended to shift
intoneutral before starting the engine.
5.usethe starter (choke) in reference to the figure.
NOTE
ifthe engine fails to start, release the start switch, then push the start switch again, pausea several
secondsbefore the next attempt. Eachcranking should be as short as possible to preserve battery energy. Do
notcrank the engine more than 10 seconds for each starting.
Itthe battery is discharged. pull the recoil starter to start engine,
Startinga warm engine
Thethrottle should be opened slightly when starting a warm engine,
Prewarming
To get maximum engine service life, prewarm, the enginebefore startting off. Never accelerate forcefully
with a cold engine.
-14-
Driveselect lever oper.:1tion and reverse driving.
CAUTION
Beforeshifting, stop the machine and return the
throttlelever to its closed position. Otherwise the
transmissionmay be damaged.
Whenshifting intoreverse.1he transmission
mustbe in the first gear. Do not shift the Reverse
HandleBar before you make sure that the ATV is in
theFirest Gear or you may break the Handle Bar.
1Reverse Handle Bar a.Forward
2.Handstart lever b.Reverse
1.Stopthe machine completely and return the
throttlelever to the dosed Position.
2.Applythe rear brake pedal.
3.Shlftthe transmission into first gear,
4.Pressthe lock-button of the Reverse Handle
Barhard Into the socket the you can shift the Reverse
HandleBar. After it is moved to the proper
position,move the Handle Barand softly to make
surethe spring at the lock-button is released and
theHandle Bar is locked.
5.lncase the lock-button can not be released
afterthe Handle Bar is shifted to it's position,ask the
repairshop help.
NOTE
Whenin reverse the reverse indicator light
shouldbe on, lf the light does not come on ask a our
dealerto inspect the machine.
6.Checkfor people or obstacles behind you,
thenrelease the rear brake pedal.
7.0penthe throttle lever gradually and continue
towatch to the rear while backing.
WARNING
Whenshifting into reverse, make sure there are
no obstacles or people behind you .when it Is safe to
proceed,go slowly.
Shifting:
Thismachine has a 5·speod forward and 1-
speedreverse transmission with centrifugal automatic
clutch.To shift into neutral when driving, return
thethrottle lever to its original position and repeatedly
depressthe shift pedal until it stops.
·15-
CAUTION
Donot coast for long periods with the engine
ofI, and do not tow themachine a long distance.
Evenwhen gears are in neutral, the transmission is
only.Properly lubricated when the engine Is running.
inadequatelubrication may damage the
transmission.
Tostart and accelerate:
1.Releasothe throttle lever.
CAUTION
Alwaysclose the throttle while shifting gears.
Otherwise,the engine and drive train may be
damaged.
2.Shittinto first gear and release the shift pedal.
3Open the throttle gradually once the machine
hasobtained adequate speed. release the throttle
lever.
4.Shiftinto second gear and release the shift
pedal.
5Open the throttle gradually, Follow the same
procedure.When shifting to the next higher gear.
To decelerate:
Whenslowing down or stopping, release the
throttleand apply the brakes smoothly and even .As
youslow down, shift to a lower gear, Be sure that the
enginehas sufficiently slowed before engaging a
Iowagear. improper use of the brakes or control can
causethe tires to lose traction, reducing control and
Increasingthe possibility of an accident.
Engine break-ill
Thereis never a more important period in the
leftof your machine than the period between zero
and20 hours .During this period prolonged full
throttleoperation or any condition which might result
Inexcessive engine heating must be avoided, after
everyfull throttle acceleration ,the engine should run
atlower speed for a rest soas to rid itself of the
temporarybuild up of heat. lf any abnormality is found
duringthis period ,consult a our dealer.
1.0~10 hours:
Avoid continuous operation above half throttle. A
allowa cooling off period of five to ten minutes after
everyhour of operation. Vary the speed of the machine
fromtime to time Do not operate it atone set
throttleposition.
2.10-20hours:
Avoidprolonged operation above 2/4 throttle revolving
themachine can freely through the gears
durinrunning of engine but do not use full throttle
anytime.
3After break-in
Avoidprolonged full throttle operation. change
speedsoccasionally.
Parking
Whenparking. Stop the engine and shift Into
NeutralTurn the fuel to "OFF" and apply the parking
brake.
-16-
Avoidparking on hills or other inclines .If you
have10 park on an incline put the machine in low
gear.apply the parking brake and block the front and
rearwheels with rocks or other object. Do not park
theATV on the hills' that are sosteep that you could
not walk up them easily.
1-Applingthe brakes In low gear to slop the
machine.
2.Stopthe engine With the rear brake lever and
pedalapplied, apply the parking brake and slowly
release the rear brake pedal,
Accessories;
Payattention to the following points.
chooseonly accessories designed for you ATV
Ourdealer has a variety of genuine accessories.
Choosea genuine accessory.
WARMNG
1Accessories should be rigidly and securely installed.
2.Donot Install an accessory where it could interfere with your ability to control the ATV Examples
includea heavy or bulky objectattached to the handlebars
whichcould make steering difficult, an accessory
thatlimits your ability to movearound on the
seat,or one that limits you view. Use extra caution
whenriding an ATV with accessories.
Loading
Neverexceed the weight Limitsshown An
overloadedATV can be unstable.
Youmust use common sense andgood judgment
whencarring cargo or towing a trailer. Keep the
followingpoints in mind:
Maximum loading limit
VehicleLoading limit (total weight of cargo, rider
andaccessories):165kg
Frontluggage carrier:30kg
Rear luggage carrler:60kg
Toolkit;2/(g
Pullingload (total weight of trailer and cargo):
330kg
Verticalweight on trailer hook :15kg
Donot exceed the maximum pulling weight.
Adjustthe load in the trailer.
Cargoshould be put as close to the center of
theATV as possible .Putcargo at the front of the rear
-17-
luggagecarrier. Put the cargo on the middle position
andfix it on the earlierfirmly.
Makesure cargo in the trailer 'IS loadedfirmly
andsafety Otherwise an accident would be happen.
Makesure the load does not interfere with controls
or your sighting.
Ridemore Slowly than you would with a load,
Themore weight you carry, the slower you should go
,AlthoughConditions is different ,it is not allowed to
exceed2nd gear whenever you are carrying heavier
loadsor when towing a trailer ,Allow more braking
distance.A heavier vehicle takes longer to stop, Avoid
makingsharp turns unless at very slow speeds.
Avoidriding on hills and roughroad surface.
Andchoose terrain carefully .Extra weight willaffects
thestability and operation of the ATV.
Thismachine could be used to carry cargo and
passengersis prohibited.
OPERATION
·1.Geltraining if you are unexperienced,
Beginnersshould be trained at the guide of professional
person.Drive with this ATV with low speeds
firstto familiar with its perlormance ,even ifyou are
anexperienced rider, do not attemp to operate at maximum performance until you are totally familiar with
ATVs performance.
2.Dress
Alwayswear a motorcycle helmet when riding
.Alsowear the following protective tools eye protection
(gogglesor dust-proof shield, gloves, boots long-sleeved
shirtor jacket, pants)
3.Do not operate after drinking alcohol or drugs
containingsleeping pill composition, because operator
wouldbe slow in driving in such way.
4.Alwayscheck your ATV each time before you
uesit to make sure the reliability of ATV. Always follow
theinspection and maintenance procedures in
theoperation manual to protect you A1V
5.Always select the size and type of tires sped
-18-
fiedin the operation manual for this vehicle to keep
thenormal tire pressure.
6.Speed limit valve
Thisvalve Is used for beginners to limit the max
Speed of the ATV. Rotate the bolt clockwise to
Increase rnax.speed, and rotate it counterclockwise
todecrease rnax speed_
7.Alwayskeep your feet on the footboards
duringoperation .otherwise your feet may contact the
rear wheels,
Neverattempt stunts ,suchas wheelies or
jumps.
WARNING
Don'ttry to show off
8.Improperinstallation of accessories or
modificationof this vehicle may cause changesin Harding
whichin some situations ,could lead to an accident,
Nevermodify this ATV through improperinstallation
oruse of accessories. All partsand accessories
addedto this vehicle should be genuine our or
equivalentcomponents designed for using on this
ATVand should be installed and used according to
instructionsour dealer .If you have questions consult
an,authorized ATV dealer.
9.Exhaustsilencer
Theexhaust silencer is very hot during driving.
Toavoid burn, do not touch theexhaust cylinder .Park
themachine where pedestrians or children can not
touchit.
10,Know where you should ride
Thismachine Is designed to drive on off-road
RidingOn asphalt road may lose control.
Don'tride the ATV on asphalt road ,including
sidewalks,driveways, parking lots and walk streets.
Prohibitto drive the machine on any driveway,
streetsor highways,
Know the terrain where you ride
Ridecarefully in complicated terrain ,stay alert
torholes, rocks or roots or roots In the terrain otherwise
maycause the rnachine to tip over.
Whenriding in an area where you might not
easyto be seen ,such as dune and hilly land ,must
-19-
mounta caution flag on the machine to remind other
vehicles.Do not ride in areas of forbidding pass. Do
notride on private property.Operation course
CAUTION
Donot shift gears without releasing thethrottle.
Otherw'lsemay cause damage 10 theengine or
drivegear.
r---~'---=--"
~SIo~~do,Nn'":'"';pp;jn(C~~'lseth.
throttleand brake gradually. As youbrake,shift to
lowergear .Ensure that theengine has sufficiently
slowedImproper use of Ihe brakes or shifting can
causethe tires slidding to lose the control.
Mustmake the engine to slow dOwn fully before
engaginga lower gear.
'fiH"l:lillg
- Must make the turning practice in low speed
beforemaking a turn.
Turnyour ATV according to proceduresin operation
,manualPracflce shOUld be done before turn·
ingin high speed.
Theturning speed should not be too high.
As you approach a ourve, slow down and bog'ln
toturn the direction rod .Then put you gravity center
on1he footboard 10 the outside of the curve and lean
yourbOdy inside .Make the engine to maintain an
evenspeed when passing the curve. This maneuver
willlet the tire on the inside of the curve slip slightly.
Theturning practice should be in fiat area without
anyobstacles. Improper operation may make
yourATV to go straightlf the ATV doesn'tturn, stop it
andpractise again ,If the riding surface is loose and
slippery,move your weight forward.
Onceyou have learnthis technique you can turn
yourATV at higher speed.
Thesudden acceleration, brako, incorrect body
positionand too high speed will cause the ATV to
slip.If the ATV slips while passing a curve and the
-20-
ATVmachine leans inward ,you should release
thethrottle and move your body grayity cantor to outw
sideof the curvE! to avoid tipping over.
Remember:rldeat higher speed only after you
arethOroughly famtliar with the operation of yourATV
Climhing slope
Don'tride on slope before you are very familiar
withATV operation skill.otherwlse It will cause
accidents.
Neccessarypractice is required. when climbing
thehill,move your body gravity canfer forward and
operationmanual.
Climbthe hill according to the method In
manu1:il.
Climbthe hill aCGording to the method in
manual.
Checkcarefuly before climbing.
Donot drive 011 slippery and loose slope.
Transferyour body gravity canter forward and
avoidabrupt acceleration and shift.
Drivein low speed when climbing the hilI.
WARNING
Theremay be other vehicles and persons on
theother side of slope.
Ifyour ATV can not climb the slope,turn round
yOur ATV.
Maketurning practice according to procedures
inoperation manual:Do nol make turn on slope .Be
morecareful when making a turnon slope.Be more
carefulwhen making a turn on slope and avoid to
Climbsteep slope when possible ,when climbing
theslope:
Donot drive on depression and slippery slope
anddrive according to procedures in operation
manual.
Ensurethe ATV not to SliP when stop it on slope.
Theshift should be proper and speed shuld be
stablewhen climbing slope. losing traction force,you
shouldtransfer the gravity conter forward and brake
themachine.Close the brake closing piece after stopping
themachine.
Ifthe machine slips backward
Transferyou gravity center backward;
Use front brake;
-21-
DO not use rear brake
Closethe brake closing piece after stopping
themachine.
Riding d.ownhill
Moveyour gravity center backwa,rd,when riding
ATVdownhill,your and griSp steering bar and drive at
lowspeed.
Noto:Thebrake performance is very important
WheneverpossiblO,rlde your ATV straight,Tur~
ingmay cause the ATV to tip over,Avoid too high speed
sothat you have time to deal with accident.
CAUTION
Practisethe braking skill when decending 1he
hllUookover the terrain carefully before decending
andtransfer your body gravity canter backward. Ride
inlow speed when decanding the hill turning speed
shouldnot be too high when makinga turn,and keep
drivingstraight as far as possible.
Crossing dcpressi{lo
Whencrossing depression,balance your ATV
withbody gravity center,YOLl should be familiar with
basicskillS before crossing depression.Avoid to lose
balance10 cause accident.
Don't,make a turn on a slope before grasping
turningskill totally. You should be careful and cautious
jfmaking a turn on any slope.
When crossing procedure
Alwaysfollow proper prouclures in operation
manual;
Avoidslope with slippery or loose surlace.
Leanyour gravity center in the slope direction.
Crossing through shtlllow water
TheATV can be used to cross shallow water of
maximumdistance of 35cm.Check your path Clue,
fullybefore crossing, and avoid of ride where there is
sharpdrop off,Drive slowly and carefully.
-22-
Payattention that wot brakes may reduce brake
ability.Chockyour brakes after leaving water.lf
r'lecesary,applythem to let friction dry out the linings
severaltimes.
Ridingover rough terrain
Becareful when riding on rough terrain .when
ridingover terrain which maydamage the ATV,lay
yourtests on the foot pedals to avoid jumping and
los$of control.
Don'ttry to ride over bigobstacles such as rock
andtree on the road .Follow tho proceduces in operation
manualwhen riding over obstacles.
Slipping
TheATv may Jose control when driving on loose
andslippery surface. Moving you gravity center forward
ishelpful to control the slipping of front wheels
.whenthe rear wheel begin toslip,steer direction
properly.Applythe brake only until you have stopped
theSlipping.
Practrsesafely control SlipPIng at low speed.
onvery slippery surefaces,sUCI) as ice,drive slowly
toaVO"ld loss ofcontrol.
Theabove introductJon is only for reference.
Readit carefully and act according to circumstances.
-23-
PERIODIC MAINTENANCE AND ADJU&iMENT
Periodlcinspection ,adjustment,and lubrication will keep your machine in the safety and most efficient
condition.Thepoints of machine inspection,adjUstment,and lubrication are detailed infollowing.
NOTE
Turnoff the engine when maintaining unless specified. Have a OUr dealer pertormservice if you are not
familiarwith maintenance.
Operation manual and tool kit
Youare recommended to put this operation manual in the vinyl bag and lay it under the seat as shown. Put
thetool kit and low -pressuretiro gauge in the storage case.
Themaintaining information InCluded in this manual is provided you with thenecessary informatIon for
completingpreventive maintenance and minor repairs by yourself,The tools provided in the tool kit aresufficient
forthIs purpose,except a torque wrench necosary to tighten nuts and bolts.
NOTE
Ifyou do not have a requiredtorque wrench during maintenance,take you machine to a our dealer to check
ttletorque settings and adjust them as necessary.
-24-
PERIODIC MAINTENANCE/LUBRICATION
ITEMRQVnNE INlTAL EVERY
~'S
1montmonth 6rnonth$ 6months Wear
Checkvalve clearance,Adjust if necessary. 0 0 0 _ .... -
Sparkplug Check conditio.~:~?just gap and clean. Replace If necessary. 0 0 0
Airfilter Claan.Replce if necessary.Every 20 -40 MU IS( more often I n wel or dusty omQS) _..
CarbureorCheck idle speed/Starter operatlon.Adjust if necessary. 0 0 0
.1--.
Cylinderhead Check breather hOse for cracks Of damage, Replace if
0 0 breather systemecessary. 1-----
Exhaustsystem Cheek lor leakage. Retlghtan ifnecessary,Repaae gasl~et if nee-
0 0
j0!lSsry
Sparkarrester Clean. 0 0 . .... _--, ...
Fuellino Check fuel hose for crackS or damaoo,Raoiaceifnecessary. 0
Engineoil Replace(Warm engine before draining). 0 0 0
Engineoil filler Clean. 0 0 0
Engineoil strainer Clean. 0 0 0
Fin~1 gear o~~ ... Check ojllevel{oillea.kage.Reli!lac.~:.. 0 0
-25-
PERIODIC MAINTENANCE/LUBRICATION
_.
ITEM ROU11NE INITAL EVER"Y
1mMt/1 months 6monthS 6month$ 1Year
-~ ...
BrakesCl1eck operation,Adjust if necessary. Cl Cl Cl
-~ ...
clutchCheck operaion.~~ust ifnecessary. Cl Cl 0 f..-.
WheelsOneck balance/damage/runout Replace if necessary. 0 Cl
~--------... ...
Wheelbearings Check balance assembly tor looseness/damage.
Replacejf damaged . 0 Cl
.__ ...
Frontand roaf suspensjon~ Check operation.Correct if necessary. 0 0 -----... --...
Steeringsystem
. Check operation.Gorroct If necessary,Check toe ·in . 0 0 " .. ",-_ ...
Steeringsystem Adjust if necessary. 0 0 0 0
....-
_Stee ring shaft Lubricateevery 6months.(uso U grease) 0 0 ... ... __ .. .....
Fittingsand Fasteners~ Ctloor an chassis fillings andfasleners,Gorrijct if f1eces$(!.ty.0 0 0 0
L-. ... . ..
·2:6·
Engineoil
1.Engine 011 level measurement
a.Place the machine on a flat surface wram up
theengine for several minutes and turn off il.wait
morothan 10 minutes for 1he oil to drain back Into
thecrankcase beforo chocking the 011 level.
1.Dipstick2. Maximum level mark 3.Minimum
levelmark
b.Wlpethe dipstick off with a clean rag. Insert
thedipstick In the filler hole.
c.Removethe dIpstick and inspect the oil level.
d,Theoil level should be between maximum
andminmum marks .If level is low,add ol!to raise it
toproper level.
1,Drain plug
2.0-ring
3.Compression
spring.
4.0ilstrainer
1.0llfiltarcover
2.0ilfilter
3.0-ring
-27-
2,Engine oil replacement and oilfitter element
cleaning
a,Placethe machine in a flat suface,Warm up
theengine for several minutes and turn off place a
containerunder the engine. Remove the dipstick and
openthe drain plug to drain the oH,
b.Removethe ail fiter cover and oilfilter,clean
the011 stramer and oll1ilter with solvent.
c,lnspectthe O-ring and replace if damaged,
d.Reinstallthe oil filter,O-ring and oil filter cover.
Replacethe oil strainer,compression spring,O-ring
anddrain pulg ,Then tighten the drain plug and filter
coverbolts to the specified torque.
Tighteningtorque:
Drainpulg(engine):
43Nm(4.3m.kg)
Filercover bolt
1ONm(1 ,Om,kg)
a,Addoil to the engine with oil and install the
dipstick.
CAUTION
Besure no foreign material enters the
crat,lkcase.
f,Warmup the engine for several minutes at
idlespeed.Check for oil leakage when warming up.
CAUTION
Ifoil leakage is found ,turn off the engine
promptlyand chock for the cause.
Recommended011 :see page 11
Oilquantity:
Periodicoil change:
1.SL(1.3mpqt)
Withoil filter replacement:
1.6L(1.4mpqt)
Totalamout:
1.8L(1.6mpqt}
3.0ilpressure inspection
a.-Wrap the cylinder with a cloth.
1.oilgallery bul
-28-
b.Sllghtlylooson the 011 gallery bolt in the cylInder
head.
c.Startthe engine and keepit at idle speed unil
beginsto seep fron the oil gallery bolt.lf no oil comes
outafter one mlnute,stop the engine to find cause.
d.Restart the engine and check the oil pressure.
a.AfterCheCklng.tighten the 011 gallery bolt to the
specifiedtorque 7Nm(O.7m.kg)
f,Remeberto Inspect oil pressure after replac~
Ingthe engine 011.
iJubrication oil of gear case
a.Measurementof lubrication oil of gear case.
Placothe machine on a level place. Remove the
OilfHler bolt and check the oillevol.lt ShOuld be up to
thebrim of the hole.lf should be up to the brim of the
hole.lfthe level Is too low,add oil to raise it to the
proper level.
b.llis1al!the 011 filler bolt andtighten to the spedfied
torque:23Nm(2,3,kg,17ftlb)
Lubrit:ation oil replacement of gear case
a.Removethe gear case cover.
b.Placetho machine on a flat surfaoe.
c.Placea con1ainer under the final gear case.
d.Removethe 01 filler bolt and the drain plug to
drainthe oil.
e.lnsta!lthe drain plug and tighten the specified
torque:23Nm(2.3m.kg)
f.Fillthe gear case with oil.
Recommendedoil:
-29-
SAE80API~GL·4"Hypoid goar oil
Oilquality
Periodicoi! change:
o.25L(O.21Imp qt,)
Total amount
O,27(O.23Impqt,)
1.Drainplug
g.lnstaUthe filler bolt and tighten to the specified
torque:2.3Nm(2.3m,kg)
h.Ch?ckfor oil leakage.lf oil leakage is found,
checkfor the cause
i. Reinstall the finalgear case cover.
Spark plug inspection
Youshould periodically remove and check the
sparkplug because heat and deposits will cause
slowdamage and erosion of the sparkplug if elec~
trodeerosion is excessive,you should replace the
sparkplug with one of the propet type D7RTC
Beforeinstalling the new spark pulg measure
theelectrode gap with a feeler gauge and adjust to
speclifcation.
..... ~
1.Sparkplug gap
Sparkplug gap:
Q.6·0,7mm
Wheninstalling the spark pulg,generai!y clean
the.gasket surface and use a new gasket Clean off
anygrime from the threads and tighten to
specification.
Sparkplug torque:17.5Nm{1.75m.kg)
-30-
Airfll11er cleaning
Thereis a check hose at the bottom of tho air
tUltercase.if there are dust or water collects in this
hose,omptythe hose and clean the air filter element
andair fliter case.
1.Checkhose
i.Removethe seat.
2.Removethe air filter case Cover
1.Airfilter element 2.Foam cover
3,RemovQthe air filter element.
4.Removethe foam cover from the air filter
element.
STapthe element lightly to remove most of the
dustand dirLBlow out the remaining dirt with com~
pressedaIr ,If the element IS damaged,replaceit.
6.Washthe foam cover gently thoroughly inwater
orsolvent,
7.Squeezethe excess water or solvent out of
thefoam cover and let it dry .Donot twist the foam
-31-
coverwhen squeezing it
S.Checkthe foam coverJf damaged, replace it.
9.reinstallthe foam cover to the air filteralemen'!.
1 O.Reinstall the' removed air filter unit and parts
removed.
CAUTION
Thecarburetor was set at the our factory after
manytests .If the settingsare disturbed by somenone
withoutsutncient technical knowledge,poor engine
performanceand damage may result
CAUTION
Neverrun the engine with the air filter element
removed.Thiswillis! unfiltered air enter,causing rapid
wearand possible damage of engine.Additionally,
operationwithout the filter element will weak the
performanceof carburetor and causeoverheating of
engine.
Carburetoradjustment
Theidle speed may be performed by customer
asa part of the routine maintenance.
Idlespeed adjustment
1.Startthe engine and warm it up for a few min~
utesat approximately 1.000 to 2,000 rlmin, increase
thespeed of engine to 4000 to 5000r/min ,
2.Setthe specified idle speed by adjusting the
throttteadjusflng screw,Tum the SCrew into increase
enginespeed,and out to deCrease engine speed.
SpecifiedIdle speed:1450·1550 rirnin
1.Throttleadjusting screw
Valveclearance adjustment
Incorrectvalve dearance wiU result in improper
fuellairsupply or engIne noise.To prevent this ,the
varveclearance must be adjusted regularly,but the
adjustmentshould be done by a professional
mainteranco'teeh nleian,
Throttlelever adjustment
NOTE
Adjustthe engine Idle speed before adjusting
thethrottle lever.
1.los$enthe locknut.
2.Flotatothe adjusting bolt until the throttle lever
freeplay is 3-5mm(O.12-0.20inJ
-32-
3.Tightenthe locknut,
1.AdJustlngbolt
,2.Locknu1
a.3-5mm(O.12-
0.20In)
Frontand rear brake shoe inspeC1ion
Awear indicator is mounted on each brake.The
wearof brake shoo could be checked under the condition
ofdisassembling brake .If theindicator
reachesthe wear limit Une ,ask a our Group dealer
to replace the shose as aset.
1.WearIndicator
2.Wearlimit
Frontbrake lever free play adjustment
Inspectthe front brake shoes ,before adjusting
thebrake,
Thefront brake lever free play should be adJusted
to5-7mm(O.2-03in) If the free play is incorrect,
adjustas following steps:
1.Locknut
2.Adjustlngnut
1.Loosenthe iocknut and fully turn in the adjusting
boltof the front brake lever.
2,Makesure the cable joint of the balancer is
straightwhen applying the brake, If not,rotate the ad~
justingnut at the front hubs until the cable joint becomes
straight.
- -33-
1.Adjust)f)gnUt
(fronthub),
3.Retatethe adjusting bolt at the front brake le~
verto make the free play satisfy the requirement.
4. Tighten the locknut '
Aftermainta.ining,pay attention to :
Makesure the brakes operate smoothly and
thefree play meet the requirement;
Make sure the b(akes do not skid.
Replacementof brake components requires
professionalknowledge.These procedures should
bedone by our Group dealer.
Rear brake adjustment
1.Brakepedal
a.Fullyloosen the adjusting nut on the brake
cable.
b,Rotatetho adjusting nut on the brake rod untill
freeplay )$ 20~30mm.
1.Brakooable adjusting nut 2.Brake rod adjusting
Nut
-34-
a.20-30mm
2.Brake lever
a.Loosenthe locknut and fully turn in the adjusting
nuton the handlebar.
b.Turnin the adjusting nut on brake cable to get
agap of 0-1 mm between the lever and pin of pivot.
1. LQCknut2.Adjustlng nut
1.Brake cable adjusting bolt
a,Owlmm(O·O.4 in)
c,Rotatethe adjusting nut until free play is 5-
7mrn,
dTightenthe locknut.
1,Locknut 2.Adjusting nut a,5·7mm
Aftermaintaining ,pay attention to:
Makesure the brakes operate smoothly and
thefree play is correct.
Makesure the brakes do not skid.
Replacementof brake components requires
-35-
professionalknowledge.These procedures should
bedone by our Group dealer.
Clutchadjustment
1.Loosenthe lock nut
2,Slowlyrotate the adjusting bolt counterclookwise
untilresistance is fel1 then, rotate it by1l8 turn
cIOckwj$e,Le.45~.
1.Locknut2.Adjusting bolt
3,Tightenthe Jocknut to specified value .Tjght~
aningtorque:15Nm(1.5m.kg)
NOTE
Turn the adjusting bolt counterclockwlse to de~
creasethe clutch free play and turn it clockwise to
increasethe free play.
cableinspection and lubrication
Thedamage of outer covering of control cable
-
cancause corrosion,fray or kink of cable .Operation
ofcables could be strictlyexecuted, which could
cause an accident or injury.
Inspect cable frequently and replace damaged
cables.Lubricate the inner cables and the cable
jQints.Jfthe cables do not operate smoothly ,ask a
ourGroup dealer to replace them.
Recommendedlubricant
SAE10W30 Lubricant
Steering vertical tube lubrication
Usea grease gun fa lubricate the pivots.
RevommendedlubricantUthlum-base grease
Wheel removal
1.Liftthe wheel by placing a suitable support
underthe frames.
2.Removethe nut on the wheel.
3.Removeto wheel assembly.
-38-
Wheel installation
Wheninstalling the wheel reverse the removal
procedure.Pay attention to the following points;
1.Arrowmark
1.Thearrow mart<' ) »on the tire must point to
therotation direction of the wheel.
2.Taperedwheel nuts are used for both front
andrear wheels .lnstalJ tapered side of the nut towards
theWheel
3.Tightenthe wheel nut.
1. Tapered nut
Wheelnut torque:
Frontwheel :5SNm(S.5m.kg)
Rearwheel :S5Nm(S.Sm.kg)
Battery
WARNING
Avoidcontact with skin,eyes orclothing,Always
shield eyes when working near batteries,keep out
Use and maintenance
1 ,Don't remove electrolyte cover after enclosed
batterybeing used.Pleaso obey the operatlon instruction
on battery to use the battery,
2,lfATV Is suspended from use for a month or
much longer time,remove the battery and storeIn a
cooland dark place,oharge fully before reusing,
2. lf the battery is stored over the above men
-37-
tionedtime,check the voltage at least one month.
Chargethe battery when the vOltage is lower than
12V.
/
(/.. ~,.
,'
,~
1.Battery
1 .Main fuse 2.Start relay
Fusereplacement
1. The fuse case is put under the seat.
2.lftf le fuse is blown ,switch off the main switoh
and rep/acs with a new fuse ofthe same speciflct"lon.
Ifthe fuse immodiately blows again ,consult a ourGroup
dealer,
Specifiedfuse:20A
CAUTION
Topfevent accidental short-circuting,SWitch off
themain switch when checking or replacing a fuse.
Replacing the headlight bulb
Ifthe headlight bulb burns out,roplace the bulb
as following steps;
1.Removethe headlight cover.
2.Removethe cover ,and rotate the bulb holder
countorclockwiseand remove the defective bulb.
i.Headlight
-38-
1.Covor(x2)
1.Bulbholder
WARNING
Waitfor the bulb to cool before removing it.
3.!nstalla new bulb to the bulb holder
4.Reinstalllthe cover and headlight cover,Adjust
theheadlight beam If necessary.
Spark arrester cleaning
Selecta well-ventilated area free of combustible
materialsand make Sure the exhaust and silencer
arecool.
1.Removethe bolt.
2.Startthe engine ,block the end of sillencer
witha dowal,which will increase the speed about
twentytimes by momentarily producing exhaust system
backpressure.
3.Stopthe engine and cool the exhaust pipe.
4.fnstaflthe bolt and tighten it.
-39-
CLEANING AND STORAGE
CLEANING
Generalspeaking ,thorough cfeaning of your
ATVWill Improve its runing pertormance and pro-
long the service life of many components.
1.8efore cleaning the ATV:
a.Blockoff the exhaust pipe with plastic bag or
strongrubber band to prevent water entry,
b.MakeSUrf'! the spark plug and all fitler caps
areproperly installed.
2It the engine case Is excessively dlrtY,wash
withdegreaser,Do not use degreassr for wheel axlos,
3,Ainse the dirt and remove oildirt on the soft
hose.
CAUTION
Excessivewater pressure may cause water
seepageand deterioation of wheel bearlngs,brakes,
tfansmissionseals and electrical equipment.
4.Whenrinsing dirty material for many times, use
warmwater and rnild,datergenHype soap.Use old
toothbrushor bottle brush to wash hard ~to-get-a1
places.
5.Aftercleaning ATV with clean water,immediately
dryall surtaces with a chamois ,clean towel or soft
absorbentcloth.
6,Cleanthe seat with a vinyl upholstery cleaner to
keepthe cover pliable and glossy.
7.Applyautomotive type wax to all ohrome plated
surfaces.Avoiduse combination cleaner -waxes.Atter
usingabrasives to protect scratched suriace,let the
engineidle for several minutes.
·40-
Afterwashing the brakes,let engine brake soveral
timesat slow speeds to dry thelinings.
8.8torage
Longterm storage(60 days or more) of your ATV
wiltrequire some protective procedures to prevent
ATVfrom damage. After thoroughly cleaning the ATV,
adoptthe following protective measures:
1.Addfresh fuel into fuel tank.
2.Addone tablespoon of SAE 1 OW30 or 20W40
motoroil in the spark plug.Ground the spark plug
wireand run the engine over several times to coat
thecyllnder body with 011.
3.Lubrlcateall control cables.
4.Elovalethe engine body to raise all Wheels off
theground
5.Seal with plastic bag over the exhaust pipe
outletto prevent moisture from entering.
6.If storing ATV in a humid or saft-a.]r
atmosphere,coverall exposed metal surlaces with
a light plastic film of oil .00 not apply oil to anyplastic
partsor the seat cover.
7.Takeout the battery and store it In a dlY place.
Thebattery should be stored in the place where the
ambienttemperatrue shOUld be 30<c maximum and
O'Cmínimum
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MAIN DATA AND SPECIFICATIONS
Itemspecification litem specification
.._-----_ ..
Dimension:Engineoil:
~ ..
Overalllength !880mm .. Periodic oilchange 1.DL
OveralWI'dth 1040mm With ail f)lIterreplacement 1.1 L
Overallheight 1140mm Total amount 1 1 L
Seat height 810mm Totalarnout of gear oil O.27L
Wheelbase 1170mm Main fuel tank capacity 121.
Minimumground clearance 155mm Reservefuel tank capacity 161.
Minimumturning radius 2900mm Carburetor:
TypeVacuum film piece type
Basicweight: Spark plug type D8EA
WithoH and futl fuel tank 220kg Spark plug gapO.6-0.7mrn
EngineAir cooledA"stroke,single-cylinder Clutch type . Wet centrifugal automatic
Displacement193.2ml TransmiS$Fon:
BoreX Stroke 63 X 62mm Pr'lmryreduction system Spur gear
Primaryreduction ratio 3.333
CompreSSionrallo 9.0;1 Secondary reductionsystem Shaft dnve
Startingsystem Electric starter Secondary reduction ratio 3.15
Lubricationsystem Pressure splash
Transmissontype Constant mesh,5-speed
forward"speedreverse
0p.erationleft foot operation ., ,.
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MAIN DATA AND SPECIFICATIONS
!ternspecification htem specification
1-::--'_- -- ......
Gearratio: Suspension Supporting rod
1st 2.769 Front Rotary rod
2nd1.882 Rpoc
3rd1.400 Shock absorber:
4th1.130 Front Spring/Oildamper
5th0.960 Rear .. SQring/oil damper
Reverse_.. . 34.427 Wheel travel:
FrameFront 135mm
FrameIype Steel tube Rear 135mm
CasterAangle 4" Electrical:
Trail20mm Ignition system CDI
Tire:Generator system A. C. Magneto
TypeVacuum BatterytypeJvoltage,capacity 12N14·BS/12V,14AH
Size:FrontAT22 X 7·10 Headlight 12v,30W/30W X 2
Size:RearAr22 X 10·10 Tail!ight 12V,12W/5W Brake:
........_ ..
Frontbrake type Disc brake Neutralindicator 12V,3W X 1
OperationRight hand operation Reverseindicator 12V,3W X 1
Rearbrake type Drum brake Hight beam indicator light 12V.3W X 1
QQerationLeft hand and ri9.bUoot operation
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MAINTENANCE RECORD
Maintenancetimes, receipts of purchased componects and assembly will be required to berecorded,
whichshould be done according to the warranty,The chart below only acts asmaintonance record,not as
maintenance proof
MAlNTENACEDATE
INTERVALOF DRIVINQM1LEAGESERVICING DEALER NAME AND ADDERSS REMARKS
TIME MAlNTEN...A. NC _.. .
1Month -
3Mon1hs
6Months
12Mont1s
18Months.
.........- "-_ ...
24Months
30Months
36Months
42Months
-'"
48Months .......... -
54Monlhs _.. .. .. ....
OOMonths
.
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