CFMoto CF625-C Owner`s manual

CF500-5B/CF500-5C
CF625-B/CF625-C
This ATV should not be ridden by anyone under 16 years of age.
Passenger under 12 are prohibited.
Improper vehicle use can result in SEVERE INJURY or DEATH
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER:
●Operate without proper training or instruction .
●Operate at sppeds too fast for your skills or the conditions .
●Use ALCOHOL or DRUGS before or while operating this vehicle .
ALWAYS:
●AvOid paved surfaces, which may adversely affect handling and control.
●Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and
rough terrain,and in turns.
●Wear eye protection, helmet and protective clothing.
READ OWNER’S MANUAL.
FOLLOW ALL INSTUCTIONS AND WARNINGS.
The engine exhaust fumes from this product contains
Chemicals known to cause cancer, birth defects
Or other reproductive harm.
A card containing important ATV safety information should be attached
to the owner’s manual on the next page. If you cannot locate this card,
or if it has been removed, please contact your dealer.
INTRODUCTION
Congratulations on your purchase of the ATV.
This manial will provide you with a good basic understanding of the features and
operation of this ATV. This manual includes improtant safety information.
It provides information about special techniques and skills necessary to ride your
ATV. It also includes basic maintenance and inspection procedures. If you have
any questions regarding the operation or maintenance of your ATV, please consult
your dealer.
The manufacturer reverves the rights to make any
improvement on the product at any time without
prior notice and without any obligation whatever
TABLE OF CONTENTS
VEHICLE IDENTIFICATION NUMBERS................................................... 1
SAFETY.....................................................................................................3
FEATURES AND CONTROLS..................................................................37
OPERATION............................................................................................ 55
MAINTENANCE AND LUBRICATION...................................................... 79
CLEANING AND STORAGE.....................................................................118
TROUBLESHOOTING..............................................................................124
TROUBLE CODE ................................................................................... 130
SPECIFICATIONS.................................................................................... 134
ELECTRICAL DIAGRAM.......................................................................... 1
. 40
VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers in the spaces provided. Remove the spare
key and store it in a safe place. Your key can be duplicated by using one of you existing
keys. If you lose both, you will require a replacement ignition barrel and keys.
1.Frame VIN:
2.Vehicle Model Number:
3. Engine Serial Number:
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Operator Safety
SAFETY
Failure to follow the warnings contained in this manual can result in serious injury or
death. An ATV is not a toy and can be hazardous to operate. This vehicle handles differently
from other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail
to take proper precautions.
Read and understand your owner s manual and all warnings before operating an ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under the age of 16.
Know Your vehicle
As the operator of the vehicle, you are responsible for your personal safety, the safety of
others, and the protection of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle, including safe
operating procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on safety training
course that covers all aspects of vehicle safety.You were also provided with
printed materials that explain safe operating procedures.
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Operator Safety
SAFETY
You should review this information on a regular basis.
If you purchased a used ATV from a party other than a dealer, you can request this free safety training from any
authorized dealer.
This ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this
vehicle in your area.
We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual.
This preventive maintenance program is designed to ensure that all critical components on your vehicle are
thoroughly inspected at specific intervals.
The following signal words and symbols appear throughout this manual and on your ATV. Your safety isinvolved
when these words and symbols are used. Become familiar with their meanings before reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
The safety alert warning indicates a potential hazard that may result in serious injury or death.。
The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.
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SAFETY
Operator Safety
Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in
further detail within your owner’s manual.
●Read this manual and all labels carefully, and follow the operating procedures described.
●Never operate an ATV without proper instruction. Take a training course. Beginners should receive training
from a certified instructor. Contact an authorized ATV dealer to find out about the training courses nearest you.
●Never allow anyone under 16 years of age to operate this ATV.
●Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and
has completed a certified safety training course.
●Always avoid operating an ATV on paved surfaces , including side-walks , driveways , parking lots , and streets.
●Never operate an ATV on a public street, road or highway, including a dirt or gravel road.
●Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection
( goggles or face shield ), gloves, boots, a long-sleeved shirt or jacket, and long pants.
●Never consume alcohol or drugs before or while operating an ATV.
●Never operate at excessive speeds. Travel at speeds appropriate for the terrain, visibility and operating
conditions, and your experience.
●Never attempt wheelies, jumps or other stunts.
●Always inspect your ATV before each use to make sure it s in safe operating condition.
●Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual.
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SAFETY
Operator Safety
●Always keep both hands on the handlebars and both feet on the foot-rests of the ATV during operation.
●Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain
conditions.
●Never operate on excessively rough, slippery, or loose terrain.
●Always follow proper turning procedures as described in this manual. Practice turning at low speeds before
attempting to turn at faster speeds. Do not turn at excessive speeds.
●Always have the ATV inspected by an authorized dealer if it s been involved in an accident.
●Never operate 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. Check the terrain carefully before ascending a hill.Never
climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle
suddenly or make sudden gear changes. Never go over the top of a hill at high speed.
●Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before
you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at
an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.
●Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose
surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until
you ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of
a steep hill when possible.
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SAFETY
Operator Safety
●Always use proper procedures if you stall or roll backwards while climbing a hill . To avoid
stalling ,maintain a steady speed when climbing a hill. If you stall or roll backwards, follow
the special procedure for braking described in this manual. Always dismount on the uphill
side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and
remount following the procedure described in this manual.
●Always check for obstacles before operating in a new area. Never attempt to operate over
large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating
over obstacles as described in this manual.
●Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and
use extra caution to reduce the chance of skidding or sliding out of control.
●Avoid operating the ATV through deep or fast-flowing water . If it s unavoidable, travel
slowly , balance your weight carefully, avoid sudden movements, and maintain a slow and
steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle
changes.
●Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If
necessary, apply them lightly several times to allow friction to dry out the pads.
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Operator Safety
SAFETY
●Always check for obstacles or people behind the ATV before operating in reverse. When it s
safe to proceed in reverse, move slowly and avoid turning at sharp angles.
●Always use the size and type of tires specified for your ATV, and always maintain proper
tire pressure.
●Never modify an ATV through improper installation or use of accessories.
●Never exceed the stated load capacity for your ATV. Cargo must be properly distributed and
securely attached. Reduce speed and follow the instructions in this manual for carrying
cargo or towing. Allow a greater distance for braking.
●Always remove the ignition key when the vehicle is not in use to prevent unauthorized use
or accidental starting.
●Child or pets shall not be carried on the brackets.
●Never touch running parts, such as wheels, drive shaft, etc.
FOR MORE INFORMATION ABOUT ATV SAFETY,
PLEASE CONTACT WITH YOUR DEALER.
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SAFETY
Operator Safety
Equipment Modifications
We are concerned with the safety of our customers and for the general public. Therefore ,
we strongly recommend that consumers do not install on an ATV any equipment that may
increase the speed or power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the vehicle create a
substantial safety hazard and increase the risk of body injury. The warranty on your ATV
is terminated if any equipment has been added to the vehicle, or if any modifications have
been made to the vehicle, that increase its speed or power.
NOTE:The addition of certain accessories, including (but not limited to) mowers, blades,
tires, sprayers, or large racks, may change the handling characteristics of the vehicle.
Use only approved accessories, and familiarize yourself with their function and effect on
the vehicle.
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SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WAHT CAN HAPPEN
The risk of an accident is greatlly increased if the operator does not know how to operate
the ATV properly in different situations and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the certified training course offered
by dealer. Operators should regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.
For more information about the training course, contact an authorized ATV dealer.
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
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SAFETY
Operator Safety
WHAT CAN HAPPEN
Severe injury and/or death could occur if a child under the minimum age recommendation
operates and ATV,
Even though a child may be within the recommendation age group for operating some ATV,
he/she may not have the skills, abilities, or judgment needed to operate an ATV safely
and could be susceptible to accident or injury.
HOW TO AVOID THE HAZARD
No one under the age of 16 should operate this ATV.
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SAFETY
Operator Safety
POTENTIAL HAZARD
Carring a passenger on the rear rack.
WHAT CAN HAPPEN
A passager riding on the rear rack could be ejected from vehicle unexpectedly or may contact
moving components, both of which can result in severe injury or death.
HOW TO AVOID THE HAZARD
Never allow passengers to ride on the rear rack.
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Operator Satety
SAFETY
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye protection and protective
WHAT CAN HAPPEN
Operating an ATV without an approved helmet increases the risk of a severe head injury or
death in the event of an accident.
Operating without eye protection could result in an accident and could increase the chance
of a severe injury in the event of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield),
gloves, boots, long-sleeved shit or jacket, and long
pants.
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SAFETY
Operator Satety
POTENTIAL HAZARD
Operating the ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Consumption of alcohol and/or drugs could seriously affect
operator judgment. Reaction time may be slower and operator
balance and perception could be affected.
Consuming alcohol and/or drugs before or while operating an ATV could result in an accident
causing severe injury or death.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while operating an ATV.
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Operator Satety
SAFETY
POTENTIAL HAZARD
Operating the ATV at excessive speeds.
WHAT CAN HAPPEN
Excessive speed increases the operator’s chance of losing control of the ATV, which can
result in an accident
.
HOW TO AVOID THE HAZARD
Always operate the ATV at a speed that’s proper for the terrain, visibility and operating
conditions, and your experience.
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN HAPPEN
Attempting stunts increases the chance of an accident,
including an overturn,
HOW TO AVOID THE HAZARD
Never attempt wheelies, jumps or other stunts,
Avoid exhibition driving.
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SAFETY
DRIVER SAFETY
POTENTIAL HAZARD
Operating thie ATV/QUAD without proper inspection,ATV/QUAD improper maintain.
What will happen.
Improper maintain will increase accident occurrence and equipment damage probability.
How to avoid such dangerous.
Alwaysdo inspection on ATV before operate it to make sure that the vehicle in safe
operating state, Always strictly follow the inspection and maintainance procedure
described in your owner’s manual.
Potential hazard
Both of your hands off the lever or both feet leave foot board.
What will happen
Eight one hand or one foot leaves will weaken the control of the vehicle, or cause the
operator lose his balance and catapult out.
If the operator donot hold his feet firmly enough,the feet may touch rear wheel,
so cause damage and accident.
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SAFETY
DRIVER SAFETY
How to avoid the hazard.
Always use both hands hold the levers and keep the feet on foot boards when driving the ATV.
Potential hazard
Careless driving on unfamiliar terrain.
What will happened
Unfamiliar terrain(hidden rocks,bumps,or holes
that may cause lose balance even rollover.
How to avoid the hazard
Go slow and pay much more attention when driving on unfamiliar terrain,
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SAFETY
DRIVER SAFETY
Potential hazard.Careless driving on over rugged,slippery,soft terrain.
What will happened.
Driving on over rugged,slippery,soft terrain may cause lose traction
or lose control of the vehicle,so cause accident or rollover.
How to avoid the hazard.
Please also drive carefully when on the bad terrain with technique.
Potential hazard
Improper turns
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SAFETY
Driver Safety
WHAT CAN HAPPEN
Improper turns could cause loss of control and lead to a collision or overturn.
HOW TO AVOID THE HAZARD
Always follow the turning methods described in the owner’s manual.
Practise turning at a low speed before you trying to turning at a high speed.
Never try to sharp turn in high speed.
POTENTIAL HAZARD
Diving on too steep area.
WHAT CAN HAPPEN
The vehicle may overturn.
HOW TO AVOID THE HAZARD
Never driving ATV on too steep terrain or on area beyond ATV ability.Never driving ATV
on hillside slope big than 25℃.
Practice driving on small hillside before try to drive on big slop hillside.
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SAFETY
DRIVER SAFETY
POTENTIAL HAZARD
Improper climbing method.
WHAT CAN HAPPEN
Improper climbing may cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Always follow the proper climbing method instruted in the owner’s manual.
Observe the terrain condition before climbing.
Never driving ATV on area grade large than 25°.
Never climbing highland too slip or soft,transfer your weight forward when climbing.
Never open the throttle suddenly when climbing,or else the ATV will overturn backwards.
Never go over any top hill in high speed, there may be people,vehicle,steepslop or barrier
on the other side of the hill.
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SAFETY
Driver safety
POTENTIAL HAZARD
Improper descent.
WHAT CAN HAPPEN
Improper descent may cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Always follow the descent method instructed in the owner’s manul.
NOTE:
You required special technique on down hill braking,please refers to Page69.
Observe the terrain carefully before down hill,also transfer your weight backwards.
Never down hill in with high speed.
Avoid down hill in slop or may cause the vehicle topple to one side,
go down as straight as possible.
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SAFETY
Driver Safety
POTENTIAL HAZARD
Improper operation when crossing or turning in highland.
HWAT CAN HAPPEN
Improper operation when crossing or turning in highland may cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Only if you mastered turning skill on plat land then you can try to turn on all terrain.
Please refers to Page68.Pay much more attention whenturning in high lands,avoid to cross
steep Notice for cross high lands
Always follow the proper procedure described in hte owner’s manual
Avoid to drive on too slip or soft,transfer your weight to ascent direction.
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SAFETY
Driver safety
POTENTIAL HAZARD
Flameout,backwards,improper down hill operation.
WHAT CAN HAPPEN
The vehicle body may may roll over.
HOW TO AVOID THE HAZARD
Keep stable speed when climbing;
Keep your weight in uphill;
Brake with front brake(or brake lever),when the vehicle complete stop, apply the rear
brake, then put into park gear.
When ATV back up on slop,you required to do:
Keep weight in uphill direction,NEVER apply engine power
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SAFETY
DRIVER SAFETY
Do not apply rear brake when move backwards,apply front brake slowly(or brake lever).
Apply rear brake when the vehicle complete stop,then putinto park gear.
Turning and downhill according to the owner's instruction,refers to Page65.Page69.
POTENTIAL HAZARD
Improper operation when span obstacles.
WHAT CAN HAPPEN
Driving across big obstacles may cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Before driving on unfamiliar terrain, observe the road condition carefully.
Try to avoid to across big obstacles such as rock or fallen tree.If must,you required to
operate
according to the owner's manual instruction carefully.
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SAFETY
Driver Safety
POTENCIAL HAZARD
The vehicle side-slip or slide
WHAT CAN HAPPEN
Vehicle side-slip or slide may cause vehicle loss control,if the tyre once again obtain pull,
the vehicle may overturn.
HOW TO AVOID THE HAZARD
When driving slowly on slippy surface such as ice,you must pay much attention to the vehicle
side-slip or slide.
POTENTIAL HAZARD
ATV overload or transport/improper pull.
WHAT CAN HAPPEN
ATV overload or improper pull may change the vehicle operating performance,
thus lead to loss of vehicle control and accident.
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Driver Safety
SAFETY
HOW TO AVOID THE HAZARD
Cannot exceed the ATV nominal load
Placing and pack the goods properly;speed-down according to the owner's instruction
when carry goods or pulling,
keep longer brake distance,refers to owner's manual Page 61.
POTENTIAL HAZARD
Driving across deepwater or rapids.
WHAT CAN HAPPEN
The tyres may float and cause loss control of the vehicle,thus lead to accident.
HOW TO AVOID THE HAZARD
Avoid to operate ATV in deepwater or rapids,if must goes to deepwater exceed Max proposed
depth,(refers to Page72),
you must to drive slowly and keep balance,avoid sudden operational motion and keep forward
slowly and steady.
Donot make adrupt turn or stop,or change the throttle.
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Driver Safety
SAFETY
Wet brake may degrade brake performance,inspect brake condition when out of water,
brake lightly for several times to dry the brake pads.
POTENTIAL HAZARD
Improper vehicle reverse.
WHAT CAN HAPPEN
ATV may make collide with obstacle or person and cause serious accident.
HOW TO AVOID THE HAZARD
Check if there is any person when during reversing.
Reverse slowly after look over.
POTENTIAL HAZARD
Using off-gauge tyre,under inflation tyre,uneven pressure between tyres on ATV.
WAHT CAN HAPPEN
If using off-gauge tyre,under inflation tyre,uneven pressure between tyres on ATV can cause
loss control of the vehicle.
Or accident.
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SAFETY
Driver Safety
HOW TO AVOID THE HAZARD
Always use the specified types and size of ATV tyres described on the owner's manual.
Always maintain right tyre pressure.
POTENCIAL HAZARD
Drive improper remodel ATV
WHAT CAN HAPPEN
Install unfit parts or do improper modification on the vehicle may change vehicle operating
performance and lead to accident.
HOW TO AVOID THE HAZARD
Neverinstall unfit parts or do improper modification on the vehicle,all added fititngs or
spare parts must be original parts or the same size parts designedfor this ATV and installing
accordingto approved instructions.
Please inquiry the dealers for more information.
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SAFETY
Operator Safety
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the ATV/Quadricycle and /or the operator fall through
the ice.
HOW TO AVOID THE HAZARD
Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting
in serious injury or death. Always remove the ignition key when the vehicle is not in use.
After any overturn or accicent, have a qualified service dealer inspect the
entire vehicle for possible damage, including(but not limited to)brakes,
throttle and steering system.
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SAFETY
Operator Safety
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SAFETY
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SAFETY
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SAFETY
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SAFETY
GEAR
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SAFETY
Safe riding gear
Always wear clothing suited to the type of riding.ATV/Quadricycle
riding requires special protective clothing for comfort and to
reduce the chance of injury.
1.Helmet
Your helmet is the most important piece of protective gear for
safe riding.An approved helmet can prevent a severe head injury.
2.Eye protection
Do not depend on sunglasses for proper eye protection for your eyes.
They should be kept clean and be shatterproof design.
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
4.Boots
The best footwear is a pair of strong over-the-calf with heels,like moto-cross boots.
5. Clothing
Always wear long sleeves and long lants to protect arms and legs.Riding pants with
kneepads and a jersey with shoulder pads provide the best protection.
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FEATURES AND CONTROLS
Electrical Switches
Activate override switch while throttle is open can cause loss of
control,resulting in severe injury
or death.Never press override switch while throttle is open.
1
1.Override Switch
Top speed is limited when in 4WD-LOCK condition.If more engine
power required when riding,push and hold this switch to override
the 4WD-LOCK speed limit. (Refer to page45 for detailed explanation about the override switch)
2
Speed limit restores when the switch released.
The overide indicator will be light while switch
is pushed.
2.Headlight Switch
Headlight switch consists of four posutions:
1.“
”
、2.“
”、3.“OFF”、4.“
When the switch
When the switch
in “1 ”position,
in “ 2 ” position,
”
high beam is on.
low beam is on.
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Electrical Switches
FEATURES AND CONTROLS
When the switch is at“3 ”position,all lghts are off.
When the switch is at“4”position,the front/rear position light and
instrument light are on.
3.Turning light switch
Press the switch to“
” ,Left turning indicator and left turning light are on.
Press the switch to“
”,Right turning indicator and right turning light are on.
4.Horn Switch Button
Press the button,the horn will sound.
5.Start switch
Press the button,start motor runs.
6.Stop Switch
: Engine stops.
:
Engine starts.
7.Hazard Warning Indicator Switch “ ”
Press the button: Left/right indicator is on.
Left/right turning light is on.
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CAUTION:
Do not use the headlights for
for thirty minutes.The battery
may discharge and the starter motor
will not operate properly.If this
should happen, remove the battery and
recharge it.
FEATURES AND CONTROLS
1
Brake
Front brake lever
Front brake lever 1 is located on the right
handlebar.Pull it toward the handlebar to apply
the front brake.
Combined brake
Brake pedal 2 is located on the right of the engine,
combined brake lever 3 is located on the left handlebar.
Step on the pedal or pull the lever toward the handlebar
to apply the rear linkage brake.
3
2
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FEATURES AND CONTROLS
Brake
Always test brake lever and master cylinder fluid level before riding.When squeezed,the lever should feel
firm.Any sponginess would indicate a possible fluid lrak or low master cylinder fluid level,which must be
corrected before riding.Contact your dealer for proper diagnosis and repairs.
Brake Fluid
Check the brake fluid level in front brake oil cup and linked brake main pump oil cup before using
the ATV/Quadricycle.The front brake oil cup is located in the right handlebar.The
linked brake main pump oil cup is on the top of brake pedal.
1
Check brake fluid level: brake fluid level should be higher than
LOWER 1
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FEASTURES AND CONTROLS
Brake
An over-full master cylinder may cause brake
drag or brake lock-up,which could result in
serious injury or death.Maintain brake fluid
at the recommended level.Do not overfill.
NOTE:When checking the fluid level,the
ATV/Quadricycle must be on level ground
with the handlebars straight.If the fluid
level is low,add DOT3/DOT4 brake fluid.
Fluid level can not be lower than lower range of
"LOWER" 1
Never store or use rest brake fluid in the bottle;Brake fluid is hygroscopic, can rapidly aborb
moisture from the air.The moisture causes the drop of boiling temperature of thhe brake f l u i d.
Aft er opening a bottle of brake fluid,always discard any unused portion.
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FEATURES AND CONTROLS
Brake
Parking Brake
When parking,stop the engine and shift the gear selector Lever① into the park position.
Operation the ATV/Quadricycle while the parking
brake is engaged could result in an accident and
serious injury or death.
Always check to be sure the parking brake is disengaged.
Before operatiog.
Important Safeguards
● The parking brake may relax if left
for a long period of time.Always block the wheels
to prevent rolling.
Never depend on the parking brake alone if the ATV/Quadricycle is parked
on a hill.Always block the wheels on the downhill side of the ATV/Quadricycle to prevent rolling.
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FEATURES AND CONTROLS
Efisystem
● Disassemblyof the EFI system is forbidden;
● Ignition switch must be off while connector is on or off on order not
to damage electric elements;
● Do not diamantle battery while engine is working;
● Engine starting is not allowed in case of no fuel or fuel below warning
line to protect oil pump damaged;
● Idling adjustment is handled by EFI system only and does not need
manul adjustment;
Fuel tank
Fuel tank filter cap ① is loacated below the handlebar. Remove the fuel tank
turning it counterclockwise. Install the fuel tank filler cap turning it clockwise.
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Fuel safety
FEATURES AND CONTROLS
Fuel is highly flammable and explosive under certain circumstances.
●Always handling fuel in a extremely attentive and careful state on mind;
●Always refuel while engine stops in a well ventilated situation;
●Never fill gass while plastic fuel tank is on the rack. Static electricity between rack and
tank could cause a spark;
●Refuel after engine stops in a well ventilated situation and do not smoke or create a spark
in gas station or storeage place.
●Do not overfill the gas;
●Wash with soap or change clothes if gas is sprayed on skin or clothes. Do not start engine
in a closed situation. Engine exhaust is posionous and could lead to human unconsiousness;
Pressure relief is a must before assembly because EFI system enjoys a high
gas pressure; Pressure relief procedure: Disassemble oil pump relay and
then start the engine until engine kill.
Engine exhaust gas may contain chemicals causing cancer or harmful to human health.
Always operate the vehcile in a well ventilated outdoors.
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FEATURES AND CONTROLS
Gearshift
Gearshift unit is on
left side of the
vehicle.
L:Low gear
H:High gear
N:Neutral
R:Reverse gear
In order to shfit into reverse gear, step onto brake pedal first. It the same to shift out of
reverse gear;
CAUTION:
When engine speed is above idle speed or change gears while vehicle is moving, engine could be
damaged.Stop vehicle while changing gears and engine in idel speed.Then change the gears;
Step onto brake pedal before changing into reverse gear or parking;
Parking gear should be applied while nobody is in charge of the vehicle;
In case of any problems regarding the gearshifting, consult your dealer if necessary.
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FEATURES AND CONTROLS
Belt life-span
Changing into low gear while pulling heavy stuff to prolong belt life-span;
If it is necesary to pull vehciles, change into neutral gear for better flexibility to protect
belt from being damaged;
Recoil starter
If power is not enough to start the engine, please use
① recoil starter.Vehicle is still operable while it is
under overraul. ① is on left side of vehicle. Engie is
equipped with pressure reliefer. It is able to renew the
pressure when engine turning speed is enough to start.
1.Park vehicle on flat ground and change into P gear;
2.Hold tight of the handle and pull gently until starter
mechanism;
3.Pull the rope suddenly and start the engine;
- 44 -
FEATURES AND CONTROLS
Recoil starter
CAUTION
Recoil starter could be damaged if rope is pulled too long, possibly lead to starter fails;
If the rope is not in correct position,water might penetrate and damage components;
Make sure the handle is within housing, expecially while riding in wet situation:
All-Wheel Driven(AWD)System
2
1
Lock switch based on 4 wheel drive or differential choice;
The vehicle is equipped with“2WD”/“4WD”① and
differential“LOCK”/“4WD”②;
Change into proper driven gear based on
circumstances;
●Two-wheel drive(2WD):driven power only to rear wheels;
●Four-wheel drive(4WD):driven power to rear and front wheels;
●Four-wheel drive and differential lock(4WD-LOCK):Under lock situuation,fourwheel driven at the same time. But unlike 4WD, direction stays unchanged.
- 45 -
FEATURES AND CONTROLS
All-wheel drive(AWD)System
Choose 4WD based on actual need.
“2WD/4WD”switch
Stop the vehicle to change 2WD to 4WD if
necessary. And then change switch to “4WD”.
When in 4WD, on dashboard will show “
”
Stop the vehicle and make sure the handle
bar ① is in position in 4WD position.
1
1
2
2
4WD differentuial lock switch①
In order to lock 4WD,make sure switch is in 4WD based
on actual need, stop ATVand pull ② to “ ”posi t ion
and then change switch to “lock”position. While in“lock”
position,the light shows“DIFF.LOCK”and will shine at the same time with the one on the
dashboard. In order to switch off the lock, stop ATV and switch on to 4WD.
- 46 -
FEATURES AND CONTROLS
All-wheel drive(AWD)System
NOTE:
●When switch is in “lock”position, dashboard light shows continuously;
●In case light shines,4WD is not locked and ATV should be driven in low speed. High speed
drive will probably cause injury or even death;
●When ATV is in “4WD-LOCK”position, maximum speed should be 35km/h;
●In order to accquire full power, press the assistor switch and
disable the speed limitator of “ 4WD-LOCK ” switch
throttle tie-rod①
When engine is working, pulling tie-rod will improve
1
engine speed to adjust ATV speed. ATV will decrease the
speed because of the spring-equipped throttle. And engine will be in idle speed when the
throttle is released.
Check the throttle is running smoothly before starting the engine. Make sure engine is in idel
speed after releasing the throttle tie-rod.
- 47 -
FEATURES AND CONTROLS
All-wheel drove(AWD) System
CAUTION
Check throttle tie-rod before starting the engine. In case of problems, check and solve
the reasons before riding the ATV. Contat local dealer if necessary.
Speed limitator
Spped limitator can provent throttle full open
even if throttle is in highest position:Turn
bolt ② gain highest power to decrease max
speed of the ATV.
CAUTION
Never adjust the bolt longer than 12mm, make sure
throttle clearance is between 3-5mm.
- 48 -
FEATURES AND CONTROLS
Main switch
Functions:
ON:Start the engine and key cannot be taken out in this position;
OFF: Close all electric circuits and key can be taken out in this position.
- 49 -
FEATURES AND CONTROLS
Indicator light and caution light
4WD indicator lights①
Switch“(2WD)/(4WD)”onto position “(4WD)", the indicator light shows;
Switch“LOCK-”-“(4WD)”onto“LOCK-(4WD)”,the indicator light shows.
NOTE:
Due to the synchornizing mechanism in front gear box,4WD indicator light will show
Only after ATV starts moving;
Left turning indicator②
Press light to “ ”
Then the indicator shows;
Low gear indicator“L”③
In low gear, the indicator “L”shows;
High gear “H” 4
When in high gear, indicator “H”shows and
Neutral“N” 5
In neutral gear, the indicator shows“N”.
12
11
- 50 -
FEATURES AND CONTROLS
Indicators and caution lights
Parking gear indicator“R”⑥
When gear in position “R”, the indicator shows;
Parking indicator“P”⑦
When gear is in“P”position, the indicator shows;
Turning righg indicator⑧
Press turning
The indicator shows;
Assistor light indicator⑨
Switch on the assistor, the indicator shows;
High beam indicator⑩
Swith on front light“
”, the indicator shows;
Position
”, the indicator shows;
Press position l i ght“
Trouble 12 in case of trouble, see Page 134.
NOTE:
。
In case of indicator or speedometer does not show the speed while driving, contact local
dealer if necessary;
- 51 -
FEATURES AND CONTROLS
Dashboard
Coolant temperature indicator
When the temperature indicator is in the white area of side C, it means that
the temperture is normal. The red area of the side H indicates temperature is
high.If so please stop the engineuntil temperature is down. In case temperature
frequently goes high, check coolant capacity or contact the dealer.
CAUTION:
●Engine may overheat if ATV is overlaoaded. Reduce
Weight to specification in case of this.
●After restarting, make sure the temperature in the
White area of side C. Continuous use while temperature
Indicator in the red area of H will damage engine
Speedometer:shows speed;Odometer:show total
distance traveled;
Fuel
。 sensor:remaining fuel;“F”total amount;
Total capacity is 18L;Refuel when indicator shows on
Red area. Red means remaining fuel is only 4.0L
- 52 -
FEATURES AND CONTROLS
Puller electric outlet, position,power
Output :12V 1
This spare electric loutlet provides
power for rearlights, rear
turning lights etc of the the
puller.(CF625- B/ CF625- C)
1
- 53 -
Driving
55.
6.Less load ,more better。
7.check oil and filter by Each 25 hours or each month during break-in period.
- 54 -
Driving
Pre-Ride Inspection
If a proper inspection is not done before each use ,severe injury or death could result.always
,
inspect the vehicle before each use to ensure it s in proper operating co n d io n .
Pre-Ride Checklist
Item
Remarks
See page
37,105
Brake system/lever travel
Ensure proper operation
Brake fluid
Ensure proper level
38
Front suspension
inspect,lubricate if necessary
116
Rear suspension
inspect,lubricate if necessary
116
Steering
Ensure free operation
-
Tires
Inspect condition and pressure
32
Wheels/fasteners
Inspect,ensure fastener tightness
110
- 55 -
Driving
Pre-Ride Inspection
brake light/tail lamp
Inspect,ensure tightness
Ensure proper level
Ensure proper level
Inspect for leaking
Ensure proper operation
Ensure proper operation
Inspect,clean
Drain deposits whenever visible
Check operation
Check operation
Riding accessories
Wear helmet,goggles,protective clothing
Frame nuts,bolts,fasteners
Fuel and oil
Coolant level
Coolant hoses
Throttle
Indicator lights/swithches
Air filter
Air box sediment tube
Headlamp
- 56 -
86
91
47
35,50
97
113
115
34
Driving
- 57 -
Driving
Starting engine
4.release throttle completely and puse the srart switch.
NOTE:
● If the engine fails to start, release the start switch,then
push the start switch again.pause a few seconds before
the next attempt.Each cranking should be as short as
possible to preserve battery energy.Do not crank the
engine more than 10 seconds on each attempt.
● If the battery is discharged,pull the recoil starter to
start the engine.
- 58 -
Driving
- 59 -
Driving
- 60 -
Driving
When you shift into reverse,make sure there are no obstacles or people behind you.
When it is safe to proceed,go slowly.
Hauling Cargo
Carrying a load on only the front rack or the rear rack may cause an imbalanced condition and increases
the possibility of vehicle overturn.
● do not exceed the stated load capacity.
●speed-down and keeping longer distance for breaking.
●speed-down and less loading when driving in rough treeain or hill.
●load distribution.
rear rack should as far forward as possible,as lower as possbile;
Carry a higher load can increase barycenter and reduce the stability that can not.
it,s better less loading in this condition.make the load stablely that can not
ensure if the barycenter removal.be particularly careful when handling.
● fix all loads before driving.
Unfixed loads may move when driving and cause unstable condition and make the
vehicle loss control.
● be particularly careful
,
In the transport is longer than the rack,can effect the vehicle s stability and flexibility,even case
vehicle turn over.
- 61 -
Driving
- 62 -
Driving
- 63 -
Driving
Driving Procedures
- 64 -
Driving
- 65 -
Driving
- 66 -
OPERATION
- 67 -
OPERATION
Driving safely
Driving Uphill
Braking and handling are greatly affected when operating in hilly terrain. Improper procedure
could cause loss of control or overturn and result in serious injury or death.
Avoid climbing steep hills (25°maximum)
Use extr eme caution when operating on hills,and followproper
operating procedures outlined in the owner’s manual.
Sidehilling
Improperly crossing hills or turing on hills can result in loss of control or vehicle
overturn,resulting in severe injure or death.Avoid crossing the side of a hill when possible. Follow
proper procedures as outlined in the owner’s manual.
Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do
enter into a situation where sidehilling is nesssary,follow these precautions:
1.slow down
- 68 -
OPERATION
- 69 -
OPERATION
- 70 -
OPERATION
1.
2.
- 71 -
OPERATION
100
- 72 -
OPERATION
- 73 -
OPERATION
- 74 -
OPERATION
- 75 -
OPERATION
- 76 -
OPERATION
- 77 -
MAINTENANCE AND LUBRICATION
- 78 -
MAINTENANCE AND LUBRICATION
- 79 -
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Maintenance Interval
Item
(Whichever comes first)
Hours
Steering
Front suspension
Rear suspension
Tires
Break fluid level
Brake lever/pedal travel
Brake system
Wheels/fasteners
Frame fasteners
Engine oil level
Error light
Air filter
Air box sediment tube
- 80 -
Calendar
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Daily
Daily
Remarks
Mile(km)
Make adjustments as needed.
Refer to Pre-Ride Checklist
on Page 55 - Page 56.
Inspect and clean often
Drain deposits when visible
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Coolant
Daily
Check level daily,change coolant
Every 2 years
Headlamp/tail lamp
Daily
Check operation
Air filter,main element
Weekly
Recoil housing
Weekly
Inspect, replace as needed
Drain water as needed, check often
if operating in wet condition.
Brake pad wear
10H
Monthly
100
Inspect periodically
Battery
20H
Monthly
200
Check termianals;clean;test
Front gear case oil
25H
Monthly
250
Inspect level;change yearly
Rear gear case oil
25H
Monthly
250
Inspect level;change yearly
Transmission oil
25H
Monthly
250
Inspect level;change yearly
-
1M
250
Perform a break in oil change at one month
50H
3M
500
Lubricate all fittings,pivots,cables,ect.
Engine oil change(break in)
General lubrication
- 81 -
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
■
■
- 82 -
Shift lever
28H
1M
500
Inspect;lubricate;adjust,
Steering
50H
3M
500
Lubricate
Front suspension
50H
6M
500
Lubricate
Rear suspension
50H
6M
500
Lubricate
Throttle Cable/ETC Switch
50H
6M
500
Inspect;adjust;lubricate;
Replace, if necessary
Drive belt
50H
6M
500
Inspect;adjust.Replace if necessary
Cooling system
50H
6M
500
Engine oil change
100H
6M
1000
Inspect coolant strength seasonally;
pressure test system yearly.
Perform a break-in oil change
at 25 hours/one month
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
■
■
Fuel tank vent hose
100H
12M
1000
Inspect routing condition
Valve clearance
100H
12M
1000
Inspect;adjust
Fuel system
100H
12M
1000
Radiator
100H
12M
1000
Inspect;clean extemal surface
Cooling hoses
100H
12M
1000
Inspect for leaks
Engine mounts
100H
12M
1000
Inspect
Exhaust muffler/pipe
100H
12M
1000
Inspect
Spark plug
100H
12M
1000
Inspect;replace
as needed
,
Wiring
100H
12M
1000
Inspect for wear,routing,security;apply
dielectric grease to connectors
subjected to water,mud,etc.
Check for leaks at tank cap,lines,fuel valve,
filter,carburetor;replace lines every
two years.
- 83 -
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
■
Clutches
(drive and driven)
100H
12M
1000
Inspect;clean;replace worm parts
■
Wheel bearings
100H
12M
1000
Inspect;replace as needed
■
Brake fluid
200H
24M
1000
Change every two years
Spark arrestor
300H
36M
1000
Clean out
■
■
Idle speed
Inspect parts
Toe adjustment
Inspect periodically;adjust when
parts are replaced.
Auxiliary brake
Inspect daily;adjust as needed
Headlamp
Adjust as needed
*Replace transmission belt every 2000km
- 84 -
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the Periodic Maintenance
Chart beginning on page 79.Items not listed in the chart should be lubricated at the
General Lubrication interval.
Lubrication Chart Key
More often under severe use, such as wet or dusty conditions
★All Seasons Grease
●Use U-Joint Lube every 500 miles, before long periods of storage,or after pressure
washing or submerging
Item
Lube
Method
Engine
SAE15W-40/SG
Add to proper level on dip stick
Brakes
DOT3 or DOT4 fluid
Maintain level between fill lines.See P38
Front Gear case
SAE15W-40/SG or SAE80W/90GL-4
See Page 90
Rear Gear case
SAE15W-40/SG or SAE80W/90GL-4
See Page 92
Ball Joint
Grease
Locate fitting on back side of struts and
grease with grease gun
- 85 -
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
Engine oil
Always check and change the engine oil at the
intervals outlined in the Periodic Maintenance Chart
beginning on Page 80.Always change oil filter whenever
chnaging oil.
Engine Oil Check
1.Pull outward on the areas shown ①
2.Position the ATV on a level surface
3.Start engine and left it idle for 20-30 seconds;stop the engine.
4.Wait a few minutes until the oil settles
5.Remove engine oil dipstick ①
6.Insert the dipstick in the oil filler hole and screwing
it in,then remove it again to check the oil level
NOTE:
The engine oil should be between the upper and lower
limit marks
- 86 -
MAINTENANCE AND LUBRICATION
Engine Oil Check
7.If the engine oil is at or below the lower limit
remark, add sufficient oil of the recommended type to
raise it to the correct level.
8.Insert the dipstick into the oil filler hole,and then
tighten the oil filler cap.
9.Install the panel.
To change the engine oil
1.Start the engine,warm it up for several minutes,and then turn it off
2.Place an oil pan under the engine to collect the used oil,
and then remove the engine oil filler cap.
3.Remove engine oil drain bolt① to drain the oil
from the crakcase.
4.Remove the oil filter cartridge with an oil filter
wrench
NOTE:
An oil filter wrench is available at a nearby dealer.
- 87 -
MAINTENANCE AND LUBRICATION
To change the engine oil
5.Apply a light coat of engine oil to the O-ring of
the new oil filter cartridge.
NOTE:Make sure the O-ring is seated properly.
6.Install the new oil filter cartridge with an oil
filter wrench, and then tighten it to the specified
torque with a torque wrench.
NOTE:Oil filter cartridge tightening torque::17N.m
7.Install the engine oil drain bolt, and then tighten
it to the specified torque.
NOTE:Engine oil drain bolt tightening torque:30N.m
8.Add the specified amount of recommended engine oil, and then install the engine oil
filler cap and tighten it.
NOTE:Without oil filter cartridge replacement oil quantity::1.9L
With oil filter cartridge replacement oil quantity:2.2L
9.Start the engine and warm it up for several minutes. While warming up, check for oil
leakage.If oil leakage is found,turn the engine off immediately and check for the cause.
10.Turn the engine off, and then check the oil level and correct it if necessary.
- 88 -
MAINTENANCE AND LUBRICATION
To change engine oil
Rear gear case oil
The rear gear case must be checked for oil leakage
before each ride. If any leakage is found,have your
dealer check and repair the ATV
Rear gear case oil replacement
1.Place the machine on a level place.
2.Place a container under the rear gear case to collect
the used oil.
3.Remove the oil filler bolt and the drain bolt to drain the oil.
4.Install the drain bolt and tighten it to the
specified torque.
NOTE:Drain bolt(rear gear case)tightening torque:23N.m
5.Fill the rear gear case with oil
NOTE:Periodic oil change oil quantity:0.25L
Total amount quantity:0.30L
- 89 -
MAINTENANCE AND LUBRICATION
Rear gear case oil replacement
6.Install the filler bolt and tighten to the specified torque.
NOTE:Filler bolt(rear gear case)tightening torque:23N.m
7.Check for oil leakage.If oil leakage is found,check for the cause.
NOTE:Be sure no foreign material enters the rear gear case
Front gear case oil measurement
1.Place the machine on a level place.
2.Remove the oil filler bolt and check the oil level.It should be up to the brim of
the hole.If the level is low,add sufficient oil to raise it to the specified level.
3.Install the oil filler bolt and tighten it to the
specified torque.
NOTE:Oil filler bolt tightening torque:23N.m
Front gear case oil replacement
1.Place the machine on a level place
2.Placce a container under the front gear case to
catch the oil
3.Remove the filler bolt and drain bolt to drain the oil
- 90 -
MAINTENANCE AND LUBRICATION
Front gear case oil replacement
4.Install the drain bolt and tighten it to the
specified torque.
NOTE:Drain bolt tightening torque:10N.m
5.Fill the front gear case with oil
NOTE:Periodic oil change oil quantity:0.28L
Total amount oil quantity:0.33L
6.Inspect the filler bolt and tighten it to the
specified torque.
7.Check for oil leakage.If oil leakage is found,check for the cause.
NOTE:Be sure no foreign material enters the front gear case.
Cooling system
1.Place the ATV on a level surface
2.Check the coolant level in the coolant reservoir when the engine is cold as the
coolant level will vary with engine temperature.
NOTE:The coolant should be between upper and lower limit marks.
- 91 -
MAINTENANCE AND LUBRICATION
Cooling System
3.If the coolant is at or below the lower limit mark,
remove the reservoir cap,add coolant to the uuper
limit mark,install the reservoir cap,and then
install the panel.
NOTE:Coolant reservoir capacity(up to the upper
limit mark):0.3L
CAUTION:
Hard water or salt water is harmful to the engine.
You may use soft water if you can not get coolant
NOTE:If water is hot, water level raise and radiator fan does not work,check antifreeze
fuild capacity in the reservoir firstly.If the antifreeze fulid is filled fully,
thermoswitch can adjust water tempearture automatically.If engine temperature is higher
than 80 degree,cooling fan begins to work.
To change coolant
1.Place ATV on a level place
2.Place a container under the engine,and then remove the coolant drain bolt(Use a trough
or a similar object as shown to prevent coolant from spilling on the footrest)
3.Remove the radiator cap.
4.Remove the coolant reservoir cap.
- 92 -
MAINTENANCE AND LUBRICATION
Changing the coolant
5.Disconnect the hose on the on the coolant reservoir,
and then drain the coolant out.。
6.After draining out the coolant, flush the cooling
system with clean water.
7.Replace the coolant drain bolt washer if damaged,
and tighten it as per stipulated torque.
NOTE:Torque:10N.m
8.Install the coolant reservoir hose.
9.Fill the radiator with recommended coolant till full.
NOTE:
Recommended anrifreeze:
High quality ethylene glycol antifreeze
with anti corrosion aluminum engine
Mix Ratio between antifreeze and water:1:1
Total Amount:1.9L
- 93 -
MAINTENANCE AND LUBRICATION
Changing the coolant
Coolant reservoir capacity
(Up to the Upper limit mark)
Capacity:0.3L。
CAUTION
Hard water or salt weater is harmful to engine.
Make sure to use soft water once you can’t get coolant.
10.Instasll the radiator cap.
11.Start the engine, and keep it runing in idle
speed for several minutes;Shut the engine, and then
check the coolant level;If the level is low,
fill the coolant till the top of radiator.
12.Fill the coolant into reservoir till up to Upper
limit.
13.Install the coolant reservoir cover, and check
the leakage.
NOTE:If there is any leakage, have your dealer check
the cooling system.
14.Install the top cover and front rack.
- 94 -
MAINTENANCE AND LUBRICATION
Axle boots
Check the protective boot for hole or tears.
If there is any damage,have your dealer replace it.
Check the spark plug
Removal
1.Remove the panel.
2.Remove the spark plug cap.
3.Remove spark plug with wrench in the tool kit
as per instruction.
- 95 -
Inspection
MAINTENANCE AND LUBRICATION
Spark plug is an important engine part,and is easy to inspect.
The condition of spark plug can indicate the engine condition.
For a normal ATV,The ideal color on the white white insulator
around the center electrode is medium-to-light brown color.
Do not attempt to diagnose the problem by yourself, but have
your dealer inspect it.Periodically remove and inspect the spark
plug, because the heat and deposit will cause the spark plug
damage and erode corrosion slowly.If there is excessive
electrode erosion or too much carbon and other deposits,
replace specific spark plug.
NOTE:Spark plug specification:DPR7EA-9(NGK)
Installation
1.Measure the celectrode gap with thickness gauge.
Adjust the gap as per specification if necessary.
NOTE:Spark plug gap:0.8-0.9mm
2.Inspect deposit,corrosion, or carbon on porcelain head of spark plug
electrode and center part.Replace the spark plug if there is excessive deposit.
Clean the carbon and deposit with spark plug clean agent or brush.
- 96 -
MAINTENANCE AND LUBRICATION
Installation
3.Install the spark plug and tighten it as per stipulated torque.
NOTE:Spark plug torque:17.5N.m。
If you have no torque wrench when you install the spark plug, 1/4 to 1/2 turn more after
tightening the spark plug by hand will be appropriate.Tighten the spark plug to stipulated
torque as soon as possible.
4.Install spark plug cap.
5.Installthe panel.
Cleaning Air filter element
NOTE:There is a check soft hose in air filter box.If there is dust or water in the sofr
hose, clean the sofe hose, and air filter as well as air filter box.
- 97 -
MAINTENANCE AND LUBRICATION
Cleaning Air filter element
1.Remove the seat;
2.Open the bracket and remove air filter box cover;
3.Remove air filter;
4.Disassemble air filter from bracket;;
5.CLean the air filter quitely with solvent;;
6.Squeeze the excessive solventout out of the air filter,
and then dry it.
CAUTION:
Do not damage the air filter when squeezing the solvent;
7.Check the air filter and replace it if damaged;
8.Apply special oil or other good quality foam air filter
oil on the air filter.If there is not such foam oil, use
engine oil.
NOTE:The air filter element can be wet, but do not drip
water on it.
9.Pull the air filter element out from the bracket;
10.Install the air filter element;
11.install air filter box cover and make sure the soft hose connected.
- 98 -
MAINTENANCE AND LUBRICATION
Cleaning air filter element
12.Install the seat;
NOTE: Clean the air filter element every 20-50 hours;More frequent cleaning and lubrication
should be done when operating the vehicle in dust area.After each use, inspect the intake hole
on the air filter box cover for obstruction.Inspect the sealing between air filter rubber
connector and air hose joint of the carburetor;Tighten all fitting securely to avoid
unfiltered air entering the engine.
CAUTION
Do not operate the engine when removing the air filter. That would allow the unfiltered air
enter the engine, and to fasten the tear or damage.In addition, operating the engine without air
filter device will affect the carburetor jetting performance, and possible engine overheating.
Cleaning spark arrester
Make sure the exhaust pipe and muffler are cool when cleaning the spark arrester.。
1.Remove the bolts;
2.Pull out the pipe from muffler;
3.Tap the exhause pipe quietly, and remove all carbon deposit from spark arrester in the pipe.
- 99 -
MAINTENANCE AND LUBRICATION
Cleaning spark arrester
4.Insert the exhaust pipe into the muffler aligning the bolt hole;
5.Install and tighten the bolts.
Cool down the muffler when cleaning the spark arrester.;
Not allowed to operate immediately shut the engine.
V-belt cooling duct inspect soft hose
If there is deposit or water inside, remove the soft hose
and clean it.
- 100 -
MAINTENANCE AND LUBRICATION
V-belt case drain bolt
When riding the vehicle in water, which reaches
height of V-belt case, remove the bolt to
drain the water from V-belt cae.
NOTE:If draining water from V-belt after
removing the drain bot,have you dealer check
the ATV,because water may affect other engine
parts.
- 101-
MAINTENANCE AND LUBRICATION
Adjusting throttle lever
1.Loosend half nut;
2.Turn the adjusting nut to keep 3-5mm throttle lever free play.
3.Tighten haf nut.
- 102-
MAINTENANCE AND LUBRICATION
Inspecting from brake caliper
Check the brake disc for damage and wear.
If thickness of brake disc is less than 3.0mm, have your dealer replace the whole
brake pads.
NOTE:Need to removethe wheels to check the brake pads.
- 103-
MAINTENANCE AND LUBRICATION
Checking rear disc
Check the brake disc for damage and wear.
If the brake disc thickness is less than 6.5mm,
have your dealer replace the brake pads.
Check the brake fluid level
Insufficient brake fluid may allow the air enter
the braking system.and cause the brake in disorder;
Before riding, check the brake fluid level
above the Lower Limit mark,and add brake fluid
if necessary.Front master cylinder resorvior
is located on the right side of handlebar;Rear
master cylinder fluid resorvior is located near the
rear brake pedal.
1
Front
- 104-
Rear
MAINTENANCE AND LUBRICATION
Checking brake fluid level
Observe these precautions:
1.When checking brake fluid level,turn the grip to make sure top level of master
cylinder resorvior.
2.Only use appointed good quality brake fluid, otherwise, rubber seals will be deteriorated,
causing leakage and poor brake performance.
NOTE:Recommended brake fluid:DOT3 or DOT4。
3.Refill with same type brake fluid till full. Mixed brake fluid may cause hramful chemical
reaction and lead to poor brake performance.
4.Be careful not to allow water entering master cylinder reservoir, when refilling brake
fluid; water will significantly lower the boiling point of the fluid.
5.Brake fluid may deteriorate painted surfaces or plastic parts.Always clean up spilled
fluid immediately.
6.Have your dealer check the reason why the brake fluid level goes down.
- 105-
MAINTENANCE AND LUBRICATION
Process to Replace Brake Fluid
Replacement shall be done only by trained service man;
Dealers need to replace Brake Fluid when making Maintenance ,or when parts are damaged, or
when Break Fuid leaks
●Replace Oil Seal once every two years.
●Replace Braking Hose once every four years.
●Free play at end of Braking Lever
shall be zero mm;otherwise please ask your dealer
to check the Braking System.
Make Sure after Maintenance that
●Braking successfully with enough clearance.
●No obstacle when braking.
●No air remains in braking system.
Replacement of brake components requires professional knowledge.
These procedures should be performed by your dealer.
If adjustment is necessary, please make sure follow procedure as below:
- 106 -
MAINTENANCE AND LUBRICATION
Adjustment of Rear Brake Lever and Footpedal
Adjustment of Rear Brake Lever Clearance
Rear Brake Lever clearance is 0.5-2mm
1.Unscrew Locking Screw①。
2.Turn Bolt 2 to increase clearance; Turn Bolt 2 with
direction
3.Tighten Screw①。
Please send to dealer if adjustment cannot be done.
NOTE:When adjust clearance,make sure
●Make sure the brakes operate smoothly
●Braking Footpedal does not move
Procedure to adjust height of Rear Braking Footpedal:
Note:Adjust Rear Braking Kit before check Rear Brake Gasket
- 107-
MAINTENANCE AND LUBRICATION
Rear Brake Pedal Adjustment
Top of Rear Brake Pedal shall be 72mm higher from
the end;otherwise please ask your dealer to adjust.
After servicing,make sure that
●Make sure the brakes operate smoothly and that
the free play is correct.
●Make sure the brakes do not drag.
All air must be bled from the brake system.
Replacement of brake components requires professional
knowledge. These procedures should be performed
by your dealer.
T he rear brake light switch,which is activated by
The rear brake light switch, which is activated
by the brake pedal and brake levers, is properly
adjusted when the brake light comes on just before
braking takes effect. If necessary, adjust the brake light switch as follows.
- 108 -
MAINTENANCE AND LUBRICATION
Rear Brake Pedal Height Adjustment
Turn adjustment nt while pushing rear brake light switch;Brake light is on in advance while
turning with direction ① Brake light on is delayed while turning with direction ②
Inspection and lubrication of wiring and cables.
It is necessary to inspect oftenly the wirings and cables;replace if there is
any damage.Lubricate the moving point of cables;
If cables are not moving well,contact your dealer
for replacement.
NOTE:Recommended lubricante: oil SAE10W-30
Lubricate Upper&Lower Shaft Joint of Rear
Steering Knuckle with a Spray Gun
NOTE:Recommended Lubricante --Lithium base grease
- 109-
MAINTENANCE AND LUBRICATION
Wheel Removal
1. Loosen the wheel nuts.
2. Elevate the ATV and place a suitable stand under the frame.
3. Remove the nuts from the wheel.
4. Remove the wheel.
Wheel Installation
1. Install the wheel and the nuts.
NOTE:● Tapered nuts are used for both the front and rear
wheels. Install the nut with its tapered side towards the wheel.
mark on the tire must point toward the rotating direction of the wheel.
● The arrow
- 110-
MAINTENANCE AND LUBRICATION
Wheel Installation
2. Lower the ATV so that the wheel is on the ground.
3. Tighten the wheel nuts to the specified torque.
NOTE:Wheel Nut Torque:Front 55N.m;Rear:55N.m
This machine is equipped with a sealed-type battery. Therefore it is not necessary to
check the electrolyte or add distilled water in the battery. If the battery seems to have
discharged, consult your dealer.
NOTE:
Do not try to remove the sealing caps of the battery cells. You may damage the battery.
Avoid contact with skin, eyes or clothing. Always shield eyes when working near
batteries. Keep out of reach of children.
Antidote:
EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention.
EYES: Flush with water for 15 minutes and get prompt medical attention. Keep batteries
away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging
or using in a closed space.
- 111-
MAINTENANCE AND LUBRICATION
Battery Maintenance
When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place.
Completely recharge the battery before reinstallation.
CAUTION:
A special battery charger (constant voltage/ampere or constant
voltage) is required for recharging a sealed- type
battery. Using a conventional battery charger may shorten
the battery life.
2. Always make sure the connections are correct when putting
the battery back in the machine.
Fuse Replacement
1. The main fuse case and the fuse box are located under the seat.
2. If a fuse is blown, turn off the main switch and install a new
fuse of the specified amperage. Then turn on the switches.
If the fuse immediately blows again, consult your dealer.
Always use a fuse of the specified rating.
Never use a material in place of the proper fuse.
- 112-
1.Start Relay
3 Servo Start Relay 1
5.Fuse(10A)
7.Fuse(15A)
9.Fan Relay
11.Servo Start Relay 2
2.Main Fuse(20A)
4.Fuel Pump Relay
6.Fuse(15A)
8.Fuse(10A)
10.Head light Relay
12.Auxiliary Fuse(20A)
MAINTENANCE AND LUBRICATION
Replacement of Fuse
CAUTION
To prevent accidental short-circuiting, turn off the main switch
when checking or replacing a fuse.
Replacement of Headlight Bulb
+
W5W
1.Pull out Rubber Cover at the back of headlight.
2.Remove Rear Holder of headlight.
3.Remove headlight from headlight rear holder.
+
+
E40013486
HS1
+
Wait till bulb is cold before any touch or removal of bulb.
- 113-
MAINTENANCE AND LUBRICATION
Replacement of headlight Bulb
4. Insert a new headlight bulb into the headlight bulb holder,
and then lock it by spring.。
5. Install the bulb holder by turning it clock-wise
6. Install the rubber cover at the rear of the headlight
7. Install the headlight cover with the bolts.
Headlight Beam Adjustment
CAUTION
It is advisable to have your dealer make this adjustment.
Turn the adjusting screwscan raise or lower the beam.
- 114-
E40013486
MAINTENANCE AND LUBRICATION
Tail/Brake Light Bulb Replacement
If the tail/brake light bulb burns out, replace it as follows:
1. Remove the screws , and then pull tail/brake light cover ② out.
2. Remove the tail/brake light bulb by pushing it in and turning it counter-clockwise.
3 . Insert a new tail/brake light bulb, push it in, and the turning it clockwise.
4. Install the tail/brake light cover with the screws.
- 115-
MAINTENANCE AND LUBRICATION
Front and Rear Suspenson Adjustment
The spring preload can be adjusted to suit the rider s weight
and riding conditions.
NOTE:When adjusting the rear shock absorbers,
the rear wheels need to be removed.
Adjust the spring preload as follows.。
To increase the spring preload, turn the adjusting ring in
direction(a)(b)
To decrease the spring preload, turn the ad-justing
ring indirection(b)
NOTE:A special wrench can be obtained at a dealer to make
this adjustment .Standard position: B
A- Minimum (soft)
BE- Maximum (hard)
Always adjust the shock absorbers on the left and right side to the same setting.
- 116-
MAINTENANCE AND LUBRICATION
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can result if the
machine is not thoroughly inspected. Take the vehicle to your dealer before
starting the engine.
If it s impossible to take your ATV to a dealer before starting it, follow the
steps outlined below.
1. Move the ATV to dry land or at the very least, to water below the footrests.
2. Remove the spark plug.
3. Check the air box and drain if there is water.
4. Turn the engine over several times using the electric start.
5. Dry the spark plug and reinstall, or replace it with a new plug.
6.Start the engine; Repeat above process several times to dry engine,if necessary.
7. Take the ATV to your dealer for service as soon as possible, whether you succeed in
starting it or not.
NOTE:If water has been ingested into the CVT, follow the procedure on page 101for drying
out the CVT. Otherwise owner shall be responsible for the damage from this.
- 117-
Cleaning and Storage
Cleaning of ATV
Keeping your ATV clean will not only improve its appearance but it can also extend the life of
various components. With a few precautions, your ATV can be cleaned much like an automobile.
Washing the ATV
The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water.
Use a professional type washing mitten, cleaning the upper body first and the lower parts last.
Rinse with water frequently and dry with a chamois to prevent water spots.
NOTE:If warning and safety labels are damaged, contact your dealer for replacement.
It is not recommended to use high pressure type car wash system for washing the ATV.
If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings,
transmission seals, body panels, brakes and warning labels.
NOTE:Grease all zerk fittings immediately after washing, and allow the vehicle to run for a
while to evaporate any water that may have entered the engine or exhaust system.
Waxing the ATV
Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners
since they can scratch the body finish.
CAUTION
Certain products, including insect repellants and chemicals, will damage plastic surfaces.
Use caution when using these products near plastic surfaces.
-118 -
Cleaning and Storage
CAUTION
Starting the engine during the storage period will disturb the protective film created
by fogging and damage could occur.Never start the engine during the storage period.
Clean the Exterior
Make necessary repairs and then clean the ATV/Quadricycle thoroughly with mild soap
and warm water to remove all dirt and grime.Don't use harsh detergents or high pressure
washers. Some detergents deteriorate rubber parts.Use dish soap type cleaners only.
High pressure washers may force water past seals.
Stabilize the Fuel
Fill the fuel tank.Add Carbon Clean Fuel Treatment or Fuel Stabilizer. Follow the instruction
on the container for the recommended amount.(Carbon clean will also reduce the possibility
of bacterial growth in the fuel system) Allow 15-20 minutes of operation for the stabilizer
to disperse through the fuel in the tank and carburetorand then drain the carburetor bowl.
- 119-
Cleaning and Storage
Air Filter/Air Box
Inspect and clean or replace the pre-cleaner and air filter.Clean the air box and
drain the sediment tube.
Breather Filter
Inspect and clean or replace the breather filter.
Fluid Levels
Inspect the following fluid levels and change if necessary:front gear case;
transmission; brake fluid(change every 2 years or as required if fluid looks
dark or contaminated).
Lubricate the Engine
Remove the spark plug and add 2-3 tablespoons of 4 Synthetic SAE15W-40/SF
engine oil.To access the plug hole,use a section of clear1/4 hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
NOTE: Do this carefully! If you miss the plug hole,oil will drain from the spark
plug cavity into the hole at the front of the cylinder head, and appear to be an
oil leak.Install the spark plug and pull the engine over slowly with the recoil
starter.Oil will be forced in and around the piston rings and ring lands,coating
the cylinder with a protective film of fresh oil.
- 120-
Cleaning and Storage
Fog the Engine
If you choose not to use Fogging Oil,perform the following procedure.
1.Support the front end of the machine,so the engine is level or tilted slightly
rearward.
2.Remove the spark plug.Rotate the piston to BDC and pour approximately two
ounces of oil into the cylinder.
3.Apply dielectric grease to the inside of the spark plug cap and install the cap
onto the plug.
4.Turn the engine over several times to ensure coverage of piston rings,cylinder
walls and crankshaft bearings.
5.Treat the fuel system with Carbon Clean.
6.If fuel system additive is not used,fuel tank,fuel lines,and carburetor shoud
be completely drained of gasoline.To eliminate fuel remaining in the carburetor,
run the engine until it stops.
Lubricate
Inspect all cables and lubricate with Cable Lubricate.Follow lubrication guidelines in the maintenance section of the service or owner's manual to completely
grease and lubricate the entire vehicle with All Season Grease.
- 121-
Cleaning and Storage
Battery Storage
Remove the battery from the vehicle and ensure that it's fully charged before
placing it in storage.
Engine Anti-freeze
Test engine coolant strength and change if necessary.Coolant should be replaced
every two years.
Storage Area/Covers
Set the tire pressure and safely support the ATV/Quadricycle with the tires 3050mm off the
ground.Be sure the storage area is well ventilated, and cover the machine with a
ATV/Quadricycle cover.
NOTE:Do not use plastic or coated material.They do not allow enough ventilation
to prevent condensation,and may prromote corrosion and oxidation.
Transporting the ATV/Qudricycle
Follow these procedures when transporting the vehicle.
1.Turn off the engine and remove the key to prevent loss during transporting.
2.Always place the transmission in park.
3.Be sure the fuel cap,oil cap and seat are installed corrctly.
4.Always tie the frame of the ATV/Quadricycle to the transporting unit securely
using suitable straps or rope.
- 122-
Cleaning and Storage
Chrome Wheel Care(if equipped)
Proper maintenance will protect chrome wheels from corrosion,preserve wheel
life and ensure a "like new" appearance for many years.
1.Wash chrome rims frequently.Use a mild detergent to remove any salt,dirt,mud
or grime.Never use abrasive cleaners on plated or painted surfaces.
2.Polish the clean chrome wheels periodically.Use an automotive grade chrome
polish.
3.Routinely and liberally apply a weather resistant wax to each polished chrome
wheel. Choose a product suitable for chrome finishes.Read and follow the product
labels and instructions.
4.Chrome wheels exposed to road salt(salt in the air in coastal sreas) are more
susceptible to corrosion if not properly cleaned.Clean chrome wheels more often
if they're exposed to salt or other corrosive elements.
Removing Corrosion
If light rust is found on the chrome finish,use steel wool(#0000-OTT grade)to
remove it. Gently rub the affected areas withe the steel wool until the corrosion
has been removed. Clean and polish the wheel as outlined above.
- 123-
TROUBLESHOOTING
Drive belt and cover problems
Solution
Possible Cause
Driving the ATV/Qudricycle onto a
pickup or tall trailer in high range
Starting out going up a steep incline
Shift transmission to low range during loading of the ATV/Qudricycle to prevent
belt burning.
When starting out on an incline,use low range or dismount ATV/Qudricycle(after
first applying the park brake) and perform the K-turn as discribed on page 67.
Driving at low RPM (at approximately5-11 MPH) Use low range more frequently.The use of low range is highly recommended for cooler
CVT operating temperatures and longer component life.
Insufficient warm-up of ATV/Qudricycle
exposed to low ambient temperatures
Warm the engine at least 5 minutes.With the transmission in park,advance the throttle to about
1/8 throttle in short bursts,5to7times.The belt will become more flexible and prevent belt burning.
Slow and easy clutch engagement
Use the throttle quickly and effectively for efficient engagement.
Towing /pushing at low RPM
Use low range only
Utility use/plowing snow,dirt,etc.
Use low range only
- 124-
Drive belt and cover problems
Solution
Possible Causes
Shift
Stuck in mud or snow
the
aggressive
Excessive
transmission
throttle
throttle
to
low
application
may
cause
range
to
and
engage
loss
of
use fast,
.WARNING:
carefully
clutch
control
and
vehicle
overturn
.
Climbing over large objects from a
stopped position.
Shift the transmission to low range,and carefully use fast,brief,aggressive throttle
application to engage clutch.WARNING:Excessive throttle may cause loss of control
and vehicle overturn.
Water or snow ingestion into CVT system
Shift the transmission to park.Using the throttle,vary the engine RPM from idle to
full throttle.Repeat several times as required.During this procedure,the throttle
should not be held at full position more than 10 seconds.Clutch seals should be ispected
for damage if repeated leaking occurs.
Clutch dosen't work
Contact your dealer for inspection of clutch components
Poor engine performance
Check for fouled plugs or foreign material in gas tank,fuel tank,fuel lines,
or carburetor. Contact your dealer for service.
- 125-
Contact your dealer for service if you're unable to identify solutions us ing following charts.
Engine doesn't Turn Over
Possible Cause
Solution
Tripped circuit breaker
Low battery voltage
Reset the breaker
Recharge battery to 12.5VDC
Loose battery connections
Check all connections and tighten
Check all connections and tighten
Loose solenoid connections
Engine Turns Over,Fails to Start
Possible causes
Solution
Out of fuel
Refuel
Clogged fuel valve filter
Water is present in fuel
Inspect and clean or replace
Drain the fuel system and refuel
Fuel pump out of use
Replace
Old or non-recommended fuel
Replace with new fuel
Inspect plug(s),replace if necessary
Fouled or defective spark plug(s)
No spark to spark plug
- 126-
Inspect plug(s),verify stop switch is on
Engine turns over, fails to start
Possible causes
Solution
Crankcase filled with water or fuel
Immediately see your dealer
Clogged fuel filter
Low battery voltage
Replace the filter
Mechanical failure
See your dealer
Recharge battery to 12.5 VDC
Engine Pings or Knocks
Possible cause
Solution
Poor quality or low octane fuel
Replace with recommended fuel
Incorrect ignition timing
See your dealer
Incorrect spark plug gap or heat range
Set gap to specified or replace
- 127-
Engine Backfires
Possible Cause
Solution
Weak spark from spark plugs
Inspect,clean and/or replace spark plug
Incorrect spark plug gap or heat range
Set gap to specified or replace plugs
Old or non-recommended fuel
Replace with new fuel
Incorrectly installed spark plug wires
See your dealer
Incorrect ignition timing
See your dealer
Mechanical failure
See your dealer
Engine Runs Irregularly,Stalls or Misfires
Possible cause
Fueled or defective spark plug
Solution
Inspect,clean and/or replace spark plug
Worn or defective spark plug wires
See your dealer
Incorrect spark plug gap or heat range
Set gap to specified or replace plugs
Loose ignition connections
Check all connections and tighten
Water present in fuel
Replace with new fuel
Low battery voltage
Recharge battery
to 12.5 VDC
1
- 128-
Engine Runs Irregularly,Stalls or Misfires
Possible Weak Spark Cause
Kinked or plugged fuel vent line
Solution
Incorrect fuel
Inspect and replace
Replace with recommended fuel
Clogged air filter
Inspect,clean and repalce
Reverse speed limiter malfuntion
See your dealer
Other mechanical failure
See your dealer
Possible lean fuel mixture cause
Solution
Low or contaminated fuel
Low octane fuel
Add or change fuel,clean the fuel system
Low pressure of fuel pump
Incorrect jetting
Replace fuel pump
See your dealer
Possible Rich Fuel Mixture Cause
Solution
Fuel is very high octane
Replace with lower octane fuel
Incorrect jetting
See youe dealer
Replace with recommended fuel
- 129-
Engine Stops or Loses Power
Possible cause
Solution
Outl of fuel
Refuel
Kinked or plugged fiel vent line
Inspect and replace
Water present in fuel
Replace with new fuel
Defective fuel pump or fuel pump relay
Inspect/replace
Fouled or defective spark plugs
Inspect and replace plug if necessary
Worn or defective spark plug wires
See your dealer
Incrrect spark plug gap ot heat range
Set gap to specified or replace plugs
Loose ignition connections
Low battery voltage
Check all connections and tighten
Recharge battery to 12.5VDC
Incorrect fuel
Replace with recommened fuel
Clogged air filter
Inspect,clean or replace
Reverse speed limiter malfunction
See your dealer
Other mechanical failure
See your dealer
- 130-
Engine Stops or Loses Power
Possible cause
Solution
Clean radiator screen and core if equipped
Overheated engine
Clean enginen exterior
See your dealer
- 131-
PCODE LIST
MSE3.0
No
PCODE
Faiure Analysis
Heating Control Circuit
Failure Type
Of Oxygen Sensor is open circuit.
Signal Failure
Oxygen Sensor Heating Control Circuit Short- to-Ground
Minimum Failure
Oxygen Sensor Heating Control Circuit short-to-power
Maxmum Failure
Internal Resistance of Oxygen Sensor Heating is
improper
Air Inlet Pressure Sensor Signal No Variable
Improper Air Inlet Pressure Sensor
Air Inlet Pressure Sensor Short-to-Ground
Minimum Failure
Air Inlet Pressure Sensor Short-to-Power
Maxmum Failure
Low Voltage of Air Inlet Temperature Sensor
Maxmum Failure
High Voltage of Air Inlet Temperature Sensor
Minimum Failure
Improper Engine Coolant Temperature Sensor
Low Voltage Limit of Engine Coolant Temperature Sensor
High Voltage Limit of Engine Coolant Temperature Sensor
Minimum Failure
The Voltage of Throttle Postion Sensor is too low.
Minimum Failure
The Voltage of Throttle Postion Sensor is too high.
Maxmum Failure
Improper Signal of Oxygen Sensor
Voltage of Oxygen Sensor is too low.
- 132-
Maxmum Failure
Signal Circurt Voltage of Oxygen Sensor is too high.
Oxygen Sensor is worn out.
Signal Circurt Failure of Oxygen Sensor
self studying found closing loop control air fuel ratio is unusual when making End of line Testing
self studying found closing loop control air fuel ratio is too thin when making End of Line Testing
self studying found closing loop control air fuel ratio is too thick when making End of Line Testing
Control Circurt of Cylinder 1 injector is open circurt.
Signal Failure
Control Circurt of Cylinder 2 injector is open circurt.
Control Circurt of Cylinder 1 injector is short-to-ground.
Minimum Failure
Control Circurt of Cylinder 1 injector is short-to-power.
Maximum Failure
Control Circurt of Cylinder 2 injector is short-to-ground.
Control Circurt of Cylinder 2 injector is short-to-power.
Reference Point of Rotate Speed Sensor Fault
Non-rotate Speed Sensor Pulse Signal(Open Circurt or Short Circurt)
Control Circuit of Idle Air Control Valve open circurt
Signal Failure
Voltage of Control Circuit of Idle Air Control Valve is too low.
Voltage of Control Circuit of Idel Air Control Valve is too high.
The signal of Rotate Speed Sensor is unusual.
Signal Failure
Rotate Speed of Idle Control is slower than that of Target Idle.
- 133-
Rotate Speed of Idle Control is faster than that of Target Idle.
Pin of Stepping Motor Driver is short to ground.
Pin of Stepping Motor Driver is short to power.
Pin of Stepping Motor Driver is open circurt.
Votage Signal of Battery is unusual.
Unusual Failure
Low Votage of Battery
Minimum Failure
High Votage of Battery
Maximum Failure
ECU Code Failure
Control Circurt of Fuel Pump Relay is incomplete.
Signal Failure
Control Circurt of Fuel Pump Relay is short-to-ground.
Minimum Failure
Control Circurt of Fuel Pump Relay is short-to-power.
Maximum Failure
Drive Circurt of MIL Light is fault.
Figure of Self Studying found Closing Loop control Air Fuel Ratio exceeds the upper limit.
Figure of Self Studying found Closing Loop control Air Fuel Ratio exceeds the lower limit.
Oxygen Sensor is worn out (too thin)
Oxygen Sensor is worn out (too thick)
PCODE uses 4 digit flashing.
For Example: “0650”
- 134-
“0” flashes 10 times.
“6” flashes 6 times.
“5” flashes 5 times.
“0” flashes 10 times.
Main Technical Data
Model
Data
Overall Size
(mm)
Wheel Base
(mm)
CF500-5C/CF625-C
CF500-5B/CF625-B
2100×1180×1230
2300×1180×1230
1290
1490
Min. Ground Clearance
(Load)
(mm)
Nearest
Min. Turning
Diameter
(L,R)
(mm)
Furthest
Min. Turning
Diameter
(L,R)
(mm)
275
6000
8000
6500
9500
- 135-
Main Technical Data
Model
Data
Weight(kg)
CF500-5C/CF625-C
344
358
Front Track(mm)
920
Rear Track(mm)
880
Model
Data
CF500-5B/CF625-B
CF500-5C/CF625-C
Fuel Capacity(L)
18
Reserve Fuel Capacity(L)
4
Fuel Type
(Kerb Mass)
Axle Loaded
Front Axle
(kg)
Rear Axle
(kg)
- 136-
CF500-5B/CF625-B
Unleaded Gasoline 93 or Above
183
194
161
164
Main Technical Data
Model
Data
Frame Type
Caster(mm)
Wheel
Rake(o)
CF500-5B/CF625-B
CF500-5C/CF625-C
Steel
26.5
Front Wheel
Camber:1±0.5(Unloaded)
Rear Wheel
Camber:1±0.5(Unloaded)
o
Caster Angel
9 52'
Kingpin Offset(mm)
26.5
Toe in(mm)
4-10
- 137-
Main Technical Data
Model
Data
CF500-5B/CF625-B
CF500-5C/CF625-C
Front Wheel
(mm)
Plate 12×6.0AT/
Light Alloy 12×6.0AT
Rear Wheel
(mm)
Plate 12×7.5AT/
Light Alloy 12×7.5AT
Front Wheel
185/88-12 40J
Rear Wheel
270/60-12 47J
Rim Type
and Size
Tire
Size
Front Wheel
Tire
Type
Tubeless tire
Rear Wheel
- 138-
Main Technical Data
Model
Data
Type
Front
Brake
Operation
Mode
Type
Rear
Brake
operation
Mode
Front Wheel
Tire
Pressure
(kpa) Rear Wheel
Front, Rear
Suspension
CF500-5B/CF625-B
CF500-5C/CF625-C
Hydraulic Disc
Manual Opeartion
Hydraulic Disc
Manual and Foot Connection Operation
Front Wheel35,Rear Wheel30
IIndependent Swing Arm
- 139-
Main Technical Data
Model
CF500-5C/CF625-C
CF500-5B/CF625-B
Data
Steering Gear
Mechanial Type
Absorber(Front, Rear)
Helix-Spring-Damped Type
Max. Turning Angle, Fr. Wheel
31
Locking Angle of Steering
30
(L,R)(o )
Model
CF500-5B/CF625-B
Data
Initial Temperature 71±3: Full Openning Temperature 80∽83
Thermostat(oC)
o
Boiling / Freezing Point of Coolant(C)
- 140-
CF500-5C/CF625-C
109/-35
Main Technical Data
Model
CF500-5C/CF625-C
CF500-5B/CF625-B
Data
Coolant Capacity
(L)
Shift Operation Mode
Muffler Type
Initial:2.0;Replacement:1.9
Manual
Compound Impedance
- 141-
Main Technical Data
Model
CF500-5C/CF625-C
CF500-5B/CF625-B
Data
Battery
Battery Type
Front Light
Bulbs,
Head Light
Quantity,
Type
12V18AH/12V30AH
12V 5Wx2;
W5W
H1/H3 12V55W×4
Turning Light
Amber Lamp Cover:R10W12V10W
Transparent Lamp Cover:RY10W12V10W
Rear Brake/
Rear Light
Red:R21/5W12V21W/5W
2 pcs
Engine:
-142 -
Lead-acid Battery
Single Cylinder, Liquid-Cooled,SOHC、4-Stroke
Bore×Stroke(mm):87.5×82
Displacement(ml):493
Compression Ratio:10.2∶1
Starting:Electrical Starting/Manual Starting
Single Cylinder, Liquid-Cooled,SOHC、4-Stroke
Bore×Stroke(mm):96×82
Displacement(ml):594
Compression Ratio:10∶1
Starting:Electrical Starting/Manual Starting
ZHE JIANG CFMOTO POWER CO.,LTD.
Add: NO.116 Wuzhou Road, Yuhang Economic Devel opment
Zone, Hangzhou, Zhejiang 311100, China
Tel: 0571-89265684
Fax:0571-89265696
Website: WWW.cfmoto.com
EU1003