Linhai LH40DA, Owner'S/Operator'S Manual

Page 1: ...Operation Maintenance THIS VEHICLE IS NOT DESIGENED FOR USE ON RENTAL TRACKS OR RACING LH40DA BEFORE OPERATING THIS VEHICLE THE OWNER AND EACH OPERATOR MUST HAVE READ AND HAVE AN UNDERSTANDING OF ALL THE INSTRUCTIONS FOR PROPER ASSEMBLY AND SAFE OPERATION AS WELL AS THE INSTRUCTIONS CONCERNING THE ENGINE AND ALL OTHER PORTIONS OF THE VEHICLE ...

Page 2: ...a toolbox has been provided in the rear of the ATV for storage of this manual and addendums Please keep this manual and addendums in the storage area toolbox so that it can be found easily and referenced when needed ...

Page 3: ...2 UNDERSTANDING WARNING 6 3 SAFETY WARNING 8 4 DAILY PRE RIDE INSPECTION 12 5 OPERATION WARNING 13 6 V I N 30 7 CONTROL AND FUNCTIONS 31 8 STARTING THE ENGINE 46 9 VEHICLE BREAK IN PERIOD 47 10 RIDING GEAR 48 11 CARRYING LOADS 4 ...

Page 4: ...9 12 RIDING 51 13 CVT SYSTEM 63 14 BATTERY 66 15 EXHAUST SYSTEM 69 16 MAINTENANCE 70 17 TROUBLE SHOOTING 102 18 TOOLS 109 19 SPECIFICATION 110 20 WIRING DIAGRAM 112 ...

Page 5: ...lease call your dealer and request to have them sent to you Important Safety Notice Never make any modifications to the engine drive system mechanical or electrical systems of your ATV Never install aftermarket parts or accessories intended to increase the speed or power of your ATV Failure to follow these warnings increases the possibility of accidents leading to DEATH or SERIOUS INJURY Additiona...

Page 6: ...g conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure 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 footrests of the ATV during operation Always go slowly and be extra caref...

Page 7: ...t to operate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding of sliding On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Avoid operating the ATV through deep or fast flowing water Avoid wa...

Page 8: ...N KNOW YOUR VEHICLE BEFORE YOU BEGING RIDING Read this manual thoroughly referring to the various areas which are being discussed on your machine Operating this vehicle carries with it responsibilities for your personal safety the safety of others and the protection of our environment NOTE Illustrations used in this manual are for general representation only Your model may differ ...

Page 9: ... messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is involved WARNING Indicates a potential hazard which could result in severe injury or death CAUTION Indicates a potential hazard which may result in minor personal injury or damage to the ATV CAUTION Indicates a situation that can result i...

Page 10: ... protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your dealer for a replacement Attention There is a risk of fire from driving the vehicle on the ground where grass has dried up or parking the vehicle on such surface while the engine is hot ...

Page 11: ...LH40DA OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 2 1 2 3 4 ...

Page 12: ...LH40DA OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 3 5 6 7 8 ...

Page 13: ...LH40DA OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 4 9 10 11 ...

Page 14: ...LH40DA OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 5 12 13 ...

Page 15: ...LH40DA OWNER S OPERATOR S MANUAL 18 0 3 SAFETY WARNING 3 6 ...

Page 16: ...rect have an authorized dealer adjust it Check the operation of the brake pedal It should move smoothly and there should be a firm feeling when the brakes are applied If not have the vehicle inspected by your dealer Brake fluid leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have t...

Page 17: ... on level ground Turn the steering wheel right and left Check for excessive free play abnormal noises or a rough feeling Have an authorized dealer repair as necessary for proper operation 9 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to your dealer for co...

Page 18: ...g the vehicle Consult an authorized dealer if you can t find or solve the problem yourself WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperl...

Page 19: ...ng too fast or sharp or a combination of conditions increase the risk of tip over If you are in a situation where the vehicle is tipping over do not put your arm or and leg outside the vehicle do not try to stop tipping with your arm or leg You could be severely injured You could suffer a crushed hand arm leg or foot if part of your body is caught underneath the vehicle WARNING POTENTIAL HAZARD Pi...

Page 20: ...r distance for braking WARNING POTENTIAL HAZARD Carrying a passenger passengers in the cargo bed WHAT CAN HAPPEN The passenger s could fall be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger passengers in the cargo bed This cargo bed is designed to carry cargo only WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven...

Page 21: ...d in this manual have the vehicle inspected by an authorized dealer WARNING POTENTIAL HAZARD Operating vehicle without being familiar with all controls WHAT CAN HAPPEN Loss of control which could cause an accident or injury HOW TO AVOID THE HAZARD Read the Owner s Manual carefully If there is a control or function you do not understand ask our authorized dealer WARNING POTENTIAL HAZARD Freezing co...

Page 22: ...cargo or pulling a trailer Allow greater distance for braking WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of access...

Page 23: ...ect 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 an authorized dealer WARNING POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of...

Page 24: ...n 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 WARNING POTENTIAL HAZARD Usi...

Page 25: ...t if the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it WARNING POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let frictio...

Page 26: ...ident and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment...

Page 27: ...ttempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always...

Page 28: ...D THE HAZARD Always keep both hands on the steering wheel and both feet on the footrests of your ATV during operation WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly ...

Page 29: ...trol the ATV on such terrain Always be especially cautious on these kinds of terrain WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills wit...

Page 30: ...ual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities Practice on sm...

Page 31: ... down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in t...

Page 32: ...ep weight uphill never apply engine power Apply the brake gradually When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operatin...

Page 33: ...ater WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operating the ATV through water which exceeds the recommended maximum depth in this manual Avoid operating the ATV through deep or fast flowing water If you cannot avoid water go slowly balance your weight carefully avoiding sudden movement maintain a slow...

Page 34: ...es or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or uneven tier pressure may cause loss of control and increases the risk of an accident HOW TO AVOID THE HAZARD Always use the size and type ties specified in the Owner s Manual for this vehicle Always maintain proper tire pressure a described in the Owner s Manual U...

Page 35: ...r modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult our authorized dealer WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death c...

Page 36: ... judgment and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death WARNING POTENTIAL HAZARD Operating this ATV on extreme off road terrain extreme slopes or jumping WHAT CAN HAPPEN It might lead to operator and passenger severe injured or dead the damage of the s...

Page 37: ... Operating the ATV through water WHAT CAN HAPPEN There is a risk of short circuit or leakage from wading driving the vehicle It might lead to operator and passenger severe injured or dead vehicle damaged or even ignited HOW TO AVOID THE HAZARD Operating this ATV on the dry terrain ...

Page 38: ...y and store in a safe place Your key can be duplicated only by obtaining a key blank and having it cut by mating it with your existing key Record Key Number The vehicle frame and motor serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle were stolen these numbers are essential to...

Page 39: ...key into the key switch WARNING Never turn the key to OFF position when the ATV is in motion Otherwise the electrical system is shut off which is likely to result in losing control or having an accident Always make sure that the ATV is stopped before turning the key to OFF position ...

Page 40: ...rt mode spare 16 Power Indicator 9 Economy mode spare Throttle WARNING Do not start or operate an ATV with sticking or improperly operation throttle controls A stuck or improperly operating throttle could cause an accident resulting in severe injury or death Always contact your dealer for service repairs whenever throttle problems arise Failure to check or maintain proper operation of the throttle...

Page 41: ...e is located under the seat The fluid should be kept between the maximum and minimum marks CAUTION Once a bottle of brake fluid is opened use what is necessary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbe moisture from the air This cause the boiling temperature of the brake fluid to drop which can lead to early brake...

Page 42: ...e notches on the lever body Release the brake lever To release the parking brake lock squeeze the brake lever It will return to its released position Important Safeguards The parking brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the parking brake for more than five minutes Always block the downhill side of the wh...

Page 43: ... of control Auxiliary brake lever Your ATV has an auxiliary brake provided brake as a safety feature It is located on the left handlebar and is operated by the left hand It is intended as a backup to the main brake system especially if the main system becomes inoperative If the rear wheels slide apply the rear brake with the left hand to some extent Aggressively applying the rear brake when backin...

Page 44: ...id needs to be added the window will be clear NOTE When checking the fluid level the ATV must be on level ground and the handlebars must be straight If the fluid level is low add DOT 3 only On some models there is a side window the fluid level can be seen through it and should be maintained between the indicated max and min marks on the reservoir Operator s Seat CAUTION To avoid personal injury 1 ...

Page 45: ...uld cause transmission damage Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function Should you experience any shifting problem see your dealer WARNING POTENTIAL HAZARD Engaging a lower gear when the engine speed is too high WHAT CAN HAPPEN The wheels could ...

Page 46: ...protective gear for safe riding A helmet can prevent a severe head injury Select an approved off road motorcycle type helmets that fits properly 2 Eye Protection A pair of goggles or helmet face shield offer the best protection for your eyes 3 Gloves off road style 4 Boots A pair of strong over the calf type boots with heels such as motocross boots 5 Clothing To protect your body long sleeves and ...

Page 47: ...ed motorcycle helmet increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long ...

Page 48: ...g of the front rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam with cargo Use of low forward gear is recommended in heavy pulling situations to extend belt life WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics Overloading or incorrect positioning of the load affects the vehicle s turnin...

Page 49: ...racks raises the center or gravity of the vehicle and creates a less stable operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating conditions OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS Avoid handling off centered loads which cannot be centered Always attach the tow load to the hitch point designated for your A...

Page 50: ...inery should it separate from the tractor drawbar Use a chain with the strength rating equal to or greater than the gross weight of the towed machinery Attach the chain to the tractor drawbar support or other specified anchor location Allow only enough slack in the chain to permit turning Do not use safety chain for towing ...

Page 51: ...killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fitting across your hips and chest and is latched securely Driving Procedure 1 Disconnect the charging cable if connected 2 All riders should wear substantial footwear long pants and a close fitting shirt A hard hat or helmet and approved eye prote...

Page 52: ...e park brake and remove the key when leaving the vehicle unattended WARNING You must inspect you ATV each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result See 4 DAILY PRE RIDE INSPECTION Making turns Practice making turns at slow speeds This ATV is equipped with a solid rear axle which drives both rear wheels equally at...

Page 53: ...ring slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 4 Never apply brakes during a skid Complete loss of ATV control can result 5 Do not operate on excessively slippery surfaces 6 Always reduce speed and use additio...

Page 54: ...void steep hills 15 maximum 2 Keep both feet on the footrests 3 Transfer you weight forword 4 Proceed at a steady rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV Sidehilling Side hilling your ATV is one of the most dangerous types of riding and should be avoided If you do enter into a situation where sidehilli...

Page 55: ...icle control or overturning of the ATV could occur causing severe injury or death Traveling Downhill Whenever descending a hill always 1 Drive directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs WARNING Do n...

Page 56: ...ing uphill of ATV turn handlebars full left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward 6 Lock the parking brake and remount ATV from the uphill side maintaining body weight uphill 7 Restart engine with transmission still in forward release parking bra...

Page 57: ...plying light pressure to the lever until braking action is normal CAUTION Never operating the ATV through deep or fast flowing water NOTE After running the vehicle in water it is critical your machine is serviced as outlined in the maintenance chart see 16 maintenance The following areas need special attention engine oil transmission oil rear gear case and all grease fittings Trail Obstacles Keep ...

Page 58: ...e or person behind you or the vehicle could tip over rearward on a steep incline causing severe injury or death Backing up 1 Avoid backing up on steep inclines 2 Always back slowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing NOTE This ATV is equipped with a reverse speed limiter Do not operate a...

Page 59: ...l to build in the exhaust resulting in engine popping and or engine damage WARNING Opening the throttle more than required may cause excessive fuel to build in the exhaust and ignited by the catalyst in the muffler MAY RESULT IN THE MUFFLERS OVERHEATING AND FIRE RISK Never ride with engine popping more than 1 minutes Parking on an incline ...

Page 60: ...ine off 2 Place the transmission in gear 3 Set the parking brake 4 Shut off fuel supply 5 Avoid parking on an incline If it is neceddary to park on an incline always block the rear wheels on the down hill side as shown above 6 Do not leave the ATV on a hill depending on the parking brake for more than five minutes ...

Page 61: ...ysician immediately Eyes Flush with water for 15minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Battery Removal 1 Disconnect hold down straps holding the electrical box and battery in position and remove ...

Page 62: ...to allow cleaning solution or tap water into the battery 1 Set the battery in its holder 2 First connect and tighten the red positive cable 3 Second connect and tighten the black negative cable 4 Reinstall battery cover and attach the hold down strap 5 Verify that cables are properly routed NOTE When you ATV is placed in storage for one months or more the battery should be removed charged to prope...

Page 63: ... on 3 Batteries can freeze if left uncharged at low ambient temperatures Percent Charged 100 50 0 Approximate Freezing Point 51 C 18 C 4 C FEATURES AND CONTROLS Main Power Connector NOTICE Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected Always disconnect the main power connector before servicing or unplugging any elec...

Page 64: ...ng procedures as outlined on vehicle safety labels and in this manual Battery Handling Precautions Always keep battery terminals and connections clean and free of corrosion at all times Always maintain a full charge on the batteries For best battery life avoid discharging the batteries more than 80 Make sure new batteries are fully charged before using New deep cycle batteries need to be cycled se...

Page 65: ...harging When not in use park the vehicle and connect the battery charger WARNING Failure to provide adequate ventilation while charging batteries can result in an explosion Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling Always ensure a minimum of five 5 air changes per hour in the charging area Never charge the batteries in an area subject to a flame or spark i...

Page 66: ...omatically cycle in and out of the trickle charge mode to maintain the charge 9 When disconnecting the charger always disconnect the extension cord from the wall receptacle first then disconnect the cord from the vehicle s charge receptacle Battery Inspections Inspect battery terminal connections monthly Clean batteries as recommended Using an insulated wrench torque bolts to 8 ft lbs 11 Nm If you...

Page 67: ...s or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc Away Ventilate when charging or using in an enclosed space Always shield eyes whe...

Page 68: ... the vehicle first then plug the cord into a wall receptacle 8 Make sure the charger uses a dedicated circuit to prevent overloading If charging multiple vehicles each vehicle should use a dedicated circuit TIP After the batteries have fully recharged the battery charger will automatically cycle in and out of the trickle charge mode to maintain the charge 9 When disconnecting the charger always di...

Page 69: ...id batteries are recyclable Return whole scarp batteries to a distributor manufacturer or lead smelter for recycling For neutralized spills place residue in acid resistant containers with absorbent material sand or earth and dispose of in accordance with local state and federal regulations for acid and lead compounds Contact local and or state environmental officials regarding disposal information...

Page 70: ...n adjustment and lubrication intervals of important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adju...

Page 71: ... Pre ride Pre ride Pre ride inspection item Headlamp Inspection Daily Daily Check operation daily apply dielectric grease to connector when replaced Tail lamp inspection Daily Daily Check operation daily apply dielectric grease to socket when replaced Battery 20 hrs Monthly Check clean Terminals check fluid level D Brake pad wear 10 hrs Monthly Inspect periodically Item Hours When Remarks Rear Gea...

Page 72: ...on 50 hrs 6 months Inspect lubricate tighten fasteners Rear Suspension 50 hrs 6 months Inspect tighten fasteners D Shift selector box D R N 200 hrs 24 months Change grease every two years D Brake fluid 200 hrs 24 months Change every two years D Toe adjustment As required As required Periodic inspection adjust when parts are replaced Headlight Aim As required As required Adjust if necessary ...

Page 73: ...mendations Item Lube Rec Method Frequency 1 Brake Fluid DOT 3 Only Maintain level Between fill lines See 7 CONTROL As require change every two years or 200 hours 2 Rear Gear case oil SAE GL 4 85W 90 See 16 MAI NTENANCE Rear Gear case Lubrication Change annually or at 100 hours ...

Page 74: ...vot shaft and grease with grease gun Every 3 months or 50 hours 8 Front Rear Wheel bearings Grease Inspect and replace bearings if necessary Semi annually 9 Tie rods Grease Locate fittings and Grease Semi annually 10 Front Rear Prop Shaft Shaft Yoke Grease Locate fittings and Grease Semi annually 11 Ball joints Inspect Inspect and replace it if necessary Semi annually 12 Prop Shaft Shaft Yoke Grea...

Page 75: ...NTENANCE 12 9 Cable and replace it if necessary hours 14 Rear Axle Bearing on swing arm model Grease Locate fittings and grease Every 3 months or50hours 15 Swing Arm Bearing on swing arm model Grease Locate fittings and grease Monthly or 20 hours ...

Page 76: ...E 1 More often under severe use such as wet or dusty conditions 2 Grease Light weight lithium soap grease 3 Grease M molybdenum disulfide MoS2 grease water resistant 4 When suspension action becomes stiff or after washing 5 Hours are based on 10 mph 16Km h average ...

Page 77: ...NTENANCE 12 11 PERIODIC MAINTENANCE RECORD Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 10 Hrs 15 Hrs 20 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs ...

Page 78: ...w the top of the fill hole NOTE Do not add lubricant to the bottom of the fill plug threads The correct gear case lubricant to use is SAE GL 4 85W 90 Weight Gear Lube Oil Changing Procedure 1 Remove drain plug Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque drain plug to 11 14 ft lbs 15 20N m 3 Remove fill plug and add 550ml of SAE GL 4 85W...

Page 79: ... or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block to 10 12 ft Ibs 14 16Nm NOTE Tighten bolts so there is an equal gap at the front and rear of the handlebar block Improper gap will result in improper fit of upper pod The following items should be checked occasionally for tightness or if they have been loosened for maintenance service Wheel Nut Torqu...

Page 80: ...r Tapered nuts install with tapered side against wheel Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts If loose nuts and bolts are found have your dealer tighten them before riding your vehicle Camber and Caster The camber and caster are non adjustable WARNING Do not attempt to adjust the tie rod for toe alignment Severe injury or de...

Page 81: ...ch can lead to early brake fade and the possibility of serious injury The front brake is hydraulic disc brakes which is depressing the foot pedal on the side of the right floorboard These brakes are self adjusting and require no adjustment The following checks are recommended to keep the brake system in good operating condition How often they need checking depends upon the type of driving that has...

Page 82: ...e other than periodic checks of the pads for wear Pads should be changed when the friction material is worn to 3 64 1mm Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by the brake lever being moving...

Page 83: ...arking lever 4 Tighten the jam nuts securely against the adjusters 5 Make sure the rear wheels turns freely without dragging 6 Turn the adjustor the one on the lever and apply the lever While adjusting it is important you apply the lever back and forth for operation free play and the locking of the parking position 7 Make sure the rear wheels turns freely without dragging and parking brake works p...

Page 84: ...djuster until 1 16 to 1 8 2 to 3mm freeplay is achieved at thumb lever NOTE While adjusting freeplay it is important you flip the throttle lever back and forth 3 Tighten locknut and slide boots over cable adjuster WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tire will affect vehicle handling which could cause an accident resulting ...

Page 85: ...ar Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel Tire Pressure front rear 150kPa 21 7PSI 150kPa 21 7PSI Wheel Installation 1 With the transmission in gear and the parking brake lock...

Page 86: ...e refer to your Owner s Manual for tire specifications LIGHTS WARNING Keep your headlights and taillights clean Poor light while riding can result in an accident causing severe injury or death CAUTION Do not service while headlight is hot Serious burns may result Do not touch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot which will shorten the life of the ...

Page 87: ...contact your dealer for replacement Warning 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 Care must be taken when using these products plastic surfaces STORAGE TIPS CAUTION Do not start the motor during the storage...

Page 88: ...0mm off the ground Be sure the storage area is well ventilated Cover the machine with a CUV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation TRANSPORTING Whenever the CUV is to be transported the following measures should be taken 1 Turn off the power and remove the key 2 Be certain the oil cap an...

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Page 90: ...Load Capacity Combined Rider Payload 150kg 330 lbs Tongue Weight 10kg 22 lbs Tow Capacity 190kg 418 8 lbs Drive System Electric motor 48V PMSM Front Tire 24X8 12 Rear Tire 24X8 12 Tire Pressure front 150 kPa 21 7 PSI Tire Pressure rear 150 kPa 21 7 PSI Brake System Front Brake Service Brake Rear Brake Hydraulic Disc Parking Brake All Wheel Hydraulic Lock Auxiliary Brake Rear Brake Hydraulic Disc S...

Page 91: ...ry 48V 100AH Head light 35W 35W x2 Front Turn Indicator Light 12V LED Front Position Light 12V 5W x2 Rear Turn Indicator Light 12V 10W x2 Rear Position Light 12V 5W x2 12V DC OUT Fuse 15 A Backup Fuse 15 A Main Fuse 20 A Specified fuses Signaling Lighting System Fuse 15 A In The Fuse Box ...

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