your atv can be hazardous to operate. · ways, parking lots, and streets. † never operate this...

Your ATV can be hazardous to operate.

position 65

The Safety Alert Symbol meansATTENTION! BE ALERT! YOURSAFETY IS INVOLVED.

ING WARNING indicates a hazardous sit-uation which, if not avoided, couldresult in death or serious injury.

N CAUTION, without the safety alertsymbol, is used to address practicesnot related to personal injury.

: A NOTE provides key information tomake procedures easier or moreclear.

WARNING xhaust from this product containswn to the State of California to

birth defects or other reproductive

A collision or rollover can occur quickly, even during routine maneu-vers such as turning and driving on hills or over obstacles, if you fail totake proper precautions. For your safety, it is important to understandand follow all of the warnings contained in this Operator’s Manual andthe labels on your ATV prior to riding.Keep this Operator’s Manual with this vehicle at all times. If you loseyour manual, contact your authorized dealer for a replacement. Thelabels should be considered permanent parts of the vehicle. If a labelcomes off or becomes hard to read, contact your authorized dealer fora replacement. Contact the manufacturer for proper registration infor-mation.FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THISMANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.ALWAYS USE COMMON SENSE WHEN OPERATING THISVEHICLE.Children differ in skills, physical abilities, and judgment. Some children maynot be able to operate an ATV safely. Parents should supervise their child’suse of the ATV at all times. Parents should permit continued use only if theydetermine that the child has the ability to operate the ATV safely.For your safety, it is important all operators be properly trained to oper-ate an ATV. Training is available: U.S. owners, call 800-887-2887;Canadian owners, call 613-739-1535.Particularly important information is distinguished in this manual bythe following notations:

California Pro

!! WARN

CAUTIO

NOTE

!The Engine Echemicals knocause cancer,harm.

1

of this manual covers important information, operator-tenance, and storage instructions. If major repair or servicered, contact an authorized dealer for professional service.f publication, all information and illustrations in this manualally correct. Some illustrations used in this manual are usedrposes only and are not designed to depict actual conditions.

Road and the ATV Safety Institute (U.S.) recommend thatrators ride the appropriate-sized ATV according to age.

Parts and Accessories

ed of replacement parts, oil, or accessories for your ATV, benly GENUINE PARTS, OIL, AND ACCESSORIES. Only

rts, oil, and accessories are engineered to meet the stan-requirements of this vehicle. For a complete list of acces-r to the current ATV/ROV Accessory Catalog.rvice and maintenance procedures on this vehicle, a Servicevailable through your authorized dealer.

Age (Years) Speed Limitations (mph) NOTES12 or Older 15 - Limited

30 - MaximumOperate Under

Adult Supervision14 or Older 20 - Limited

30 - Limited38 - Maximum

Operate UnderAdult Supervision

16 or Older According toLocal Regulations

—

ForewordCongratulations and thank you for purchasing a Tracker Off RoadTM All-Terrain Vehicle (ATV). It is designed to provide superior ride, comfort,utility, and dependable service.This Operator’s Manual is furnished to make the operator aware of properoperating procedures. It also includes information about the general careand maintenance of your ATV.Carefully read the following pages. If you have any questions regardingthis ATV, contact an authorized dealer for assistance. Remember, onlyauthorized dealers have the knowledge and facilities to provide you withthe best service possible.

• Know all local, state/provincial riding laws,• Respect your ATV,• Respect the environment, and• You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance pro-gram as outlined. This preventive maintenance program is designed toensure that all critical components on this ATV are thoroughly inspected atvarious intervals.All information in this manual is based on the latest product data and spec-ifications available at the time of printing. We reserve the right to makeproduct changes and improvements which may affect illustrations orexplanations without notice. Because the manufacturer constantly refinesand improves its products, no retroactive obligation is incurred.You have chosen a quality vehicle designed and manufactured to givedependable service. Be sure, as the owner/operator of this vehicle, tobecome thoroughly familiar with its basic operation, maintenance, andstorage procedures. Read and understand the entire Operator’s Manual before operating thisvehicle to ensure safe and proper use. Always operate the vehicle withinyour level of skill and current terrain conditions.

Division II related mainis ever requiAt the time owere technicfor clarity pu

Tracker Offall ATV ope

Protect Your Sport

When in nesure to use ogenuine padards and sories, refeTo aid in seManual is a

CategoryY-12+

T-14

G & S

ation ................................................................................33-38ations and Functions..........................................................33...........................................................................................35Float Bowl Drain.................................................................35ick.......................................................................................35...........................................................................................36/Bracket ..............................................................................36g ATV .................................................................................36 Oil — Lubricant.................................................................37k-In ...................................................................................38

nance ..............................................................................39-49e Schedule.........................................................................39rbers ..................................................................................40rication ..............................................................................40 System .............................................................................41rakes ..................................................................................41oses ...................................................................................42ubber Boots ......................................................................42...........................................................................................43...........................................................................................46RPM Adjustment ...............................................................46le Adjustment....................................................................47

...........................................................................................47

...........................................................................................48

...........................................................................................48ement ................................................................................48...........................................................................................49mpartment/Tools ................................................................49 Storage ............................................................................... 50r Storage ............................................................................ 51

ty .......................................................................................... 52dure/Owner Responsibility ............................................... 53ion Control Statement/Warranty Coverage (U.S. Only)..54cord ...............................................................................55-56

ress, Ownership, or Warranty Transfer ............................ 57umbers Record ........................................Inside Back Cover

2

Table of ContentsForeword .........................................................................................................1Parts and Accessories ...................................................................................1

Division I — Rider Awareness/ResponsibilityATV Safety Alert..............................................................................................5Rider Training Course ....................................................................................6Hangtags .........................................................................................................7Warning Labels ...............................................................................................8Warnings ................................................................................................... 9-15Prevention ............................................................................................... 17-20

Clothing and Gear ............................................................................... 17Condition of the ATV ........................................................................... 18First Aid and Survival .......................................................................... 19

Active Riding.................................................................................................21Sound Judgment .................................................................................... 22-23

Those Around You .............................................................................. 22Environment ........................................................................................ 22Equipment ........................................................................................... 23Personal Choices ................................................................................ 23Load Capacity Ratings Chart .............................................................. 23

Supervision ...................................................................................................25Taking Responsibility .......................................................................... 25

Inexperienced/Untrained Riders ................................................... 25Experienced/Trained Riders ......................................................... 25

Division II — Operation/MaintenanceATV Specifications .......................................................................................26Location of Controls.....................................................................................26ATV Operation......................................................................................... 27-32

Basic Operating Maneuvers ................................................................ 27Starting the Engine ....................................................................... 27Starting a Cold Engine.................................................................. 27

Handling the ATV (Active Riding Techniques) .................................... 28Tips...................................................................................................... 29

General InformControl LocShift Lever .Carburetor Oil Level StSeat Lock ..Safety FlagTransportinGasoline —Engine Brea

General MainteMaintenancShock AbsoGeneral LubHand BrakeAdjusting BGas/Vent HProtective RBattery .......Spark Plug.Engine Idle Throttle CabAir Filter .....Tires ..........Wheels ......Bulb ReplacFuse ..........Storage Co

Preparation forPreparation afteLimited WarranWarranty ProceU.S. EPA EmissMaintenance ReChange of AddIdentification N

3oided, could result in death or serious injury.

perate an ATV without wearing an approved helmet that fits prop- should also wear eye protection (goggles or face shield), gloves,ng-sleeved shirt or jacket, and long pants.onsume alcohol or drugs before or while operating this ATV.erate at excessive speeds. Always travel at a speed which is properrrain, visibility and operating conditions, and your experience.ttempt wheelies, jumps, or other stunts.inspect this ATV each time you use it to make sure it is in safeg condition. Always follow the inspection and maintenance proce-d schedules described in this manual.

keep both hands on the handlebars and both feet on the footrestsTV during operation.o slowly and be extra careful when operating on unfamiliar terrain.e alert to changing terrain conditions when operating the ATV.perate on excessively rough, slippery, or loose terrain.follow proper procedures for turning as described in this manual. turning at slow speeds before attempting to turn at faster Do not turn at excessive speed.have the ATV checked by an authorized dealer if it has been in an accident.perate the ATV on hills too steep for the ATV or for your abilities. on smaller hills before attempting larger hills.follow proper procedures for climbing hills as described in this Check the terrain carefully before you start up any hill. Neverills with slippery or loose surfaces. Shift your weight forward.pen the throttle suddenly. Never go over the top of any hill at highlways follow proper procedures for going down hills and for brak-

ills as described in this manual. Check the terrain carefully beforet down any hill. Shift your weight backward. Never go down a hillpeed. Avoid going down a hill at an angle which would cause theean sharply to one side. Go straight down the hill where possible.ollow proper procedures for crossing the side of a hill as describedanual. Avoid hills with slippery or loose surfaces. Shift your weighthill side of the ATV. Never attempt to turn the ATV around on any hill have mastered the turning techniques described in this manual onund. Avoid crossing the side of a steep hill if possible.se proper procedures if you stall or roll backward when climbing a hill. stalling, maintain a steady speed when climbing a hill. If you stall orwards, follow the special procedure for braking described in this man-ount on the uphill side or to either side if pointed straight uphill. Turn

around and mount following the procedure described in this manual.

! WARNING Indicates a hazardous situation which, if not av

Division I — Rider Awareness/ResponsibilityAN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

An ATV handles differently from other vehicles including motorcyclesand cars. A collision or rollover can occur quickly, even during routinemaneuvers such as turning and driving on hills or over obstacles, if youfail to take proper precautions. SEVERE INJURY OR DEATH canresult if you do not follow these instructions:

• Parents: It is very important that your child or children understand and followthe instructions and warnings contained in this manual before operating thisATV under adult supervision. Also, it is very important that you take time towatch the Safety DVD (included in the Owner’s Packet) with your child orchildren. It contains important operating and safety instructions.

• Read this manual and all labels carefully and follow the operating proce-dures described.

• Never operate an ATV without proper instruction. Take a training course.Beginners should receive training from a certified instructor. Contact anauthorized dealer or call the ATV Safety Institute at 800-887-2887 (U.S.) orthe Canada Safety Council at 613-739-1535 (Canada) to find out about thetraining course nearest you.

• Never allow anyone under 12 years of age to operate this ATV.• Never allow a child to operate a Y-12+ ATV without adult supervision and

never allow continued use of an ATV by a child if the child does not have theabilities to operate it safely.

• Some operators, even at the age of 12, may not be able to operate an ATVsafely; parents should supervise such operator of the ATV at all times. Par-ents should permit continued use only if they determine that the operatorhas the ability to operate the ATV safely.

• Never carry a passenger.• Never permit a guest to operate this ATV unless the guest has read this

manual and all product labels and has completed a certified training course.• Never operate an ATV on any paved surfaces, including sidewalks, drive-

ways, parking lots, and streets.• Never operate this ATV on any public street, highway, or road (even a dirt or

gravel one).

• Never oerly. Youboots, lo

• Never c• Never op

for the te• Never a• Always

operatindures an

• Always of the A

• Always gAlways b

• Never o• Always

Practicespeeds.

• Always involved

• Never oPractice

• Always manual.climb hNever ospeed. Aing on hyou starat high sATV to l

• Always fin this mto the upuntil youlevel gro

• Always uTo avoidroll backual. Dismthe ATV

ot avoided, could result in death or serious injury.

the size and type tires specified in this manual. Always main- tire pressure as described in this manual.roperly install or improperly use accessories on your ATV.ll a twist grip throttle on this ATV.ed the stated load capacity for this ATV. One operator only. No

sengers, or towing.e speed limiting safety device on this ATV at your own risk. INFORMATION ABOUT ATV SAFETY, call theInstitute at 800-887-2887 (U.S.) or Canada Safety3-739-1535 (Canada).

4 ! WARNING Indicates a hazardous situation which, if n

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

• Always check for obstacles before operating in a new area. Never attemptto operate over large obstacles, such as large rocks or fallen trees.Always follow proper procedures when operating over obstacles asdescribed in this manual.

• Always be careful of skidding or sliding. On slippery surfaces, such asice, go slowly and be very cautious in order to reduce the chance of skid-ding or sliding out of control.

• Never operate an ATV in fast flowing water or in water deeper than thefootrests. Remember that wet brakes may have reduced stopping capa-bility. Test your brakes after leaving water. If necessary, apply them lightlyseveral times to let friction dry out the pads.

• Always usetain proper

• Never imp• Never insta• Never exce

cargo, pas• Remove th

FOR MOREATV Safety Council at 61


TRACKER OFF ROAD BRAND ATV IS DESIGNEDCERTAIN AGE GROUP. NEVER RIDE AN ATV THAT ISESIGNED FOR YOUR AGE GROUP. THE OPERATOR’SAL AND LABELS CONTAIN THE AGE GROUP FORATV. OPERATE A TRACKER OFF ROAD BRAND YOUTHITHOUT PARENTAL SUPERVISION. OPERATE AN ATV ON PAVEMENT. THE VEHICLE ISESIGNED TO BE USED ON PAVED SURFACES ANDE DIFFICULT TO CONTROL. OPERATE AN ATV ON A PUBLIC ROAD, EVEN AR GRAVEL ONE, BECAUSE YOU MAY NOT BE ABLEOID COLLIDING WITH OTHER VEHICLES. ALSO,TING AN ATV ON A PUBLIC ROAD MAY BE AGAINSTW. OPERATE AN ATV WITHOUT AN APPROVED

RCYCLE HELMET, EYE PROTECTION, BOOTS,S, LONG PANTS, AND A LONG-SLEEVED SHIRT OR

T. CONSUME ALCOHOL OR DRUGS BEFORE OR OPERATING AN ATV. OPERATE AN ATV AT EXCESSIVE SPEEDS. GO AT A

WHICH IS PROPER FOR THE TERRAIN, VISIBILITYTIONS, AND YOUR EXPERIENCE. ATTEMPT TO DO WHEELIES, JUMPS, OR OTHERS.S BE CAREFUL WHEN OPERATING AN ATV, ESPE- WHEN APPROACHING HILLS, TURNS, AND OBSTA-ND WHEN OPERATING ON UNFAMILIAR OR ROUGHIN. LEND YOUR ATV TO ANYONE WHO HAS NOT A TRAINING COURSE OR HAS NOT BEEN DRIVING FOR AT LEAST A YEAR.


ATV Safety AlertThe U.S. Consumer Product Safety Commission has concluded thatALL-TERRAIN VEHICLES (ATVs) may present a risk of DEATH orSEVERE INJURY in certain circumstances:*** Each year, about 650 deaths and about 100,000 injuries (including

children) related to off-road vehicles are reported.*** Many people have become severely paralyzed or suffered severe

internal injuries as a result of accidents associated with ATVs.*** Every month thousands of people are treated in hospital emergency

rooms for injuries received while riding an ATV. You should be aware that AN ATV IS NOT A TOY AND CAN BEHAZARDOUS TO OPERATE. An ATV handles differently from othervehicles, including motorcycles and cars. A collision or rollover canoccur quickly, even during routine maneuvers such as turning and driv-ing on hills and over obstacles, if you fail to take proper precautions.TO AVOID DEATH OR SEVERE PERSONAL INJURY:

* NEVER ALLOW ANYONE UNDER 12 YEARS OLD TOOPERATE A TRACKER OFF ROAD Y-12+ ATV.

* ALWAYS READ THE OPERATOR’S MANUAL CAREFULLYAND FOLLOW THE OPERATING PROCEDURES DESCRIBED.PAY SPECIAL ATTENTION TO THE WARNINGS CONTAINEDIN THE MANUAL AND ON ALL LABELS.

* NEVER OPERATE AN ATV WITHOUT PROPER INSTRUCTION.TAKE A TRAINING COURSE. BEGINNERS SHOULD COM-PLETE THE TRAINING COURSE DESCRIBED ON PAGE 6.

* NEVER CARRY A PASSENGER OR RIDE AS A PASSENGERON AN ATV. CARRYING A PASSENGER MAY UPSET THEBALANCE OF THE ATV AND MAY RESULT IN LOSS OF CON-TROL.

* EVERYFOR A NOT DMANUEACH

* NEVERATV W

* NEVERNOT DMAY B

* NEVERDIRT OTO AVOPERATHE LA

* NEVERMOTOGLOVEJACKE

* NEVERWHILE

* NEVERSPEEDCONDI

* NEVERSTUNT

* ALWAYCIALLYCLES ATERRA

* NEVERTAKENAN ATV

Rider Training CourseThe manufacturer sponsors a free Rider Training Course to teach ATVriding skills or to reinforce current riding skills. First-time purchaserswithout any previous ATV riding experience will receive a $100.00 cou-pon from the manufacturer through the Specialty Vehicle Institute ofAmerica/ATV Safety Institute after completing the training course (U.S.owners only, one incentive). The manufacturer provides free rider train-ing courses to appropriate immediate family members per ATV pur-chase. Others can take the training course for a small fee. See anauthorized dealer for details or call 800-887-2887 for training courseinformation.In Canada, the Canada Safety Council (CSC) provides an ATV Rider’sCourse to teach safe ATV operating skills. They also provide a specialATV Rider’s Course for children under 14 years of age with parentalsupervision. Call 613-739-1535 for more details. Also available aresafety training materials from the Canadian Off-Highway VehicleDistributors Council. Call toll-free at 877-470-2288.FOR MORE INFORMATION ABOUT ATV SAFETY in the U.S., call the Consumer Product Safety Commission at 800-638-2772 or the ATV Safety Institute Safety Hotline at 800-852-5344. In Canada, call the Canada Safety Council at 613-739-1535.

HangtagsThis vehicle comes with hangtags containing important safety informa-tion. Anyone who rides the vehicle should read and understand thisinformation before riding.


1411-932

2411-137

B

C

0411-836

D

5411-632

1411-574


Warning LabelsThis vehicle comes with severallabels containing importantsafety information. Anyone whorides the vehicle should read andunderstand this informationbefore riding.The labels should be consideredas permanent parts of the vehicle.If a label comes off or becomeshard to read, contact your autho-rized dealer for a replacement.

KM960A

5411-394

1411-317

G

H

E

1411-809

A

F


! WARNINGIAL HAZARDassenger on this ATV.AN HAPPEN

uces your ability to balance this ATV. Could cause ansulting in injury or death toyour passenger. AVOID THE

a passenger. The long seat is to allow the operator tons as needed during operation. It is not for carrying pas-

! WARNINGIAL HAZARD

his ATV on paved surfaces.AN HAPPENtires are designed for off-ly, not for use on pavement.aces may seriously affectd control of the ATV and

the ATV to go out of control. AVOID THE

ossible, avoid operating the ATV on any paved surfacesdewalks, driveways, parking lots, and streets. If operatingurfaces is unavoidable, travel slowly (less than 10 mph)udden turns and stops.


Warnings

! WARNINGPOTENTIAL HAZARD Operating this ATV without proper instruction and supervision.WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does notknow how to operate the ATV properly in different situations and ondifferent types of terrain.HOW TO AVOID THE HAZARDBeginning and inexperienced operators should complete the certifiedtraining course offered. They should then regularly practice the skillslearned in the course and the operating techniques described in thisOperator’s Manual.For more information about the training course, contact an autho-rized dealer or call 1-800-887-2887 (U.S.) or 613-739-1535 (Can-ada).

! WARNINGPOTENTIAL HAZARDAllowing anyone under age 12 to operate this ATV.WHAT CAN HAPPENUse of an ATV by children can lead to severe injury or death of thechild. Children may not have the skills, abilities, or judgment neededto operate the ATV safely and may be involved in a serious accident.HOW TO AVOID THE HAZARDA child under 12 should never operate this ATV. A child lacking theskills, abilities, or judgment needed to operate the ATV safely shouldnever operate this ATV. A child under the age of 16 should neveroperate this ATV without parental supervision.

POTENTCarrying a pWHAT CGreatly redand controlaccident, reyou and/or HOW TOHAZARDNever carryshift positiosengers.

POTENTOperating tWHAT CThe ATV’s road use onPaved surfhandling anmay cause HOW TOHAZARDWhenever pincluding sion paved sand avoid s


! WARNINGL HAZARD

s ATV without wearing anorcycle helmet, eye protec-ctive clothing.N HAPPEN

hout an approved helmetr chances of a severe headh in the event of an acci-

thout eye protection canccident and increases yoursevere injury in the event of

ithout protective clothingr chances of severe injury

f an accident.AVOID THE HAZARDn approved helmet that fits properly.

so wear:Eye protection (goggles or face shield)GlovesBootsLong sleeved shirt or jacketLong pants


! WARNINGPOTENTIAL HAZARDOperating this ATV on public streets,roads, or highways.WHAT CAN HAPPENYou can collide with another vehicle.HOW TO AVOID THE HAZARDNever operate this ATV on any publicstreet, road, or highway, even a dirt orgravel one.In many states it is illegal to operate an ATV on public streets, roads,or highways.

! WARNINGPOTENTIAL HAZARDOperating this ATV after or while consuming alcohol or drugs.WHAT CAN HAPPENCould seriously affect your judgment.Could cause you to react more slowly.Could affect your balance and perception.Could result in an accident.HOW TO AVOID THE HAZARDNever consume alcohol or drugs before or while driving this ATV.

POTENTIAOperating thiapproved mottion, and proteWHAT CAOperating witincreases youinjury or deatdent.Operating wiresult in an achances of a an accident.Operating wincreases youin the event oHOW TO Always wear aYou should al


! WARNINGIAL HAZARDspect the ATV before operating.roperly maintain the ATV.AN HAPPENe possibility of an accident or equipment damage. AVOID THE HAZARD

ect your ATV each time you use it to make sure the ATVerating condition.ow the inspection and maintenance procedures andescribed in this Operator’s Manual.

! WARNINGIAL HAZARDse extra care when operat- on unfamiliar terrain.AN HAPPENome upon hidden rocks,oles without enough time to

lt in the ATV overturning orf control. AVOID THE HAZARD

nd be extra careful when operating on unfamiliar terrain.alert to changing terrain conditions when operating the


! WARNINGPOTENTIAL HAZARDOperating this ATV at excessive speeds or removing the speed limit-ing device from the ATV.WHAT CAN HAPPENIncreases your chances of losing control of the ATV, which can resultin an accident.HOW TO AVOID THE HAZARDAlways ride at a speed that is proper for the terrain, visibility andoperating conditions, and your age and experience.

! WARNINGPOTENTIAL HAZARDAttempting wheelies, jumps, and otherstunts.WHAT CAN HAPPENIncreases the chance of an accidentincluding an overturn.HOW TO AVOID THE HAZARDNever attempt stunts, such as wheeliesor jumps. Don’t try to show off.

POTENTFailure to inFailure to pWHAT CIncreases thHOW TOAlways inspis in safe opAlways follschedules d

POTENTFailure to uing the ATVWHAT CYou can cbumps, or hreact.Could resugoing out oHOW TOGo slowly aAlways be ATV.


! WARNINGL HAZARD

perly.N HAPPEN

out of control, causing a collision or rollover.AVOID THE HAZARD proper procedures for turning as described in thisnual.

ng at slow speeds before attempting to turn at faster

excessive speed.

! WARNINGL HAZARD

extra care when operat-slippery, or loose terrain.N HAPPEN

loss of traction or controlich could result in an acci- an overturn.AVOID THE

te on rough, slippery, or loose terrain until you haveracticed the skills necessary to control the ATV on such

ecially cautious on these kinds of terrain.


! WARNINGPOTENTIAL HAZARDRemoving hands from handlebar or feet from footrests during opera-tion.WHAT CAN HAPPENRemoving even one hand or foot can reduce your ability to control theATV or could cause you to lose your balance and fall off the ATV. Ifyou remove a foot from a footrest, your foot or leg may come into con-tact with the wheels, which could injure you or cause an accident.HOW TO AVOID THE HAZARDAlways keep both hands on the handlebar and both feet on the foot-rests of your ATV during operation.

! WARNINGPOTENTIAL HAZARDOperating on steep hills.WHAT CAN HAPPENThe ATV can overturn more easily onsteep hills than on level surfaces orsmall hills.HOW TO AVOID THE HAZARDNever operate the ATV on hills toosteep for the ATV or for your abilities.Practice on smaller hills before attempting larger hills.

POTENTIATurning improWHAT CAATV could goHOW TO Always followOperator’s MaPractice turnispeeds.Do not turn at

POTENTIAFailure to useing on rough, WHAT CACould cause of the ATV, whdent includingHOW TO HAZARDDo not operalearned and pterrain.Always be esp


! WARNINGIAL HAZARD a hill improperly.AN HAPPEN

e loss of control or cause therturn. AVOID THE

low proper procedures for hills as described in this Operator’s Manual.ck the terrain carefully before you start down any hill.eight backward.wn a hill at high speed. down a hill at an angle that would cause the ATV to leanne side. Go straight down the hill where possible.

! WARNINGIAL HAZARD

he ATV through deep or fast flowing water.AN HAPPEN

float, causing loss of traction and loss of control, whicho an accident. AVOID THE HAZARD

ate the ATV in fast flowing water or in water deeper thans. that wet brakes may have reduced stopping capability.akes after leaving water. If necessary, apply them several out the brakes.


NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 15°

! WARNINGPOTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENCould cause loss of control orcause the ATV to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in thisOperator’s Manual.Always check the terrain carefully before you start up any hill.Never climb hills with slippery or loose surfaces.Shift your weight forward.Never open the throttle suddenly. The ATV could flip over backwards.Never go over the top of any hill at high speed. An obstacle, a sharpdrop, or another vehicle or person could be on the other side of thehill.

POTENTGoing downWHAT CCould causATV to oveHOW TOHAZARDAlways folgoing downAlways cheShift your wNever go doAvoid goingsharply to o

POTENTOperating tWHAT CTires may could lead tHOW TONever operthe footrestRememberTest your brtimes to dry


! WARNINGL HAZARD

ATV with improper tires or with improper or uneven tire

N HAPPENper tires on the ATV, or operation of the ATV withneven tire pressure, may cause loss of control increas-f accident.AVOID THE HAZARDe size and type tires specified in this Operator’s Manual

in proper tire pressure as described in this Operator’s

! WARNINGL HAZARD

iding.N HAPPEN

control of the ATV.regain traction unexpectedly, which may cause the ATV

AVOID THE HAZARDly control skidding or sliding by practicing at slow

n level, smooth terrain. slippery surfaces, such as ice, go slowly and be veryder to reduce the chance of skidding or sliding out of


! WARNINGPOTENTIAL HAZARDStalling, rolling backwards, or improp-erly dismounting while climbing a hill.WHAT CAN HAPPENCould result in the ATV overturning.HOW TO AVOID THE HAZARDUse proper gear and maintain steadyspeed when climbing a hill.If you lose all forward speed:

Keep weight uphill.Apply the brakes.Engage the parking brake after you are stopped.

If you begin rolling backwards:Keep weight uphill.Gradually apply the brakes while rolling backwards.When fully stopped, engage the parking brake.

Dismount on uphill side or to a side if pointed straight uphill.Turn the ATV around and mount following the procedure described inthis Operator’s Manual.

POTENTIAOperating thepressure.WHAT CAUse of improimproper or uing your risk oHOW TO Always use thfor this ATV.Always maintaManual.

POTENTIASkidding or slWHAT CAYou may loseYou may also to overturn.HOW TO Learn to safespeeds and oOn extremelycautious in orcontrol.


! WARNINGIAL HAZARD

crossing hills or turning on hills.AN HAPPEN

e loss of control or cause therturn. AVOID THE

ing the side of a hill or turning onever possible. Never attempt to turn the ATV around onl you have mastered the turning technique as described inr’s Manual. Practice first on level ground. Be very carefulg on any hill. the side of a hill or turning on a hill is unavoidable:

proper procedures as described in this Operator’s Manual.ith slippery or loose surfaces.eight to the uphill side of the ATV.

! WARNINGIAL HAZARDlease the parking brake before driving the ATV.AN HAPPEN

ATV with the parking brake engaged could cause aandling or loss of brakes and cause an accident. AVOID THE HAZARD

ase the parking brake before driving the ATV.


! WARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENCould cause loss of control or a collision. Could cause the ATV tooverturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Never attempt to ride over large obstacles, such as large rocks orfallen trees.When you go over obstacles, always follow proper procedures asdescribed in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of the ATV maycause changes in handling which could lead to an accident.HOW TO AVOID THE HAZARDNever modify the ATV through improper installation or improper useof accessories. All parts and accessories added to this ATV shouldbe approved components designed for use on the vehicle and shouldbe installed and used according to instructions. Never install a twistgrip throttle. If you have questions, consult an authorized dealer.

POTENTImproperly WHAT CCould causATV to oveHOW TOHAZARDAvoid crossa hill whenany hill untithis Operatowhen turninIf crossingAlways followAvoid hills wShift your w

POTENTFailure to reWHAT CDriving thechange in hHOW TOAlways rele

California Proposition 65

! WARNING The Engine Exhaust from this product containschemicals known to the State of California tocause cancer, birth defects or other reproductiveharm.


veral types of helmets on themake sure you wear a helmets with the current standardsepartment of Transportation

Snell Memorial Foundation,can National Standards Insti-. Helmets that comply with of these agency’s standardser on the inside or outside of

ets should provide full-face

or damage your helmet, get amediately. Your helmet may not protect your head fromas cracks, fissures, or other damage to its outside or core

your helmet won’t do you any good if the chin strap isn’t

tectiontection, such as goggles, to completely surround your eyes to

ng dirt or other items in your eyes. Sunglasses are not recom- don’t prevent objects from flying in through the sides.ants and Long Sleeved Shirtto protect your body from branches, long grass, airborne

nything else that could scrape your skin. The more thick andaterial, the better protection it’ll provide.

Helmets should have one of these:

1. DOT label2. Snell label3. ANSI Z90.1 label


PreventionOverviewWhen using an ATV, prevention is the name of the game. “Had you onlyknown” something could go wrong, you would have prevented it. If youdon’t notice your conditions and surroundings before riding your ATV, yougive up control over the situation. Using ATV prevention techniques helpsyou forecast potential hazards before they injure you or damage your ATV.Following the safety instructions and warnings in this manual will helpyou “P.A.S.S.” the safety test. P.A.S.S. stands for “Prevention,” “ActiveRiding,” “Sound Judgment,” and “Supervision.” Remembering P.A.S.S.and what it stands for will help you have a safe, predictable ride everytime you go out on your ATV.

You’ll find it important to dress correctly for ATVriding in order to prevent scraped skin and serioushead injuries. It’s easy and could save you time inthe long run not having to contend with an injury.Of course, it also makes sense to remember theseasons. Wear a hat under your helmet and asnowmobile suit in the winter and lighter, protec-tive clothing in the summer.

HelmetThere are semarket, but that complieof the U.S. D(DOT), Theor the Ameritute (ANSI)one or morehave a stickthe helmet.These helmprotection.If you drop new one iminjury if it hpadding.Remember, fastened.Eye ProWear eye proprevent gettimended; theyLong PThe goal is objects, or adurable the m

Clothing and Gear

ATV-0004


g the tire pressure, inspect the tread and sidewalls of the, cuts, or other damage that could indicate they need to be

ols and Cable

hand brake levers. If they feelshy,” the brakes may needeck the maintenance section

or’s Manual for instructions.TV until the brakes are oper-

.g brake and see if it locks the rear wheels; then disengage brake. Ensure that the hand brakes are working properly;uld fail during a ride if they’re not maintained.le

the ATV, push the throttlemes. The throttle should haverange of motion. If it seems to point, refer to the Generalsection of this Operator’sstructions. Driving your ATV throttle can turn your leisurely ride into an unwelcomet drive your ATV if the throttle sticks. and Electrical

e brake light and headlightsrive the ATV unless all sys-

ing. Check the ignition switch stop switch.

Check:1. Hand brake levers2. Parking brake

Check:1. Free, smooth

range of motion

Check:1. Brake light2. Headlights3. Ignition switch4. Emergency stop

switch


GlovesYour hands are targets for flying objects and branches. Along with pro-viding skin protection, gloves will shield your hands from harshweather. Wear gloves that are weather resistant and have a gripping sur-face to keep them from sliding off the handlebar.Boots/Ankle ProtectionWear a boot that covers the largest possible area of your leg (preferablyup to your knee) and can handle significant impact. Choosing boots withlow heels and a good tread will help prevent your feet from slipping offthe footrests in wet or rugged conditions or getting hurt if they get hit byrocks, dirt, or branches.

The second step in Prevention is checking the condition of your ATV.Chances are good that you’ll be using your ATV in some rough terrain, andthere’s no way you want your brakes to go out when riding downhill. Youneed to check the following parts on your ATV before every ride.

1. Tires and Wheels2. Controls and Cable3. Lights and Electrical System4. Oil and Fuel5. Chassis6. Miscellaneous Items

1. Tires and WheelsCorrect tire pressure is crucial. Consult theGeneral Maintenance section of this Opera-tor’s Manual for tire pressure guidelines.Incorrect tire pressure can cause poor han-dling, instability, and a loss of ATV control.

While checkintires for cracksreplaced.2. ContrA. Brakes

Squeeze your soft or “squiadjustment. Chof this OperatDon’t use the Aating normallyTest the parkinit to release theyour brakes coB. Thrott

Before startinglever several tia free, smooth “stick” at anyMaintenance Manual for inwith a stickingaccident. Don’3. LightsSystemCheck that thwork. Don’t dtems are workand emergency

Condition of the ATV

Check:1. Tire pressure2. Tire surface (tread

and sidewalls)


at are longer in duration and distance, the following addi-are recommended: PhonePScy Kit with Flashlight and First Aid Kit

intenance will generally elimi- for emergency repairs. Riding

rrain could cause loosening ofand fasteners. Especially on

arrying the right tools can pre-onvenience from becoming a

mportant that you need to carry of the duration of your ride. Heat exhaustion and heateep up suddenly and can take you out of commission. If youydrated, you could find yourself physically unable to safely ATV.cation does happen to you, the emergency personnel will want toou are and whom to contact. It’s possible you may be in no give them that information. Put your I.D. in your pocketide. Without it, you’re anonymous. Phone

cessary to make an urgent phone call.PS (Global Positioning System)

e unnecessary when you’re familiar with the area. But wheng on unfamiliar trails, it’s good to know where you are,ng up, and how to get back.

Carry these items on your ATV:

1. Bulbs2. Duct tape3. Rope4. Spark plugs5. Spare parts6. Tool Kit


4. Oil and FuelStart with a full tank of gas and check engineoil before every ride. Don’t forget to checkfor fluid leaks around the ATV. 5. ChassisGrass and leaves can gum-up your suspen-sion and shocks. Clear and clean the suspen-sion arms, shock springs, and fenders. Checksmoothness by turning the handlebar full-leftand full-right. Check that there is no binding,restrictions, free-play, or looseness in steer-ing components. Check and clear the drivechain and sprockets of foreign materials anddebris. Check drive chain adjustment.6. Miscellaneous ItemsInspect your air filter. Look for debris ordamage that may indicate you need toreplace it. A clogged filter can stop anengine. Check your battery terminals forcorrosion. Also, be sure to tighten any looseparts, nuts, or bolts.

You need to prepare for the unexpected. Emergencies and accidents aretraumatic enough, but they’re even worse when you’re not prepared forthem. At the minimum during every ATV ride, you should have the fol-lowing items on board:

• Tools• Water• Identification• First Aid Kit

For rides thtional items

• Cellular• Maps/G• Emergen

ToolsRoutine manate the needon rough tenuts, bolts, long rides, cvent an inccrisis.WaterWater is so iit regardlessstroke can crbecome dehoperate yourIdentifiIf somethingknow who ycondition tobefore you rCellularIt may be neMaps/GMaps may byou’re ridinwhat’s comi

First Aid and Survival

Check:1. Suspension arms2. Shock springs3. Fenders4. Steering5. Drive Chain

Check:1. Gas2. Oil3. Fluid leaks

Check:1. Air filter2. Battery3. Tighten parts,

nuts, and bolts

Emergency Kit with Flashlight and First Aid KitYou’ll need several items in your emergencykit including a flashlight. The matches willcome in handy if you need to start a fire to staywarm. Flares are appropriate for signaling help.A first aid kit is very important if an injury ofsome type should happen. A good first aid kitshould include bandages, antiseptic spray,gauze, tape, etc.

Carry these items:1. Flashlight2. Matches3. Flares4. First Aid Kit5. Money

Active RidingOverview“Active Riding” is the second part of “P.A.S.S.” It involves an under-standing of how your body weight, balance, gravity, and physical forcesaffect the handling of the ATV. Knowing how to shift your weight isnecessary to avoid rolling or flipping the ATV.For complete operating instructions, see ATV OPERATION section inthis manual.


onsider the weather. It is dangerous to ride your ATVher is bad or potentially bad. Keep abreast with weather

ose attention to the terrain you’re on even if it is familiaran’t assume that the landscape you’re used to doesn’tes to landscape can happen at nearly any time. Fences can and excavations dug in a short period of time. Weather,velopment take their toll. aware of your surroundings before and during your ride.ing

can be very hazardous. Obstacles and other hazards (thattified during daytime) are much more difficult to see andight riding, make sure the lights are properly adjusted andg order. Reduce speed; do not over-drive the headlights. an unfamiliar area or blaze a new trail at night. Alwaysht or flare for signaling an emergency.rfaces

er possible. The ATV isn’t designed for pavement. Itsmes more difficult on paved surfaces. If operating on is unavoidable, travel slowly (less than 10 mph) and

urns and stops.inggment when trail riding; that means riding on a trail thaty level. If the trail is pretty rugged, standing up on yourake it easier for you to endure the rough terrain.

visible by using headlights and taillight and pull com-trail if you need to stop.ght shifted into the slope.


Sound Judgment

People do all kinds of things that you can’t predict or control.Riding CompanionsLeave a lot of space between you and other riders, especially in dustyand dirty conditions, because it’ll be difficult to see the riders in front ofyou stopping.Do not carry a passenger on any ATV designed for single-rider use.These ATVs do not have appropriate equipment (hand-holds, footrests,etc) to accommodate riders. Additionally, the added weight and weightshift can make the vehicle difficult to control.Other VehiclesDepending on where you’re riding, you might encounter other ATVs,bikes, or motor vehicles on public lands. Respect the presence of cars ifyou’re crossing roads or riding in public areas and make yourself be seen.If you can’t see other vehicles coming, that means you’re invisible, too.HikersWith the renewed interest in hiking, camping, and other outdoor activi-ties, people can show up in remote areas where you would never expectthem. For their sake, keep your eyes open.Animals and NatureRespect the outdoors that you love. Don’t use your ATV to chase ani-mals or birds. Drive around young trees rather than over them. Keepclear of streams and ditches with standing water.Tread Lightly and leave it as you found it.

The environment you operate an ATV in is often harsh and sometimesdangerous if you don’t take proper precautions.

WeatherYou need to cwhen the weatforecasts.TerrainAlways pay clto you. You cchange. Changbe constructedclimate, and deConstantly be Night RidRiding at nightare easily idenavoid. When nin good workinNever travel incarry a flashligPaved SuAvoid whenevhandling becopaved surfacesavoid sudden tTrail RidUse sound judfits your abilitfootrests will mMake yourselfpletely off the Keep your wei

Those Around You

Environment


apacity Ratings Chart

Capacity — Total weight of operator, accessories, andnt and rear racks.

yable ride is dependent on many personal choices. An ATV,rized vehicles, can be dangerous to operate if you choose toy precautions, take unnecessary chances, or ride beyondor your vehicle’s capability. Don’t allow the thrill of free-nture to affect your ability to make good, safe choices.ysical Condition

al condition is critical to safeion. Don’t ride when tired andr health when planning longer

s Ridingssive or high speed is a factor, the potential for personaleatly increased. Ride within reason and your skill level.uvers that are reckless. Don’t show off.

Item Specifications

(lb) (kg)

apacity 175 79

max) 10 4.5

ax) 15 6.8

al Choices

Don’t ride:1. When you’re tired


It also helps to know which trails you can legally ride and who elsemight be on those same trails. These are signs currently used in someareas to designate trail types and restrictions.

ATV-0068

The last thing you expected was that your ATV would break down in themiddle of the field ... it’s usually so reliable that sometimes you forgetthe ATV has its limits.ATV MaintenanceYou have to maintain your ATV. The General Maintenance section ofthis Operator’s Manual tells you about taking care of your ATV. If, atany time, abnormal noises, vibrations, or improper functioning of anycomponent of this ATV is detected, DO NOT OPERATE THE ATV.Take the ATV to an authorized dealer for inspection and adjustment orrepair.

Load C

Max Load cargo on fro

A safe, enjolike all motoignore safetyour ability dom or adveYour PhYour physicATV operatconsider yourides. RecklesWhere exceinjury is grAvoid mane

Equipment

Trail Signs Max Load C

Front Rack (

Rear Rack (m

Person


ehavior a group, it is human nature to try to keep up with or out-d you. We can all be competitive and that can lead to riskg in serious injury or equipment damage. Know your lim-n't be afraid to slow the pace down.


Laws and RegulationsAny police officer will tell you that ignorance of the law is no defense.Your best defense is to check out your local, state, or provincial ATVlaws before riding. It’ll also make sure that you can continue to ride inyour favorite areas. The quickest way to have a land area closed is byriding over the regulations.

Group BWhen riding indo those arountaking resultinitations and do


that regardless of experience, you should never leter the age of 12 operate your ATV.cturer and the ATV Safety Institute (U.S.) recommend thatrators ride the appropriate-sized ATV according to age.

Age (Years) Speed Limitations (mph) NOTES

12 or Older 15 - Limited30 - Maximum


14 or Older 20 - Limited30 - Limited

38 - Maximum


16 or Older According toLocal Regulations

—


SupervisionOverviewYou’re responsible for supervising those who ride your ATV. Your wis-dom is valuable ... it’ll bring them all back safely — your friends, yourfamily, your relatives, and your ATV. It’s crucial that you consider your-self a supervisor for all riders of your ATV. Whether you accept respon-sibility or not, the truth is that you are responsible for others riding yourATV.

You’re to the last letter in “PASS” ... “Supervision.” You’ve just gonethrough the manual, and you’ve seen what’s involved. That puts you in agood position to be confident about what you know. So now it’s time touse your knowledge and supervise others who ride your ATV.Inexperienced/Untrained RidersYou can’t let people ride your ATV who don’t know what they’re doing.Unless they’ve had over a year of experience with ATV riding or takenan ATV training course, it’s your responsibility to keep them off yourATV. It can be dangerous (especially for underaged children) — all themore reason for you to be firm.Experienced/Trained RidersIf anyone is going to borrow your ATV, you are responsible for theirsupervision. Before they ride, have them take the training course, havethem watch the safety video, have them read the Operator’s Manual, andtrain them. ATVs are all a little different from the handling to the stability to thecontrols. So regardless of how much experience your family membershave with ATVs, they don’t have experience with your ATV. Let experi-enced riders get familiar with your ATV — show them the basics beforethey take off. You don’t want it on your conscience that someone gothurt because you didn’t tell them how to use your ATV.

Rememberanyone undThe manufaall ATV ope

Taking Responsibility

Category

Y-12+

T-14

G & S

of Controls

ke Levere Levergerakehimitereverrake Light

t Levery Stop Switchttone Lever

Stickre ATV you havemay differ slightly shown in the fig- manual.

KM961A

KM962A

KM963A

26

Division II — Operation/MaintenanceATV Specifications

Specifications subject to change without notice.

Location1. Battery2. Front Bra3. Fuel Valv4. Seat Lock5. Tool Stora6. Parking B7. Key Switc8. Throttle L9. Throttle L

10. Taillight/B11. Kick Star12. Emergenc13. Starter Bu14. Rear Brak15. Oil Level16. Shift LeveNOTE: Thpurchased from thoseures of this

ENGINE AND DRIVEType Four-Cycle/OHC/Air CooledBore x Stroke 47 x 51.8 mm (1.85 x 1.62 in.)Displacement 89.9 cc (5.5 cu in.)Spark Plug Type CR7HSASpark Plug Gap 0.6 - 0.7 mm (0.024 - 0.028 in.)Brake Type Front Double Drum/Rear Hydraulic Disc w/

Parking BrakeCHASSIS

Length (Overall) 146.8 mm (57.8 in.) Height (Overall) 96.3 mm (37.9 in.)Width (Overall) 87.6 mm (34.5 in.)Tire Size (Front) AT20 x 7-8Tire Size (Rear) AT19 x 8-8Tire Inflation Pressure 27.6 kPa (4.0 psi)

MISCELLANEOUSDry Weight (Approx) 120 kg (265 lb)Gas Tank Capacity (Rated) 5.7 L (1.5 U.S. gal.)Reserve Capacity 1.3 L (0.34 U.S. gal.)Transmission Lubricant (Recommended) SAE 80W-90 HypoidTransmission Lubricant Capacity 250 ml (8.4 fl oz)Engine Oil Capacity (Approx) 0.8 L (0.84 U.S. qt)Gasoline (Recommended) 87 Octane Regular UnleadedEngine Oil (Recommended) 0W-40 ACX All Weather (Synthetic)Headlights 12V/15WBrake Light 12V/P21/5WStarting System Electric w/Kick Start (Emergency)

27

e and hold either hand brake lever.e starter button.engine warm up.cy Starting

as an emergency kick starter to use if the electric starterperative. To use the starter, follow this procedure:

wn on the kick starter untilce is felt; then with a short,ownward stroke, start engine.until the engine starts.aking sure that the engine, apply the front brakes andthe parking brake. a Cold Engine

t is very important not to touch or compress theer during the starting procedures.

the ignition switch key to the first position (ON).

CAUTION the starter motor for more than eight seconds perempt. The starter motor may overheat causing severetor damage. Allow 15 seconds between starting allow the starter motor to cool.

! WARNING paring brake is engaged when using the emer- starter.

KM002

ATV Operation

Active riding and basic maneuvers are the foundation of your ATV ride.Without basic skills, it’s impossible to execute active riding. These areyour basic maneuvers:

Mounting the ATV

1. From the left side, grab the left-side handlebar, apply the brake, andput your left foot on the footrest.

2. Grab the right-side handlebar.3. Swing your leg over the seat and set your right foot down on the

right-side footrest.4. Get seated in a comfortable position.5. Always keep your feet planted on the footrests.

Starting the Engine

Always start with the ATV on a flat, level surface. Carbon monoxidepoisoning can kill you, so keep your ATV outside while it’s running.Follow these steps to start it up:

1. Engage the parking brake.2. Mount the ATV and sit down.3. Turn on the fuel valve.4. Turn on the ignition.5. Shift into neutral.6. Move the emergency stop switch to RUN.

7. Squeez8. Press th9. Let the

Emergen

This ATV hbecomes ino

1. Push doresistanquick, d

2. Repeat 3. After m

is warmrelease

Starting

NOTE: Ithrottle lev

1. Rotate

Basic Operating Maneuvers

• Mounting the ATV• Starting the Engine• Emergency Starting• Starting a Cold Engine

• Braking/Stopping• Parking• Dismounting the ATV

Do not runstarting attstarter moattempts to

Ensure thegency kick

de” the brakes. Even maintaining minimal pressure on aer will cause the brake shoes to drag on the drums andhe brake system.

es following the previous rules for braking; then:TV stops, shift into neutral.

ngine using the emergency stop switch.he ignition.e to park on a hill, shift the ATV into gear; otherwise, tryly on level surfaces.e parking brake.ing the ATV

llowed the procedure for parking, it’s time to dismount. parking brake is engaged.ur right leg over to the left side of the seat.e ground on the left side of the ATV.

involves moving your body. You must learn to lean andht into your turns to maintain control.pends on using safe riding techniques. Statistics from ther Product Safety Commission (CPSC) say that inexperi-ho don’t use safe riding techniques are 13 times more an ATV accident than riders who have over 1 month of

the ATV (Active Riding ues)

28

2. Compress the left-hand brake lever; then press on the starter button.

3. Allow the engine to warm up for approximately 2-2 1/2 minutes.Do not touch the throttle lever until the engine has run for at least 3minutes.

4. Run the engine for at least 10 minutes so it is thoroughly warmedup. If the engine is run for a shorter period of time, the spark plugmay not have reached a high enough temperature to burn off theexcess fuel in the combustion chamber.

Braking/Stopping

Coming to a stop should be a slow, easy process. Always allow plenty ofroom and time to stop smoothly. Sometimes quick stops are inevitable,so always be prepared. Whether you’re stopping slowly or stoppingquickly, do this:

1. Compress both right and left brake levers on the handlebars toapply both the front and rear brakes.

2. If your wheels lock, release them for a second; then apply themagain.

3. Never “ribrake levoverheat t

Parking

Parking involv1. After the A2. Stop the e3. Turn off t4. If you hav

to park on5. Engage th

Dismount

After you’ve fo1. Verify the2. Swing yo3. Step to th

Active riding shift your weigYour safety deU.S. Consumeenced riders wlikely to haveexperience.

CAUTIONDo not run the starter motor for more than eight seconds perstarting attempt. The starter motor may overheat causing severestarter motor damage. Allow 15 seconds between startingattempts to allow the starter motor to cool.

CAUTIONIf unburned fuel is collected in the combustion chamber due tolack of running time, spark plug fouling will occur more easilyduring the next starting attempt.

HandlingTechniq

29

if you accidentally stall while riding uphill; you need tobefore the ATV rolls backward down the hill.

ere you are, apply the brakes. the engine.ur body weight shifted forward.

the ATV on the uphill side.e to the left of the ATV, turn the handlebar all the way left. release the brake, but lightly hold the brake lever.

ATV roll to your right side until it faces slightly downhill. the brakes.k on the ATV from the uphill side, and keep your weight

uphill when you sit down. engine and follow the method for riding downhill.

ATV-0020 ATV-0034

ATV-0035 ATV-0036 ATV-0037

Safe riding techniques include:

Riding

Once the engine’s warm, the ATV is ready to go.1. Keep your feet on the footrests and both hands

on the handlebar.2. Hold the brake levers, and release the parking

brake.3. Release the brakes slowly and apply the throttle.

Leaning, Weight Shift, and Balance

When you turn, the trick is to move forward and slide over to the side ofthe seat that’s on the inside of the turn. Support your body weight on theoutside footrest. At the same time, lean your body to the inside of the turn.Pay attention to the handling — if you feel the tires coming off theground, reduce speed, shift more of your body weight to the side that’slifting, and make the turn wider if possible.

K-Turns

Use K-turns take action

1. Stop wh2. Shut off3. Keep yo4. Get off 5. If you’r6. Partially7. Let the 8. Reapply9. Get bac

shifted 10. Start the

Tips

• Riding• Leaning, Weight Shift, and Balance• K-Turns• Riding Uphill• Sidehilling/Traversing

• Riding Downhill• Wide Turns• Sharp Turns• Crossing Obstacles

ATV-0012

ATV-0013 ATV-0024 ATV-0025

g/Traversing

onsidered an advanced skill; it’s really tricky and unpre-hether your skills are advanced or not, try to avoid thisIf you’re in a situation where you absolutely have to side- method:

r speed low and consistent.our body weight to the uphill side of the seat; also, sup-weight on the uphill footrest. you’re driving into the hill. feels like it’s tipping, turn the handlebar downhill. If that’sle because of the terrain or other conditions or if it justrk, stop and get off. Dismount the ATV on the uphill side.wnhill

ng downhill depends on how well you know your brakes - them, or you could flip over.

ATV-0017 ATV-0028 ATV-0029

TV-0018 ATV-0030 ATV-0031

30

Riding Uphill

Many accidents happen while riding on hills and as a result of the ATVrolling or flipping. So, obviously, use extreme caution and follow thismethod for riding uphill.

1. Accelerate before you start climbing; then maintain a steady pace.2. Lean as far forward as possible. For steeper hills, come off your

seat to stand and lean forward.3. If you lose speed, quickly release the throttle (so your front tires

don’t lift), OR4. If that doesn’t work and you still have forward motion and the ter-

rain permits, do a U-turn, go back down, and try climbing again,OR

5. If you have lost all forward motion, follow the K-turn procedure.NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 15°

Sidehillin

Sidehilling is cdictable. So, wkind of riding. hill, follow this

1. Keep you2. Shift all y

port your 3. Steer like4. If the ATV

not possibdoesn’t wo

Riding Do

Success in riditake it easy on

ATV-0019 ATV-0032 ATV-0033

A

31

principles of leaning, weight shifting, and balancing - shiftdy weight to the inside of the turn.ght have to lean into the turn more than you do in a wide

ng your weight and balance aren’t enough to keep the ATV the ground, straighten out the handlebars as much as you

lly increase your speed as you come out of the turn.g Obstacles

stacles is risky; avoid it if possible. Riding over logs, rocks,ans combining all the active riding skills into one big

r ATV will respond differently for different obstacles (logs,ut these are general guidelines for overcoming two-track

ontacting the obstacle at the same time) obstacles:

our speed way down; less than 5 mph.ch the obstacle head-on.p off the seat.

our weight on the footrests. little throttle when the front tires make contact with the obstacle.rward and release the throttle when front tires clear the

e.

ATV-0027ATV-0016 ATV-0026

1. Shift your body weight as far back on the seat as possible.2. Lightly apply the brakes and ease up on the throttle.

Wide Turns

Many ATV accidents happen during turns. If you don’t understand turn-ing techniques, it’s easy for the ATV to get away from you by losingtraction, plowing, or tipping. Use this method for wide turns:

1. Ease off the throttle as you approach the turn to slow down.2. Use the principles of leaning, weight shifting, and balancing - shift

your body weight to the inside of the turn.3. Gradually increase your speed as you come out of the turn.

Sharp Turns

After mastering wide turns, practice the advanced skill of sharp turns.

1. Ease off the throttle as you approach the turn to slow down.

2. Use theyour bo

3. You miturn.

4. If shiftitires oncan.

5. GraduaCrossin

Crossing oband ruts memotion. Youruts, etc.), b(both tires c

1. Keep y2. Approa3. Come u4. Keep y5. Apply a6. Lean fo

obstacl

ATV-0046 ATV-0045 ATV-0044

ATV-0038 ATV-0039 ATV-0040

Roads

on your ATV is also a bad idea, so avoid it. If you can’t:pletely on the shoulder of the road.th directions for traffic.ear a blind corner or intersection is dangerous; don’t do it.ight across to the opposite shoulder. account that your ATV could stall while crossing; givenough time to get off the road. to assume that oncoming cars don’t see you, and if theyon’t be able to predict your actions.

l to cross public roads in some places. Know your local

the ATV

V, first release the throttle lever. Next, apply the brake. the Engine

gine, turn the ignition switch key to the OFF position orncy stop switch to the OFF position.ving the ignition switch key in the ON positionin a discharged battery.

32

7. Keep your body loose to absorb any shock.8. If the ATV starts tipping, shift your weight to keep it in balance.

To clear a single-track (only one tire contacts) obstacle, follow the samerules except:

1. Use the ATV’s momentum to clear the obstacle.2. Don’t pull up on the handlebar.3. Don’t apply the throttle.

Crossing Water

Your ATV can only handle water up to its footrests. Any more than thatand you risk engine damage and/or personal injury. Stay away from fastmoving rivers. ATV tires can be buoyant, so if the water is too deep, youmight find the ATV suddenly afloat.

1. Physically check the depth and current of the water, especially ifyou can’t see the bottom. You’re also checking for boulders, logs,or any other hidden obstacles.

2. Keep your speed slow.3. Make sure you have a way out on the other side of the water.4. If you get stuck in the sludge or mud, try rocking the ATV from

side to side.5. Once you’ve cleared the water, briefly apply the brakes to make

sure they work.

Crossing

Crossing roads1. Stop com2. Check bo3. Crossing n4. Drive stra5. Take into

yourself e6. You have

do, they w7. It’s illega

laws.Stopping

To stop the ATStopping

To stop the enset the emergeNOTE: Leacould result

! WARNING Do not operate this vehicle on a frozen body of water unlessyou have first verified the ice is sufficiently thick to supportthe vehicle, cargo, and participants. The vehicle could breakthrough the ice causing serious injury or death.

33

Brake

and release the parkinge following procedure:the parking brake leverft to engage the brake. the parking brake by the lever to the right.

ake sure the parkingges properly and thated it locks the rear wheels. the parking brake.t to push the ATV.he parking brake must lock the rear wheels. If ite rear brake system must be serviced.

hts

ts will automatically illuminate when the engine is running.

! WARNING rify the parking brake has been disengaged beforethe ATV. An accident could result if the parkingft engaged while the ATV is operated. The brakeif left engaged for a long period of time. This couldccident; therefore, do not leave the ATV on a hill on the parking brake. Always block the downhill wheels if leaving the ATV on a hill or park the ATVll position.

KM965

General InformationControl Locations and FunctionsIgnition Switch Key

Two keys come with the ATV. Keep the spare key in a safe place.Ignition Switch

The ignition switch has two positions.OFF position — All electrical circuits areoff. The engine will not start. The key canbe removed in this position.ON position — The ignition circuit iscomplete, the engine can be started witheither hand brake compressed.

Hand Brakes

The hand brakes should be applied whenever a braking situation isneeded.Apply the brakes by compressing the brake levers toward the handlebar.

Parking

To engage brake, use th

1. Rotate to the le

2. Releaseturning

Check to mbrake engawhen engag

1. Engage2. AttempNOTE: Tdoesn’t, th

Headlig

The headligh

CAUTIONLeaving the ignition switch in the ON position for a long period oftime when the engine is not running may cause the battery to dis-charge. Always leave the ignition switch in the OFF position whenengine is not running.

KM964

Always veoperating brake is lemay relax cause an adependingside of thein a sidehi

imiter Screw

ravel may be limited by adjusting the throttle limiter screw.iter should be adjusted according to the operator’s skill andadjust the throttle limiter, use the following procedure:e jam nut (A).throttle limiter screwkwise to decreasePM maximum orckwise to increaseM maximum.the jam nut (A)

e

is incorporated in-linetank. There are three RES, and OFF.ition, the valve will notto flow to the carbure- position (the normal

ion), gasoline will flowo the carburetor. In this(0.34 U.S. gal.) will remain in the tank as a reserve quantity.lve to the reserve (RES) position will allow the operatorining gasoline in the tank. When turning the valve to anyitions, be sure the indicator is pointed directly at the posi-

! WARNING the valve in the ON or RES position when the

t running.

KM028A

KM043A

34

Emergency Stop Switch

This switch will stop the engine. The engine can be started again bypressing the starter button.OFF position — The ignition circuitis off. The engine cannot be started orwill not run. If the switch is used tostop the engine without turning offignition switch, the battery may dis-charge.RUN position — The ignition circuitis on. The engine can start and run.In an emergency, slide the switch tothe OFF position to stop the engine.Apply the brakes to stop the wheels.Electric Starter Button

Pushing in on this button activates thestarter motor. Before starting theengine, make sure the ignition switchis in the ON position and the parkingbrake is engaged.Throttle Lever

Control engine RPM with the posi-tion of the throttle lever. Operatethis lever with the thumb. Pushing itforward increases engine RPM andallowing it to retract decreasesengine RPM.

Throttle L

Throttle lever tThe throttle limexperience. To

1. Loosen th2. Turn the

(B) clocengine Rcountercloengine RP

3. Tighten securely.

Fuel Valv

The fuel valvewith the gas positions: ON,In the OFF posallow gasoline tor. In the ONoperating positfrom the tank tposition, 1.3 L Moving the vato use the remaof the three postion desired.

KM063B

KM064A

KM027ANever leave engine is no

35

tor Float Bowl

the float bowl should beemove condensation. Toat bowl, use the following

suitable container beneatht bowl drain hose. the drain screw and allow the gasoline and condensation tot. the drain screw securely.l Stick

il level stick for checkingil level. To check the oil

e following procedure:he ATV should be ond when checking the

level.

w the oil level stick andwith a clean cloth.

! WARNINGme to a complete stop with the engine at idle beforee shift lever. Changing gears while moving or shift-eutral with the engine above idle could cause sud-e of direction resulting in loss of control or beingm the ATV causing severe injury or death.

KM065

KM021A

Shift Lever

1. To shift into forward gear, pullout and upward on the shiftlever until the transmissionengages in the forward gear.

2. To shift into reverse gear, pullout and push downward on theshift lever until the transmis-sion engages the reverse gear.When in reverse with the igni-tion switch in the ON position,the reverse indicator light willilluminate.

3. To shift into neutral from eitherforward or reverse gear, push orpull the lever to the center posi-tion. When in neutral with theignition switch in the ON posi-tion, the neutral indicator lightwill illuminate.

CarbureDrain

Periodically,drained to rdrain the floprocedure:

1. Place a the floa

2. Loosenflow ou

3. TightenOil Leve

There is an othe engine olevel, use thNOTE: Tlevel grounengine oil

1. Unscrewipe it

KM966A

KM966B

KM914A

Always comoving thing from nden changthrown fro

g/Bracket

rovided for mounting a flag at the rear of the ATV. Thedisplayed to make the ATV more visible.ting ATV

ting the ATV, the ATV must be in its normal operatingl four wheels) and the following procedure must be used:e parking brake and place the transmission in gear.

uel valve OFF. ATV with load rated hold-down straps.

itable hold-down straps are available from yourdealer. Ordinary rope is not recommendedn stretch under load.

CAUTIONgage the parking brake and place the transmis- could result in the ATV rolling off the trailer intie-down strap failure.

CAUTION hold-down straps, care must be taken not toATV.

36

2. Install the oil level stick completely into the engine crankcase.NOTE: The oil level stickshould be threaded into theengine crankcase for checkingpurposes.

3. Remove the oil level stick; theengine oil level should bebetween the lower level andupper level on the stick.

Seat Lock

1. To remove the seat, pull theseat lock lever rearward(located at the rear of the ATVunder the seat). Raise the rearend of the seat and slide it rear-ward.

2. To lock the seat into position,slide the front of the seat intothe seat retainers and push down firmly on back of seat. The seatshould automatically lock into position.

Safety Fla

A bracket is pflag should be Transpor

When transporposition (on al

1. Engage th

2. Turn the f3. Secure theNOTE: Suauthorized because it ca

CAUTIONDo not overfill the engine with oil. Always make sure the oil levelis between the lower and upper levels on the stick.

! WARNING Make sure the seat is secure before mounting the ATV. Severepersonal injury may result if the seat is not properly secured.

KM022A

KM013B

Failure to ension in gearthe event of

When usingdamage the

37

ended Engine Oil

ended oil to use is ACXr Synthetic engine oil,een specifically formu- in this engine. Althougheather Synthetic enginely oil recommended for

engine, use of any API- 0W-40 oil is acceptable.

CAUTION white gas. Only approved gasoline additives should

CAUTIONed in place of the recommended oil could causegine damage. Do not use oils which contain graph-bdenum additives. These oils can adversely affectration. Also, not recommended are racing, vegeta-tergent, and castor-based oils.

OILCHARTJ

Gasoline — Oil — Lubricant

Filling Gas Tank

Since gasoline expands as its temperature increases, the gas tank mustbe filled to its rated capacity only. Expansion room must be maintainedin the tank particularly if the tank is filled with cold gasoline and thenmoved to a warm area. Allow the engine to cool before filling the gas tank. Care must be takennot to overfill the tank. If overfilled, gas may leak onto the engine creat-ing a fire hazard.

Tighten the gas tank cap securely after filling the tank.Recommended Gasoline

The recommended gasoline to use in this ATV is 87 minimum octaneregular unleaded. In many areas, oxygenates are added to the gasoline.Oxygenated gasolines containing up to 10% ethanol or 5% methanol areacceptable gasolines.When using ethanol-blended gasoline, it is not necessary to add a gaso-line antifreeze since ethanol will prevent the accumulation of moisturein the fuel system.

Recomm

The recommAll Weathewhich has blated for useACX All Woil is the onuse in this certified SM

! WARNING Always fill the gas tank in a well-ventilated area. Never addgasoline to the ATV gas tank near any open flames or with theengine running or hot. DO NOT SMOKE while filling the gastank.

! WARNING Do not overfill or over-flow gasoline when filling the gas tank.A fire hazard could materialize. Always allow the engine tocool before filling the gas tank.

Do not usebe used.

Any oil usserious enite or molyclutch opeble, non-de

t 3 hours of operation, always use less than ½ throttle.gine RPM during the break-in period allows the compo- (aiding the engine component mating process) and thenwing components to cool). Although it is essential toress on the engine components during break-in, caren not to overload the engine too often. ine starts, allow it to warm up properly. Idle the engines until the engine has reached normal operating tempera-le the engine for excessively long periods of time.fter break-in should include checking of all prescribednd tightening of all fasteners. At the discretion and owner/operator, the ATV may be taken to an authorizedinitial service.

38

Recommended Transmission Lubricant

NOTE: The manufacturer recommends the use of genuinelubricants.

The recommended transmission lubricant to use is SAE 80W-90 hypoid.

Engine Break-In

New ATVs and renewed ATV engines require a “break-in” period. Thefirst month is most critical to the life of this ATV. Proper operationduring this break-in period will help ensure maximum life and perfor-mance from the ATV.

During the firsVarying the ennents to “load”“unload” (alloplace some stshould be takeWhen the engseveral minuteture. Do not idMaintenance aadjustments aexpense of thedealer for this

CAUTIONAny lubricant used in place of the recommended one couldcause serious transmission damage.

39

t and clean, adjust, lubricate, replace as necessary C = Cleancate R = Replace T = Tighten A = Adjustr maintenance ** = When using ACX All Weather Synthetic oil, oil change an be increased to every 1,000 miles or every year.

Maintenance Schedule

m Page

Initial Service

(100 Miles)

Monthly Quarterly Annually

47 I I43 I I I

onents 41 I Inspect every time before ridingeadlights 48 I Inspect every time before ridingoat bowl 35 I C and bolts — I T T T

— I Inections — I I lubricant 41 R I

40 R R** Ie — I I

46 I I— C, L I

bers 40 I46 C— I Inspect every time before riding

(Front tie e boots)

42 I Inspect every time before riding

sure 48/26 I Inspect every time before riding48 I I47 I Inspect every time before riding

e 42 I I, A

General Maintenance NOTE: Proper maintenance of the ATV is important for opti-mum performance. Follow the Maintenance Schedule and allensuing maintenance and care instructions/information.

NOTE: Proper maintenance procedures for each item canbe found on the corresponding page indicated.

If, at any time, abnormal noises, vibrations, or improper functioning ofany component of this ATV is detected, DO NOT OPERATE THE ATV.Take the ATV to an authorized dealer for inspection and adjustment orrepair.A repair shop or person of the owner's choosing may maintain, replace,or repair emission-control devices and systems.If the owner/operator does not feel qualified to perform any of thesemaintenance procedures or checks, take the ATV to an authorized dealerfor professional service.

I = InspecL = Lubri* = Deale

interval c

Ite

Air filter

Battery

*Brake comp

Brake light/h

Carburetor fl

Chassis nuts

*Drive chain

Electrical con

Transmission

Engine oil

Fuel filter/tub

Idle RPM

Chassis

Shock absor

Spark plug

*Steering

*Suspensionrods/protectivTires/air pres

Tire wear

Throttle cable

Parking brak

l

ine oil at the scheduledngine should always beil will drain easily and

TV on level ground.the oil level stick. Bet to allow contaminatese opening.he oil drain plug fromide of the engine; thenhe oil screen/filter caper the right-front of thed clean the screen.he screen/filter cap,d screen. Tighten to 11

drain plug and tightent-lb. Pour ACX Allynthetic oil in the fillll oil level stick.ngine (while the ATV isn level ground) and idle for a few minutes.

KM021A

KM041A

KM040A

40

Shock Absorbers

Each shock absorber should be visiblychecked weekly for excessive fluid leak-age (some seal leakage may be observedbut it does not indicate the shock is inneed of replacement), cracks or breaks inthe lower case, or a bent shock rod. If anyone of these conditions is detected,replacement is necessary.NOTE: When the ATV is operatedin extremely cold weather (-23°C/-10°F or colder), a smallamount of leakage may be present.Unless the leakage is excessive,replacement is not necessary.

Ramp-style adjusters are used toadjust shock preload. Rotate theadjuster toward the right to decreasepreload or the left to increase preload.General LubricationCables

None of the cables require lubrication; however, it is advisable to lubri-cate the ends of the cables periodically with a good cable lubricant.

Engine Oi

Change the engintervals. The ewarm so the ocompletely.

1. Park the A2. Remove

careful noto enter th

3. Remove tthe left sremove tfrom undengine an

4. Install tspring, anft-lb.

5. Install theto 22 fWeather Shole. Insta

6. Start the eoutside oallow it to

KM967

KM968

Rear

Front

41

e the level plug and verify oil is at the plug threads. Installl plug and tighten to 16 ft-lb.

the area around the drain plug for leaks.ake System

ng Brakesg/Adjusting heel Brake

TV enough to allow theto spin freely.brake lever/cable assem-sen both jam nuts. Turnable adjusters counter-ise until both front wheels do not spin freely.th cable adjusters in 1/4 turn increments (clockwise) until

spin with a very slight amount of drag. Tighten the jam nuts.TV, push ATV forward, and compress brake lever.

wheels lock, adjustment is correct. wheels do not lock, additional adjustment is necessary.

! WARNING nspect the hand brake system before each use. Alwaysakes according to the Maintenance Schedule.

KC555B

7. Shut the engine off; then allowoil to drain into the crankcasefor approximately three min-utes. Remove the oil levelstick and check for proper oillevel.

Transmission Lubricant

Change the transmission lubricant atthe scheduled intervals. The trans-mission should always be warmwhen the lubricant is changed so thelubricant will drain easily and com-pletely.

1. Park the ATV on level ground.2. Remove the fill plug. Be care-

ful not to allow contaminates toenter the opening.

3. Remove the drain plug from thebottom of the transmission anddrain the lubricant into a drainpan.

4. Install the drain plug and tightento 18 ft-lb. Pour the recom-mended lubricant in the fillhole. Install the fill plug.

5. Removthe leve

6. InspectHand Br

AdjustiCheckinFront WSystem

1. Raise Awheels

2. On the bly, looboth cclockw

3. Turn bowheels

4. Lower A5. If front6. If front

KM022A

KM969A

KM970A

Be sure to imaintain br

Parking Brake

e parking brake in the off positionting the parking

jam nut (A); then fin- the adjuster bolt (B)

ance is felt. he adjuster bolt (B)rn.lding the adjuster bolt (B), tighten the jam nut (A)

re should be no resistance on the brake disce pads after adjusting.

Hoses

obstruct the routing of the carburetor vent hose. Make vent hose is securely connected to the carburetor and the opposite end is always open. Rubber Boots

boots should be inspected periodically.n/Steering Arm Assembly (Right

ATV on a support stand to elevate the front wheels.oth front wheels.e suspension/steering arm assembly boots for cracks,rforations.

KC553A

42

Checking/Adjusting Rear Wheel Hydraulic Brake System

The rear wheel hydraulic brake system should be checked for properoperation before every time the ATV is ridden.

NOTE: The rear wheels should spin freely when the lefthandlebar lever is not compressed.

1. Push the ATV forward and compress the left handlebar brake lever.2. If the rear wheels lock, the hydraulic brake system is operating

properly. If they do not lock, service is necessary.Checking Parking Brake

1. With engine turned off and withthe parking brake locked,attempt to move the ATV.

2. If rear wheels are locked, brakeis operating properly.

3. If rear wheels are not locked,adjust the parking brake.

NOTE: The rear wheelsshould spin freely with the park-ing brake released.

Adjusting

NOTE: Thlever must bewhen adjusbrake cable.

1. Loosen theger tightenuntil resist

2. Loosen t1/8-1/4 tu

3. While hosecurely.

NOTE: Thefrom the brak

Gas/Vent

Do not bend orcertain that thehose holder andProtective

The protective Suspensioand Left)

1. Secure the2. Remove b3. Inspect th

tears, or pe

CAUTIONCheck through the rear brake reservoir sight glass that the fluidlevel is above the LOWER level line. If below the line, take theATV to an authorized dealer for service.

KM965

43

ery charge may be caused by ambient temperature, ignitiont draw, corroded terminals, self discharge, frequent start/ort engine run times. Frequent winch usage, snowplowing, RPM operation, short trips, and high amperage accessory

o reasons for battery discharge.g/ance g

Use of the CTEK00 for charging orMulti US 3300 force charging is rec-. Maintenance

is required on allot used for moreeeks or as required by battery drain.

hen charging a battery in the vehicle, be sure theitch is in the OFF position.

he battery terminals with a solution of baking soda and

he sealing strip should NOT be removed and NOld be added.

the charger and battery are in a well-ventilated area. Be charger is unplugged from the 110-volt electrical outlet.t the red terminal lead from the charger to the positive ter-f the battery; then connect the black terminal lead of the to the negative terminal of the battery.

800A

4. Check the bushing for free-playby grasping the steering knuckleand turning it from side to sideand up and down.

5. If boot damage is present orbushing free-play seems exces-sive, contact an authorized dealerfor service.

Tie Rod Boots (Inner and Outer/Right and Left)

1. Secure the ATV on a supportstand to elevate the front wheels.

2. Remove both front wheels.3. Inspect the four tie rod boots for

cracks, tears, or perforations.4. Check the tie rod end free-play by grasping the tie rod near the end

and attempting to move it up and down.5. If boot damage is present or tie rod end free-play seems excessive,

contact an authorized dealer for service.Battery

The battery is located under the seat.After being in service, batteries require regular cleaning and rechargingin order to deliver peak performance and maximum service life. The fol-lowing procedure is recommended for cleaning and maintaining a sealedbattery. Always read and follow instructions provided with battery char-gers and battery products.NOTE: Refer to all warnings and cautions provided with thebattery or battery maintainer/charger.

Loss of battOFF currenstops, and shextended lowusage are alsCharginMaintenChargin

NOTE: Multi US 8the CTEK maintenanommendedcharging batteries nthan two w

NOTE: Wignition sw

1. Clean twater.

NOTE: Tfluid shou

2. Be suresure the

3. Connecminal ocharger

MD0040

MD0041

battery has reached full charge, unplug the charger fromlt electrical outlet.

after charging, the battery does not perform toectations, bring the battery to an authorized

rther troubleshooting.

rting

p-starting a vehicle with a dead battery is notd but rather removing the battery, servicing it,

y charging it; however, in an emergency, it mayy to jump-start a vehicle. If so, use the following carefully and safely jump-start a vehicle.

hicle to be jump-started, remove the battery cover and anyoots.

! WARNINGndling or connecting of a battery may result in including acid burns, electrical burns, or blindness an explosion. Always remove rings and watches.

! WARNINGrvice is performed on a battery, the followingerved: keep sparks, open flame, cigarettes, orme away. Always wear safety glasses. Protectthing when handling a battery. When servicingnclosed space, keep the area well-ventilated.attery venting is not obstructed.

44

NOTE: Optional battery charging adapters are availablefrom your authorized dealer to connect directly to your vehi-cle from the recommended chargers to simplify the mainte-nance charging process. Check with your authorized dealerfor proper installation of these charging adapter connectors.

4. Plug the battery charger into a 110-volt electrical outlet.5. If using the CTEK Multi US

800, there are no further but-tons to push. If using theCTEK Multi US 3300, pressthe Mode button (A) at the leftof the charger until the Main-tenance Charge Icon (B) orNormal Charge Icon (E) at thebottom illuminates. The Nor-mal Charge Indicator (C)should illuminate on the upper portion of the battery charger.

NOTE: For optimal charge and performance, leave the chargerconnected to the battery for a minimum 1 hour after the Mainte-nance Charge Indicator (D) illuminates. The maintainer/chargerwill charge the battery to 95% capacity at which time theMaintenance Charge Indicator (D) will illuminate and themaintainer/charger will change to pulse/float maintenance. Ifthe battery falls below 12.9 DC volts, the charger will auto-matically start again at the first step of the charge sequence.If the battery becomes hot to the touch, stop charging. Resumeafter it has cooled.

NOTE: Not using a battery charger with the proper floatmaintenance will damage the battery if connected overextended periods.

6. Once the the 110-vo

NOTE: If, operator expdealer for fu

Jump-Sta

NOTE: Jumrecommendeand correctlbe necessarprocedure to

1. On the veterminal b

3300C Improper hasevere injuryas a result of

Any time semust be obsany other flaskin and clobattery in eMake sure b

45

one clamp of the positive (red) jumper cable to the positiveinal (1) of the dead battery (C) being careful not to touch

tal with the other clamp; then attach the other clamp of the (red) jumper cable to the positive (+) terminal (2) of thettery (B).

0744-527

ome jumper cables may be the same color but theends will be color-coded red and black.

one clamp of the negative (black) jumper cable to the nega- terminal (3) of the good battery (B); then attach the otherof the negative (black) jumper cable (4) to an unpaintedurface (A) on the engine or frame well away from the deadand fuel system components.

ell away from the dead battery and start the vehicle with thettery. Allow the vehicle to run for several minutes applyingarge to the dead battery.

e vehicle with the dead battery and allow it to run for several before disconnecting the jumper cables.

! WARNINGe the final connection to a battery as a spark couldrogen gases causing an explosion of the batteryn acid burns or blindness.

2. Inspect the battery for any signs of electrolyte leaks, loose termi-nals, or bulging sides. Leaking or bulging battery cases may indi-cate a frozen or shorted battery.

3. Inspect the vehicle to be used for jump-starting to determine if volt-age and ground polarity are compatible. The vehicle must have a12-volt DC, negative ground electrical system.

4. Move the vehicle to be used for the jump-start close enough toensure the jumper cables easily reach; then shift into neutral,engage the parking brake, shut off all electrical accessories, andturn the ignition switch OFF.

NOTE: Make sure all switches on the vehicle to be jump-started are turned OFF.

5. Disconnect all external accessories such as cell phones, GPS units,and radios on both vehicles.

6. Attach (+) termany mepositivegood ba

NOTE: Sclamps or

7. Attach tive (-)clamp metal sbattery

8. Stand wgood basome ch

9. Start thminutes

! WARNINGIf any of these conditions exist, DO NOT attempt a jump-start,boost, or charge the battery. An explosion could occur caus-ing serious injury.

CAUTIONAlways make sure the electrical systems are of the same voltageand ground polarity prior to connecting jumper cables. If not,severe electrical damage may occur.

CAUTIONFailure to disconnect electronic accessories during jump-start-ing may cause system damage due to power spikes.

Never makignite hydresulting i

le RPM Adjustment

just the idle, a tachometer is necessary. If one is not avail-TV to an authorized dealer.

engine and warm itmal operating tem-

idle adjustment or out until thees at 1700 RPM.

! WARNING le to the correct RPM. Make sure the engine is atting temperature before adjusting the idle RPM.

KM004A

46

10. Remove the jumper cables in opposite order of hook-up (4, 3, 2, 1).Be careful not to short cables against bare metal.

NOTE: Have the battery and electrical system checkedprior to operating the vehicle again.

Spark Plug

The ATV comes equipped with aspecified spark plug. See the specifi-cations chart for the correct sparkplug. A light brown insulator indi-cates that the plug is correct. A whiteor dark insulator indicates that theengine may need to be serviced or thecarburetor may need to be adjusted. Consult an authorized dealer if the plug insulator is not a light browncolor. To help prevent cold weather fouling, make sure to thoroughlywarm up the engine before operating.To maintain a hot, strong spark, keep the plug free of carbon.Before removing the spark plug, besure to clean the area around thespark plug. If you do not, dirt couldenter engine when removing orinstalling the spark plug.Adjust the gap to 0.6-0.7 mm (0.024-0.028 in.) for proper ignition. Use afeeler gauge to check the gap.A new spark plug should be tightened 1/2 turn once the washer contactsthe cylinder head. A used spark plug should be tightened 1/8 - 1/4 turnonce the washer contacts the cylinder head.

Engine Id

To properly adable, take the A

1. Start the up to norperature.

2. Turn thescrew inengine idl

Adjust the idnormal opera

47

the seat; then remove theews securing the air filter cover. the air filter housing

hen pull the filter out.e element in a pan larger element and spray all sidessly with cleaning solvent, letximately three minutes. larger than the element, with a mild detergent (dish soap) andash all the dirt and oil off by squeezing the element not twist-ringing out or twisting the filter can cause damage).

oam Air Filter Cleaner and Foam Air Filter Oil Aero-ilable.

ff any remaining soap. any excess water from the element by matting with a towel.he element to dry completely.il generously onto air filter and work the oil into the element. the element to remove excess oil.

ny dirt or debris from inside the filter housing.the drain cap beneath the main housing for debris and forealing.he air filter and secure with the clamp.

CAUTIONfilter can cause damage to the ATV engine. Dirt andget inside the engine if the filter is torn. Carefullye filter for tears before and after cleaning it. Replaceth a new one if it is torn.

KM032A

Throttle Cable Adjustment

The throttle has been adjusted atthe factory, and no adjustmentshould be necessary.

1. Pull back rubber boots toaccess cable adjustment nut.

2. Loosen jam nut to allow cableadjustment nut to be adjusted.

3. Turn cable adjustment nutclockwise to decrease free-playin the cable. Turn the adjust-ment nut counterclockwise toincrease free-play in the cable.

4. There should be approxi-mately 6 mm (1/4 in.) free-play in the cable.

5. Tighten the jam nut to securethe adjustment.

Air Filter

The air filter inside the air filter hous-ing must be kept clean to provide good engine power and gas mileage. If theATV is used under normal conditions, service the filter at the intervals speci-fied. If operated in dusty, wet, or muddy conditions, inspect and service thefilter more frequently. Use the following procedure to remove the filter andinspect and/or clean it:

1. Removefive scrhousing

2. Removecover; t

3. Place ththan thegenerousit appro

4. In a panwater, wing it (w

NOTE: Fsol are ava

5. Rinse o6. Remove7. Allow t8. Spray o9. Squeeze

10. Clean a11. Inspect

proper s12. Install t

CAUTIONFailure to inspect the air filter frequently if the ATV is used industy, wet, or muddy conditions can damage the engine.

KM070A

KM981A

A torn air dust may examine ththe filter wi

Tire Repair

r flat tire occur due to a puncture, the tire may be repairede repair. If the damage is from a cut or if the puncture cannotg a plug, the tire must be replaced. When operating the ATVransportation or service facilities are not readily available, it is

ended to carry a plug-type repair kit and a tire pump along.

TV on level ground and engage the front brake lever lockarking brake (rear).

e wheel nuts on the wheel to be removed.e ATV.he wheel nuts.he wheel. wheel and install wheel nuts. a crisscross pattern to 30 ft-lb.he jack.acement

ting of the bulb is shown in the chart. When replacing aways use the same wattage rating.

12V/15W

12V/P21/5W

CAUTIONcified bulb indicated in the chart as replacement

48

Tires

Tire Tread Condition

The use of worn-out tires on an ATV isvery dangerous. A tire is considered tobe worn out when the depth of the treadis less than 3 mm (1/8 in.). Be sure toreplace the tires before reaching thisminimum specification.

Tire Replacement

The ATV has low-pressure tubeless tires. Have this maintenance performedby an authorized dealer or a qualified tire repair station.

Tubeless

Should a leak ousing a plug-typbe repaired usinin areas where tstrongly recommWheels

1. Park the A(front) or p

2. Loosen th3. Elevate th4. Remove t5. Remove t6. Install the7. Tighten in8. Remove t

Bulb Repl

The wattage raburned bulb, al

! WARNING Always use the size and type of tires as specified. Refer to thespecifications chart for proper tire inflation pressure, andalways maintain proper tire inflation pressure.

! WARNING The use of worn-out tires can be dangerous and can increasethe risk of an accident.

! WARNINGUse only approved tires when replacing tires. Failure to do socould result in unstable ATV operation.

0732-649

Headlights

Brake Light

Use only spebulb.

49

amp) fuse is located in anear the battery under the

o replace the fuse, openand remove the fuse;

the new fuse. A spareted within the holder.

ny type of electrical system failure, always check the fuse

Compartment/Tools

kit is provided with thecated under the seat. tool kit with the ATV at

CAUTIONlace a blown fuse with a fuse of the same type ande new fuse blows after a short period of use, consulted dealer immediately.

KM031A

KM972

NOTE: The bulb portion of the headlight is fragile. HANDLEWITH CARE. When replacing the headlight bulb, do not touchthe glass portion of the bulb. If the glass is touched, it mustbe cleaned with a dry cloth before installing. Skin oil residueon the bulb will shorten the life of the bulb.

To replace the headlight bulb, use thefollowing procedure:

1. Remove the rubber boot from theback of the headlight housing;then rotate the socket counter-clockwise. Remove the bulb.

2. Install the new bulb into the hous-ing; then secure the socket by turn-ing clockwise.

To replace the taillight/ brake light bulb, use the following procedure:1. Remove the rubber boot and turn the socket counterclockwise.

Account for the O-ring.2. Push the bulb in and turn it counterclockwise.3. Install the new bulb by turning it clockwise while pushing in.4. Install the socket by turning it clockwise into the housing. Install

the rubber boot.

Fuse

The main (7fuse holder seat. NOTE: Tthe holder then installfuse is loca

If there is afirst.

Storage

A basic toolATV. It is loMaintain theall times.

CAUTIONWhen replacing the headlight bulb, be careful not to touch theglass portion of the bulb. Grasp the new bulb with a clean cloth.

KM971 Always reprating. If than authoriz

ht oil to the upper steering post bushing and plungers ofabsorbers.ll nuts, bolts, cap screws, and screws. Make sure rivetsomponents together are tight. Replace all loose rivets.t be taken that all calibrated nuts, cap screws, and boltsed to specifications.

ATV thoroughly.t the battery cables (negative cable first); then remove, clean the battery posts and cables, and store in a clean,

storage, use a battery maintainer or make sure they charged (see Battery section in this manual).

TV indoors in a level position.

CAUTION outside in direct sunlight and avoid using a plastic

sture will collect on the ATV causing rusting.

50

Preparation for Storage

Use the following procedure to prepare the ATV for storage:1. Clean the seat cushion (cover and base) with a damp cloth and

allow to dry.2. Clean the ATV thoroughly by washing dirt, oil, grass, and other for-

eign matter from the entire ATV. Allow the ATV to dry thoroughly.DO NOT get water into any part of the engine or air intake.

3. Either drain the gas tank or add a fuel stabilizer to the gas in the gastank.

4. Clean the interior of the air filter housing.5. Drain the carburetor float chamber.6. Plug the hole in the exhaust system with a clean cloth.

7. Apply ligthe shock

8. Tighten aholding cCare musare tighten

9. Clean the10. Disconnec

the batterydry area.

NOTE: Forbattery is full

11. Store the A

CAUTIONPrior to storing the ATV, it must be properly serviced to preventrusting and component deterioration.

Avoid storingcover as moi

51

t the battery cables making sure to connect the positiverst.he entire brake system (cables, shoes, etc.), all controls, andght; adjust or replace if necessary.the tire pressure. Inflate to recommended pressure as neces-

all nuts, bolts, cap screws, and screws making sure all cali-uts, cap screws, and bolts are tightened to specifications.

ure the steering moves freely and does not bind.he spark plug. Clean or replace as necessary.the air filter and the air filter housing. Clean or replace asry.

Preparation after Storage Taking the ATV out of storage and correctly preparing it will ensuremany miles and hours of trouble-free riding. Use the following proce-dure:

1. Clean the ATV thoroughly.2. Clean the engine. Remove the cloth from the exhaust system.3. Check all control wires and cables for signs of wear or fraying.

Replace if necessary.4. Change the transmission lubricant.5. Charge the battery; then install.

6. Conneccable fi

7. Check tbrake li

8. Check sary.

9. Tightenbrated n

10. Make s11. Check t12. Check

necessa

OID the warranty:

form the proper break-in procedure and all related maintenance,edures (if stored for extended periods), and/or service as in the Operator’s Manual.

r adjustments by anyone other than an authorized dealer.

er carburetor jets.

er gasoline, lubricating oils, or spark plug(s).

r subjecting the vehicle to misuse, abuse, or negligent operation.

ion, addition, or removal of parts unless instructed to do so by the

hicle in any way for racing purposes.

e engine for use in another vehicle.

utilation of the Vehicle Identification Number or Engine Serial

ot sold or approved by the Company.

to improper transportation.

ll not be responsible for and this limited warranty excludes recoveryive, consequential and incidental damages, lost profits, and loss ofor provinces do not allow the exclusion or limitation of incidental orages, so the above limitation may not apply to you. Our aggregateceed the price of the product. The law of the State of Minnesota

aims or disputes, exclusive of its conflicts of law provisions.

ARRANTY EXCLUSION AND ERt permitted by law, the Company excludes and disclaims all impliedhantability and fitness for a particular purpose.

fied with warranty service or repairs, you should contact us at

52

Limited WarrantyTracker Off Road (the Company) extends a limited warranty as described below on eachnew vehicle it assembles and on each genuine part and accessory assembled and soldby an authorized dealer. The limited warranty on the vehicle is extended to the originalretail purchaser for the time periods described below; however, the balance of theremaining warranty may be transferred to another party unless the purchase is forcommercial use (see below). Warranty coverage is only available in the country in whichthe original retail purchase occurs to the original retail purchaser resident in that countryor to a transferee resident in that country of the balance of the remaining warranty.

We warrant only the products we assemble and/or sell and do not warrant that otherproducts will function properly when used with the vehicle or will not damage the vehicle.The Company does not assume any liability for incidental or consequential damages.

The Company will repair or replace, at its option, free of charge (including any relatedlabor charges), any parts that are found to be warrantable in material or workmanship.This repair work MUST be done by an authorized dealer. No transportation charges,rental charges, or inconvenience costs will be paid by the Company. The warranty isvalidated upon examination of said parts by us or an authorized dealer. The Companyreserves the right to inspect such parts at its factory for final determination if warrantyshould apply.

The warranty periods are as follows:

1. Twelve months from the date of sale — for a vehicle used for recreationalpurposes.

2. Ninety days from date of invoice — for a vehicle used for commercial purposes,including rental operations (non-transferable).

3. Thirty days from date of sale of vehicle on Company-supplied batteries.

Exclusions to this warranty include normal wear, abuse, or corrosion and thefollowing parts and items:

Tires CV Boots Torn or Punctured UpholsteryOil Filter Drive Belt Cracks or Gouges in Body PanelsAir Filter Brake Pads Drive/Driven Clutch Wear PartsLight Bulbs Spark Plug(s) Windshield

The following will V

1. Failure to perstorage procrecommended

2. Repairs and/o

3. Use of improp

4. Use of improp

5. An accident o

6. Any modificatCompany.

7. Use of the ve

8. Removal of th

9. Removal or mNumber.

10. Use of parts n

11. Damage due

The Company shaof economic, punituse. Some states consequential damliability may not exshall apply to all cl

IMPLIED WDISCLAIMTo the fullest extenwarranties of merc

If you are not satis877-394-6727.

53

Responsibility dealer will examine the vehicle or part to determine if, in his opinion, andition exists. If a warrantable condition appears to exist, the dealerplace, at our option, free of charge, including any related labor costs,e found to be warrantable and any other parts which the warrantablebe damaged. You, the owner, will then be asked to sign a warrantythe Company that the warranty work was actually performed.

responsibility to maintain and service the vehicle in accordance withManual. To protect yourself and your ATV, follow all safety and service

T warrant non-emissions related repairs required as a result of notndard operator maintenance, storage procedures, and service as

perator’s Manual.

ve any questions concerning the warranty, contact an authorized

Warranty Procedure/Owner At the time of sale, an ATV Rider Training Certificate and Owner Registration form isto be completed by the selling dealer and consumer. The receipt of the form by theCompany is a condition precedent to warranty coverage. It is the selling dealer’sresponsibility to retain and/or submit appropriate copies of the form to the appropriateplace(s) to initiate warranty coverage.

The dealer will furnish to the consumer a signed copy of the form which must bepresented to the dealer when requesting warranty service. The registration form isthe consumer’s proof of ownership and warranty eligibility. The form is used by thedealer to validate the warranty claim. Retain your copy of the form and keep it in asafe place.

When warranty repair is suspected, the ATV should be taken to the selling dealer,who has the primary responsibility to perform warranty repairs. Subject to the limita-tions set forth in the Limited Warranty, in the event the selling dealer has ceased to dobusiness, you have moved, or you are in a location away from your selling dealer,warranty may be performed by any authorized dealer.

The authorizedwarrantable cowill repair or reall parts that arpart caused to form to ensure

It is the owner’sthis Operator’s tips. We will NOperforming staoutlined in the O

Should you hadealer.

/Warranty Coverage

ENTS COVEREDsions, emission-related components include any engine parts relatedtems:

system. Fuel system.

m. Exhaust gas recirculation systems.

arts are also considered emission-related components for exhaust

t devices. Crankcase ventilation valves.

Electronic control units.

parts are considered emission-related components for evaporative

Fuel Cap.

Fuel Line Fittings.

Pressure Relief Valves*.

s*. Control Solenoids*.

ntrols*. Vacuum Control Diaphragms*.

s*. Control Linkages*.

. Vapor Hoses.

Separator. Carbon Canister.

nting Brackets. Carburetor Purge Port Connector.

vaporative emission control system.

sion Control Warranty coverage questions, contact us at

54

U.S. EPA Emission Control Statement(U.S. Only)

STATEMENT/WARRANTYTracker Off Road warrants to the original retail purchaser, and each subsequentpurchaser, that all U.S. EPA-certified Tracker Off Road vehicles are designed, built, andequipped to conform to all U.S. EPA Emission Control Regulations. Please read thefollowing information completely.

Your authorized dealer will repair or replace any defective emission-related component atno cost to you during the warranty period. You may have non-warranty service performedby any repair establishment that uses equivalent components. The regulations providesignificant civil penalties for tampering that causes your vehicle to no longer meet U.S.EPA emission standards.

Tracker Off Road further warrants that the engine and its emission-related componentsare free from defects in materials or workmanship that could cause the engine to fail tocomply with applicable regulations during the warranty period.

If you have any questions about this information, or the emission warranty coveragestatement, contact your authorized dealer.

WARRANTY PERIODThe emission warranty period for this vehicle begins on the same date as the standardwarranty coverage and continues for 30 months, 5000 kilometers (3107 miles), or 500hours, whichever comes first.

OWNER’S RESPONSIBILITIESThe owner of any vehicle warranted under this Emission Control Statement is responsiblefor the proper maintenance and use of the vehicle as stated in the Operator’s Manual.Proper maintenance generally includes replacement and service, at the owner’s choos-ing, such items as air filter, oil and oil filter, or any other part, item, or device related toemissions control as specified in the Operator’s Manual. It is the owner’s responsibility toensure that the vehicle is used in a manner for which it was designed.

COMPONI. For exhaust emisto the following sys

Air-induction

Ignition syste

II. The following pemissions:

Aftertreatmen

Sensors.

III. The following emissions:

Fuel Tank.

Fuel Line.

Clamps*.

Control Valve

Electronic Co

Control Cable

Purge Valves

Liquid/Vapor

Canister Mou

*As related to the e

For U.S. EPA Emis877-394-6727.

55

ORMED/NOTES

Maintenance Record

DATE SERVICE PERF

RMED/NOTES

56

Maintenance Record

DATE SERVICE PERFO

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CLE IDENTIFICATION NUMBER:

located on the horizontal frame bar on the front fender

INE SERIAL NUMBER:

located on the left-side of the engine crankcase.

KM973

KM037A

Identification Numbers RecordThis ATV has two identification numbers: Vehicle Identification Num-ber (VIN) and Engine Serial Number (ESN)These numbers are required by the dealer to complete warranty claimsproperly. No warranty will be allowed if the VIN or ESN is removed ormutilated in any way.Always provide the ATV name, VIN, and ESN when contacting anauthorized dealer for parts, service, accessories, or warranty. If a com-plete engine must be replaced, ask the dealer to notify the manufacturerfor correct registration information.Record the Vehicle Identification Number and Engine Serial Number inthe spaces provided to assist you in ordering parts from your authorizeddealer or for reference in case the ATV is stolen.

MANUFACTURER INFORMATION:Textron Specialized Vehicles, Inc.1451 Marvin Griffin RoadAugusta, Georgia 30906-3852 USA

Dealer: 800-296-4804Consumer: 877-394-6727www.trackeroffroad.com

1. VEHI

The VIN isframe.

2. ENG

The ESN is

your atv can be hazardous to operate. · ways, parking lots, and streets. † never operate this...

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