CERTIFICATION

PREFACE

   Thank you for purchasing our vehicle, and welcome to our world-wide family of BASHAN owners. We proudly produce an exciting line of utility and recreational products. We believe BASHAN sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of our ATV, making it the finest machine we’ve ever produced.

     For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, ATV specifications, and drive safety. Due to this manual you can know necessary skill of ATV driving. Otherwise owners may find out parts you need out of part’s shape, name, coding or composed relationships through this manual, but for our products are in continue developing, can this make some difference between real object and image, please according to real object

warning

Improperly riding vehicle may cause severe injure or death.

Always use an approved helmet and protective gear.

Never carrying a passenger on an ATV.

Never operating the ATV after consuming alcohol or medicine.

Prohibited

ATV is off road,prohibited driven on the high way,it might cause traffic accident(knowing well of the local rules and policies for ATV,it could be driven on the high way only if the law permitted)

Prohibited overspeed without correct skill or under poor road condition.

Prohibited medicine or drunk driving

Prohibited passengers(except double seat)

ALWAYS:

Prohibited drive on stone-covered road,it might affect on operation.

Operate  correctly to keep from rolling on the hill,rough road or turning.

Eyes protecting devices, helmet and protect clothes are required

ATV is not toy, kids might not be able to operate by himself. It would be best with parents’accompany.

Read manual carefully, it might cause serious injure or even death if you do not follow the rules of the manual.

Perface

  Thanks for buying our ATV, and welcome to become one of our customer.Bashan is a professional manufacturing of functional and recreational vehicles. With the skill of many years, we made a great progress both on technology and design, doing best to create classic products.

  For your safety, please read the manual and follow the rules strictly.This manual contains specification,basic structure,operate,safely drive and maintainance instruction.You could know required skills for operate ATV from here.In addition you could check the parts list according to the pictures ,names and codes.But our products are always under progress, please check the real vehicle where different.

Perface……………………………………………… 1

Frame Code And Engine Code………………………4

One、Safety

Safety Equipments………………………………… 4

Safety Training…………………………………… 5

Equipment Adjust……………………………………7

Warning and Potential Hazard……………………7

Two、Control

Engine Electrical Switches…………………… 16

Throttle Lever…………………………………… 17

Light Switches…………………………………… 17

Brake Lever…………………………………………17

Fuel Valve And Fuel Filter11………………… 19

Engine Gear Selection……………………………19

Nstrument Cluster…………………………………20

Three、Operate

Fuel Safety…………………………………………20

Pre-Ride Inspection …………………………… 21

Starting The Engine………………………………22

Hauling Cargo …………………………………… 23

Driving Safely ……………………………………24

Control System…………………………………… 30

Periodic Maintenance Chart…………………… 30

Four、Feature

Lubrication Guide………………………………… 35

Oil Check…………………………………………… 36

Oil And Filter Change ……………………………36

Maintenance And Lubrication…………………… 37

Steering Assembly………………………………… 39

Filter Systems………………………………………41

Lights …………………………………………… 41

Spark Plug……………………………………………42

Spark Arrestor………………………………………44

Battery…………………………………………… 44

Cleaning And Storage………………………………47

Five、Trouble Shooting

Maintain And Repair ………………………………53

Six、Specification

Unit Specification…………………………………57

Engine Specification………………………………58

Seven、Parts List

Electrical principle diagram……………………59

Frame Parts List……………………………………60

Engine Parts List………………………………… 77

Fill the VIN and engine code below, and put one of the key in a safe place.If you lost both of the keys, you might have to change ignition lock.The VIN and engine code matches or not is a very important proof of warranty.

MODEL：                                 

VEHICLE IDENTIFICATION NUMBERS:                                  

ENGINE NUMBER:                            

caution stickers and position

The caution stickers reminds you keep attention on safety.Please read carefully and follow it.If there has difference between manual and stickers,go with the stickers.

If the stickers worn out ,please contact your dealers ask for new ones.

safety equipments

Wear suitable clothes, ATV requires special clothes for protection, will be cosy and be able to reduce injure rate.

1.      Helmet

This is the most important for your safety to keep your head from injure.It has to be reach or over the national standard. With DOT, ANSIZ90.1 or ANSZ90 approval.

2.      Eyes protection

Please do not take sunglasses as protection. Goggle or eyes protector from helmet are the best.They requires clear and breakage-proof material. Have to be with Z2.1 or VESC 8 mark.

3.      Gloves

The best choices is with articulationes digitorum manus protecting pad.

4.      Shoes

The best choice is with hard material and as long as reach to your shank. As similar as motor-cross.

5.      Clothes

Wear long sleeve and pants to protect you arms and legs.Knee pad of your pants and shoulder pad for your clothes are required.

Warning

 ATV is not toy, it is harder to control than motorcycle or car.Even you drive normally, accident could happen easily as turning, up-hill or cross hinder if you did not pay attention to the safety.

Get to know the manual before operate.

age limit Above 16 only

Knowing your vehicle

As a driver, you have to response the safety of your around and protect environment.Read the manual and get to know some vehicle, safety operation informations.

Safety training

As you buying a vehicle, the dealer would teach you something about safety and provide you paper works of information.You should read them often.

If this not a second-hand deal, you could require the dealer to provide you a safety training

ATV is off road vehicle.Please get to know well of the local rules and policies for it.

Strongly advice you to follow the maintenance procedure. These preventive maintenance program could ensure finding out hidden dangers more comprehensive in specific inspection period

If you did not follow the instruction,might cause injure or death.

Please read it carefully and follow the rule.

Without a correct operation instruction please do not drive ,and take the course of training.

Above 16 only

Never let others operate your vehicle unless he get to know all the safety informations of the owner’s manual and get trained.

Never drive on the stone covered road, include soil and grit road.

Never drive without helmet. Remember to wear eye protection (eye protector or helmet cover),gloves,boots,long sleeve T-shirt or jacket ,pants.

Never take medicine or drunk before driving.

Never drive overspeed.Control the speed with situation of road, visibility, environment and driving experiences.

Performance
To check the car, make sure the car unharmed. To follow the manual process of inspection and maintenance.
Do not take your hands off the handle bar while driving, with feet do not leave the pedal
Driving slowly on unfamiliar roads , and be especially vigilant, pay attention to the surface changes
Never drive on soft,rough and skid ground.
Follow the manual process of the correct operation of turn, if you try to turn quickly, firstly practise with the low-speed turning. Do not turn with too fast speed
If the car had an accident, must allow a authorized dealer to check
Do not drive on slopes that is too steep, even skillful enough to operate. We must first practice on the hills before a large steep hill .

To follow the correct steps, we must check the road condition before uphill. Do not dive on particularly slippery slopes. Forward the center of gravity , do not release the throttle or shift suddenly. Do not fast drive.
To follow the correct procedure while downhill and braking on the hill. Check the road before downhill. And backwards center of gravity. Do not lean downhill. Must follow the straight line.

Must follow the rule while cycling the mountain.Do not drive on too soft and too slip hill.Forward your center of gravity uphill.Do not try to turn on the hill before you get skill of it.Please do not cycle on steep hills if it is possible.
You should follow the right instruction of driving while stop as climbing or slipping backwords.Keep moving with a constantly speed without stop.

If it happened , you should follow the instruction of hand brake that mentioned in the manual.Get off the vehicle from ahead ,if it is straightly moving ,then you could take off on any direction. Turn the vehicle after taking off ,then get on again ,to follow the instruction.

Check the road before driving on a unfamiliar place, do not try to climb over a big obstacle,such as rocks or tree.

Be careful while slipping, must drive slowly on slip surface(ice),pay more attention on it to reduce the possibilities of lose control.

Avoid driving in deep water or riffle.If it is impossible, please drive slowly and keep balance, to avoid sudden movement and keep stable slow speed forwards.Do not make a sudden turning or brake ,do not shift.

A wet brake would reduce brake ability, please check the brake after get out of the water.Try to operate brake for several times to make the brake shoes dry.

Attention the people or other stuffs behind while back off.Drive slowly if no obstacle, avoid sudden brake.

Use a standard tire, keep a right pressure.

Install the vehicle with an incorrected way or freely put accessories on, to modify the vehicle are prohibited.

No overload.Goods have to be evenly put on and tied up. Reduce the speed while loading and trail following the user’s manual.

equipment adjust

We are seriously care of the safety of customers and public.Strongly suggest that do not install some speed-add or big-hp stuffs,or any modifications aimed on increase the speed.Any modification might increase the ability of safetly loophole and body injure.

If you did anything to modify the vehicle, the warranty would be canceled.

Any accessories add, include (no limited) tiller,blade,tire,sprayer,or back rack could change the function of this vehicle.Use the professional accessories and get to well know about the effection to the vehicle.

WARNING

POTENTIAL HAZARD

Danger of not fllow the right instruction

If the driver does not know the right way to operate the vehicle with different situations, the rate of accident would increase.

HOW TO AVOID THE HAZARD

New hand or the one who lack experiences should accept courses provided by distributors.Practice often of the skill you learn from courses and read from the user’s manual.

WARNING

POTENTIAL HAZARD

It is dangerous for the driver who is not on right age.

I might cause injure or death for a driver who is under suggested age.

Even a drive is on the range of suggested age, if he does not have skills,ability or juadement,it might couse accident too.

WARNIN

POTENTIAL HAZARD

Carrying a passenger on an ATV.

WHAT CAN HAPPEN

Passengers could affected the balance and control ability of the driver,it might couse injure to both of them.

HOW TO AVOID THE HAZARD

No passenger.To move easily of the driver, we designed a long seat, but for passenger.

WARNING

POTENTIAL HAZARD

drive on the stone-covered road,incude sidewalk,path,parking lots or lane,what could happen.

The tire of ATV is for off-road only.Driving on the stone –covered road could seriously affected on operate the vehicle,course lose control,accident or injure.

HOW TO AVOID THE HAZARD

Do not reduce speed,no turning or sudden brake.

WARNING

POTENTIAL HAZARD

the danger of drive on the high way.

WHAT CAN HAPPEN

could crush with another vehicle

HOW TO AVOID THE HAZARD

Prohibited driving on the high way, It is illegal in most of places.

WARINING

POTENTIAL HAZARD

No right helmet, eyes-protection or clothes

WHAT CAN HAPPEN

It might cause higher possibility of head injure or death.

increase the rate of seriously injure

HOW TO AVOID THE HAZARD

wear the right helmet

Wear eyes protection,gloves,boots and long sleeve tshit or jacket and pants.

WARNING

POTENTIAL HAZARD

drive after drinking or medicine.

WHAT CAN HAPPEN

Both could influence judgement of driver,slow down the reaction,influence on balance and perception.

HOW TO AVOID THE HAZARD No drink or medicine take before drive.

WARNING

POTENTIAL HAZARD

Over speed

WHAT CAN HAPPEN

Increase the rate of lose control, course the accident

HOW TO AVOID THE HAZARD

your speed according to the road, visibility, environment and skills.

WARNING

POTENTIAL HAZARD

Intend to do special effects.

WHAT CAN HAPPEN

It could course accident, including roll over.

HOW TO AVOID THE HAZARD No special effects

WARNING

POTENTIAL HAZARD

No inspection before drive

No maintenance before drive

WHAT CAN HAPPEN

Bad maintenance could do harm on the vehicle.

HOW TO AVOID THE HAZARD

Check before drive to ensure it is safe.

Maintenance according to the user’s manual.

WARNING

POTENTIAL HAZARD

Leave the feet off the pedal or hands off the handle bar while operating.

WHAT CAN HAPPEN

Leave off one hand or one foot might course balance problem and to fall over.If you do not put your feet tightly attached the pedal, it might scratch back tire to course accident or injure.

HOW TO AVOID THE HAZARD

Keep your feet and hands attaching the handle bar and pedal while driving.

WARNING

POTENTIAL HAZARD

Do not be on the alert on unfamiliar road.

WHAT CAN HAPPEN

It might have stone, heave or hole, which could course out of control or roll over.

HOW TO AVOID THE HAZARD

Drive slowly and be on the alert.

WARNING

POTENTIAL HAZARD

Drive on the tough slipper or soft road without vigilance

WHAT CAN HAPPEN

Might lose control or course accident or roll over.

HOW TO AVOID THE HAZARD

Do not drive on these road before got necessary skills.

WARNING

POTENTIAL HAZARD

Turning improperly

 WHAT CAN HAPPEN

It could course lose control, car crush or roll over.

HOW TO AVOID THE HAZARD

To follow the user’s manual

practice turning skill under low speed.

Do not drive overspeed while turning.

POTENTIAL HAZARD

Drive on steep hill

WHAT CAN HAPPEN

turnover

HOW TO AVOID THE HAZARD

Do not drive on over steep hills before you got enough skills.Do not drive on the hill above 20 degree.

Practice on small hill.

WARNING

POTENTIAL HAZARD

wrong way of uphill

WHAT CAN HAPPEN

lose control or turnover

HOW TO AVOID THE HAZARD

Follow the process of user’s manual

Check the road condition before uphill

Do not drive on the hill above 20 degree

Do not drive on over slipper and soft hill

Shift your weight forward.

Do not release throttle when uphill, it might course the vehicle back over.

Do not drive high speed on the hill, obstacle hill or others vehicles or people might be on the other side.

WARNING

OPTENTIAL HAZARD

wrong way of down hill

WHAT CAN HAPPEN

lose control or turnover

How to avoid

Follow the manual

Note: You need special training for downhill brake, see page 48,remember to check the road condition.

backwards your center of gravity.

Control the speed

not downhill, it might course the vehicle lean aside

straightly downhill.

WARNING

POTENTIAL HAZARD

wrong way to cycling the hill or turning on the hill

WHAT CAN HAPPEN

lose control or turnover

HOW TO AVOID THE HAZARD

Do not try to turn on the hill before got special skill from manual.

Do not climb over a side of steep hill.

To follow the manual

To avoid too slipper or too soft hill.

WARNING

POTENTIAL HAZARD

Wrong way of get off the vehicle avoid uphill ,stopping or going backwards.

WHAT CAN HAPPEN

turnover

HOW TO AVOID THE HAZARD

keep a constant speed while uphill.

If lose the motivation of forwards,keep your center of gravity forwards,if the vehicle started to slipper backwards, brake suddenly. Keep the brake lock on when completely stop.

If the vehicle started to slipper down, keep your center of gravity up without put more horsepower, and no back brake.slowly start hand brake. Use the back brake while the vehicle completely stopped ,then put on the brak lock.Get off the vehicle from the direction of uphill,if you drive vertically ,then you could get off from both side.Turn around the vehicle then drive.

Operator Safety

WARNING

POTENTIAL HAZARD

improperly drive while cross obstacle.

WHAT CAN HAPPEN

lose control or turnover.

HOW TO AVOID THE HAZARD

Check the condition before drive on a new road.

Avoid driving on the road with obstacle, rocks, fallen trees,e.g. Higher vigilant is required while inevitable and follow the direction of user’s manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

lose control

restart the vehicle after slipper could course turnover

HOW TO AVOID THE HAZARD

Special take care of driving on the ice or reduce the chance of lose control on it.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

Might crush with obstacle, people, course injure.

HOW TO AVOID THE HAZARD

Check the people or obstacle behind you before change into reverse. Reverse after make sure there has no obstacles behind you.

WARNING

POTENTIAL HAZARD

Drive in the deepwater and riffle

WHAT CAN HAPPEN

With the influence pf tire float,the vehicle might lose control because of lose traction pull.

HOW TO AVOID THE HAZARD

Try avoid drive ATV under these situation.If could not avoid,please drive slowly,and balance your center of gravity,avoid sudden move,and keep your motivation slowly and stable forwards.Do not sudden brake or turning,do not add throttle suddenly.

The brake ability might reduce after the shoes got wet.Constantly check vehicles after leave the water.start brake for several more times if necessary ,to make the shoes dry as soon as possible.

WARNING

POTENTIAL HAZARD

Use improper tire or improper tire pressure.

WHAT CAN HAPPEN

If so, it would lose control and course accident.

HOW TO AVOID THE HAZARD

Use a specified ATV tire and keep proper pressure.

WARNING

POTENTIAL HAZARD

Modify this ATV

WHAT CAN HAPPEN

It might course operation and course accident.

HOW TO AVOID THE HAZARD

Do not modify or put any accessaries on this vehicle. All the additional parts required to be produce by our factory or specified designed for it. Strictly follow the instruction while installing and operating. Get more information from local dealers.

WARNING

POTENTIAL HAZARD

overload and transport

WHAT CAN HAPPEN

These could influence on operation of vehicle and could lost control and course accident.

HOW TO AVOID THE HAZARD

Do not overload

Properly arrange the goods and put safely.

Slow down while loading or trail, get enough brake distance.

Follow the rules of the manual while loading or trail.

WARNING

POTENTIAL HAZARD

Drive on the ice

WHAT CAN HAPPEN

It might course badly injure for both people or vehicle felt down on the ice.

HOW TO AVOID THE HAZARD

Do not ride on the ice.

WARNING

Leave your keys in the ignition lock might have others stolen and course accident or death.Take it away if you don’t use it.

If any accident or turnover happened, you required to have specified dealers to check the vehicle,include(not limited) brake,throttle and turning system.

Good judgment and skilled body skill are required for safe driving. It would be more dangerous of people who are disability or with mental problem to operate, might course badly injure or death.

CAUTION

Exhausting system parts would be very hot while the vehicle still running or just stopped running.It would be hurt people or course fire.

CONTROLS

Engine Electrical Switches

 engine emergency switch

（1）When the switch parked at    ,the engine would not run.This is aimed on turn off the engine very quickly right after the emergency.

ignition

（2）Contol the whole power of the vehicle,include light,engine switch turn the switch to    if you want to start the engine,and reverse key

 clockwise. Electronic start switch

（3）Use     to start the engine.while the engine switch stopped at   ,reverse the key clockwise to   , and hold the brake with right hand, push the botton for 55 second could start engine. Quick release the switch right after engine started.

Note: Ignition could cut off all the power of the vehicle, include light ,engine. Push the button to    when engine stopped.

CONTROLS

WARNING

Constantly or improperly use throttle controller could course accident, and bad injure or death.

Do not use throttle with problems.If there has problem with it, please contact your dealer as soon as possible.It might course accident if the throttle is with problem while using and no check.The throttle handle required to be checked before start the engine.

Throttle Lever

To control the engine speed and vehicle speed ,we use the throttle handle（1）.

It controlled with spring.Release the handset ,engine would be back to idle speed.

CONTROLS

Light Switches

 LO.light switch is on left handle bar,this is for turn the light off and on ,and take it from H1 to L0.

Note:The light only works when put on

WARNING

Drive on the street ,road ,especially at night , easier to make accident or bad injure or death.

This vehicle is not certificated with road light,only for off road.

Brake Lever

This front brake is applied by stepping the brake pedal. The front brake is hydraulic disc brake, controlled by the brake pedal. Before riding, the rider shall inspect the pedal stroke and master cylinder fluid level. If the brake pedal is loose, the brake fluid maybe leaked.

WARNING： If the brake pedal is loose, please don't ride the vehicle.

CONTROLS

Master Cylinder

Brake fluid is in master cylinder, before riding,riders shall inspect the brake fluid level in the transparent master cylinder..

Remark: When inspecting the brake fluid level, the vehicle should be park in the flat ground, keep the handle bar straight, If brake fluid level is low, please infuse DOT3 brake fluid.

WARNING

Please don't use the rest brake fluid of last bottle. The brake fluid is moisture absorption, moisture can reduce the boiling point of the brake fluid and result in brake failure.

WARNING

It might course accident use parking brake while driving,might course badly injure or death.

Setting the Parking Brake。

1.      Vehicle has to be in halted state.

2.      Hold and release right handle bar(1) two or three time,then hold tight.

3.      Pull backwards the brake lock(2),and lock the brake,release the brake handle bar.

4.      tightly hold the brake handle bar while you want to release the parking bar,then release.It will recover to unlocked status. 

Important Safeguards.The parking brake may relax if left on for a long period of time.

Always block the wheels to prevent rolling.

l  Always block the wheels on the downhill side of the ATV if leaving if parked on a hill.

Another option is to park the ATV in a side hill position.

l  Never depend on the parking brake alone if the ATV is parked on a hill.

Always block the wheels to prevent rolling.

WARNING

Aggressively applying the auxiliary brake when up down a hill may cause rear tip over, which could result in serious injury or death.

Be cautious when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing lose of control and serious injury or death.

For safety, our company designed assistant brake(1).the brake lever is on the right of the handle bar, use your right hand.

Once the master brake failure, the assistant brake can be back-up brake.

Brake travel:Usually inspect the brake travel of assistant brake.

Fuel Valve

Fuel Pump

The fuel valve (1) is located on the left side panel.

Fuel Tank

The fuel tank filler cap is located directly below the handlebar. Use unleaded gasoline with a minimum pump octane number of 93 octane.

Fuel Filter

 The fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. Do not attempt to clean the fuel filter.

Engine gear selection

The gear selection of this ATV is at the right side, which is controlled

and selected by hand lever(1), according to drive speed required, and

choose a different gear. Such gear label(2) is showed as follows:

F: forward gear

N: neutral gear

R: Reverse gear

This vehicle is chain transmission, when you change the shifting,you must loosen the throttle and hold the clutch lever.,When the light of neutral gear(2) light on, it is neutral gear

The style of this model is unvariable speed（CVT）.You should relax throttle grip and enclasp clutch handle when you select different gear.

When neutral gear indicator (2) light is bright ,it is neutral position.

When you use reverse gear, need to relax grip throttle and enclasp clutch lever,meanwhile kick hand shift. When reverse gear indicator (1) light is bright, the shift is changed.

CAUTION

1.      When you select gears, you should release throttle handle in aid

2.      When the engine is in idle speed or the ATV is in low speed,you can shift gears

3.      When you shift to reverse gear,you should stop this ATV

4.      Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.

OPERATION

Fuel Safety

WARNING

Gasoline is inflammable and explosive

l  More careful of use it.

l  Do not start the engine in a closed place

l  the offgas is poisonous,it would course death from lose consciousness.

Operate this vehicle only outdoors or in well-ventilated areas.

Break-In Period

 The break-in period for your new ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use ofSF15W40 lubricant.

1.      Fill the fuel tank with gasoline.

2.      Check the oil reservoir level on the dipstick.See page 61,fill the fuel tank in a safe level if necessary,and mark it.

3.      Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4.      Vary the throttle positions. Do not operate at sustained idle.

5.      erform regular checks on fluid levels, controls and area outlined on the daily pre-ride inspection checklist.

6.      Pull only light loads.

7.      During the break-in period, change both the oil and the filter at 20 hours, 200 miles, or one month, whichever comes first.

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.

Starting the Engine

Starting the Cold Engine

WARNING

CAUTION

Engine exhaust contains poisonous carbon monoxide which can cause loss of consciousness and result in serious injury or death.

1. Put shift lever in neutral (N) position.

2. Turn the fuel tank valve on.

3. Sitting on the vehicle, holding the front brake lever or step on foot brake pedal and make it in the braking state.

4. Turn the engine stop switch to the position.

Note: Do not press the accelerator handle when starting the engine.

5. Turn the ignition key to the OPEN position, press the starting switch  to operate.

Active the starting switch  for a maximum of five seconds, releasing the key when the vehicle starts. If the engine does not start, release the starting switch and wait five seconds. Activate the starting switch for another five seconds if necessary. Repeat this procedure until the engine starts.

6. Make the engine RPM vary slightly with the throttle to aid in warm-up.

Run the vehicle immediately after starting could cause engine damage. Make the engine to warm up for several minutes before operating the vehicle.

OPERATION

Starting the Engine

Starting a Warm Engine

1.      Keep the vehicle in Horizontal position,

2.      Apply the park brake, open the oil tank valve,turn the switch to  position

3.      When the engine start,loosen the throttle immediately. If there is no other problem, but the engine still doesn't work,please change the spark plug.

Cold Weather Operation

When you ride the vehicle for many times, please inspect the oil level. If the oil level is becoming higher, there maybe have some pollutants accumulated in the oil tank.

Driving Safely

Hauling Cargo

The ATV has been designed to carry a certain amount of lead. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals.

Cargo weight should be evenly distributed. (1 / 3 on the front carrier, 2 / 3 on the rear carrier) and placed as low as possible. When operating over rough or mountain road, reduce speed and cargo weight to maintain stable driving conditions. Do not cover the lamplight with cargo.

Hauling Cargo

l  WARNING

Improper load will affect the control of the vehicle,it may be out of control or stability,and cause serious injury or even death.

While Loading, please pay attention to the following:

Driving with cargo, slow down to keep a longer braking distance.

Cargo weight should be evenly distributed. (1/3 on the front carrier, 2/3 on the rear carrier). When operating over rough or mountain road, reduce speed and cargo weight to maintain stable driving conditions. Put cargo on one carrier only increases the possibility of vehicle turnover.

Cargo to be placed as low as possible.

Higher cargo will heighten the center of gravity of the vehicle and creates a less stable operating condition.

Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

Make sure the cargo to be placed stable and safety before driving. When load the cargo which is deviated from center of gravity, please make sure fix the cargo firmly, meanwhile please pay more attention when driving. Please make sure to put the cargo in the specified place.

Riding with cargo will cause brake and operation problems. When riding with cargo, please pay special attention on brake. Avoid driving downhill.

If the cargo height is over carrier, please pay more attention while riding. It will affect the stability and mobility of the vehicle and result in turn over.

l  Do not cover the light of the front light, especially while loading on the front rack.

l  Do not drive overspeed. Do not exceed over 10 miles(16km/h) while driving on a flat grassland. Do not exceed over 5 miles(8km/h) while driving on a messy road,or making a turn,or running in a uphill or downhill..

Driving Safely

Driving Procedures

1.      Sit upright with both feet on the footrests and both hands on the handlebars.

2.      Start the engine and allow it to warm up, then shift the transmission into gear.

3.      Check your surroundings and determine your path of travel.

4.      Release the parking brake.

5.      Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening.

6.      Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

Driving Safely

Making Turns

 Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

NOTE:  Practice making turns at slow speeds before attempting to turn at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

Driving Safely

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1.      Slow down when entering slippery areas.

2.      Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

3.      Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

WARNING

 Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1.      Always travel straight uphill.

2.      Avoid steep hills (20°maximum).

3.      Keep both feet on the footrests.

4.      Transfer your weight forward.

5.      Proceed at a steady rate of speed and throttle opening.

6.      Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

WARNING

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (20°maximum).

Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.

OPERATION

Driving Safely

Sidehilling

WARNING

Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual.

Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions.

1.      Slow down.

2.      Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

3.      Steer slightly into the hill to maintain vehicle directions.

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

OPERATION

Driving Safely

Driving downhill

Whenever descending a hill, follow these precautions:

1.      Proceed directly downhill.

2.      Transfer your weight to the rear of the vehicle.

3.      Slow down.

4.      Apply the brakes slightly to aid in slowing.

Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs.

WARNING

 Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.

Operation driving safety turning around on hill.

Warning

 Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death.

Do not drive on the slope over 20°.

Use extreme caution when operating on hills, and follow proper operating procedures outlines in the owner’s manual.

If the vehicle stalls while climbing a hill, never back it down the hill!

One maneuver that can be used when you must turn around while climbing a hill is the K-turn.

1.      Stop and lock the parking brake while keeping body weigh uphill.

2． Leave the transmission in forward and shut off the engine.

3． Dismount on the uphill side of the vehicle or on left if the vehicle is pointing straight uphill.

4． Staying uphill of the vehicle, turn the handlebars full left.

5． While holding the service brake, release the parking brake lock and slowly allow the vehicle to roll around to your right until it’s pointing across the hill or slightly downward.

6． Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill.

7． Restart the engine with the transmission still in forward.

8． Release the parking brake and proceed slowly, controlling speed with the service brake, until the vehicle is on more level ground.

Driving safely

Driving through water

 Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:

1．Determine water depths and current before crossing.

2．Choose a crossing, where both banks have gradual inclines.

3．Proceed slowly, avoiding rocks and obstacles if possible.

4.After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chat. The following areas need special attention: engine oil, transmission oil, front and rear gear cases, and grease fittings.

Caution

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.

If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

Note: avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it’s impossible to take it to a dealer before starting it, follow the steps described. Have the vehicle serviced by your dealer at the first opportunity.

Operate

Driving Safely

Driving over obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on.

Be constantly alert for hazards such as logs, rocks and low hanging branches.

Warning

Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

Driving Safely

Driving in reverse

Follow these precautions when operating in reverse:

1．Always avoid backing downhill.          2．Back slowly.

3．When in reverse, apply the brakes lightly for stopping.

4．Avoid turning at sharp angles in reveres.

5．Never throttle up the engine suddenly while backing.

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it’s safe to proceed, back slowly.

Please do not use the over control switch if the vehicle required additional strength. Be careful while use this switch.

Avoid backing on inclines, and avoid turning at sharp angles.

Driving Safely

Parking on an incline

Avoiding parking on an incline if possible. If it’s unavoidable, follow these precautions:

1．Turn the engine off        2．Do not place the transmission in Neutral.     3．Set the parking brake 

4．Always block the rear wheels on the downhill side as shown in the illustration.   5．Shut off the fuel supply.

Noise emission control system

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements.

Crankcase emission control system

This engine is equipped with a closed crankcase system.

Exhaust emission control system

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at specification to achieve optimal performance.

Adjust the idle speed by customer is suggested, customers could do it freely with yourself. Other adjustment should done by authorized dealers. The lable of displacement was put on the rear seat.

Warning

 The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle.

Spark arrestor

Law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Auxiliary power outlets provide 12V, power for operating accessories. Such as hand held spot lights. Contact your dealer.

Periodic maintenance chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine parts available from your dealer.

Note: service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles pre hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe use definition

Frequent immersion in mud, water or sand

Racing or race-style high RPM use

Prolonged low speed, heavy load operation

Extended idle

Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or contact your dealer.

Maintenance chart key

Perform these procedures more frequently for vehicles subjected to severe use.

Emission control system service

Have an authorized dealer perform these services.

Warning

Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or death. Have an authorized dealer perform these services.

perform these procedures more often for vehicles subjected to severe use.

   emission control system service (California)

■ have a authorized  dealer perform these service.

Periodic maintenance record

（“H”hour ，“M”month）

▲

  perform these procedures more often for vehicles subjected to severe use.

   emission control system service (California)

■ have a authorized  dealer perform these service.

Periodic maintenance record

1.      LIBRICATION GUIDE

Check and lubricated all components at the interval oultlined in the periodic maintenance chart beginning in page66.iterms not listed in the chart should be lubricated at the general lubrication interval.

▲  move often under severe use.

★  premium ALL SEASON GREASE or grease conforming to NLGI NO.2,such as conoco superlube M or mobilegrease special

conoco superlube M mobilegrease。

●  Use  Premium U-joint Lube every 500 miles,before long period of storage,or after pressure washing or submerging.

Premium 4 synthetic lubricantP4

premium 4 All Season synthetic engine oil has been specially formulated for use in 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

Note:

See page 113 for the part numbers of products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40°F. to 120°F. (-40 to 49°C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.

Although Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40. Oil may need to be changed more frequently if Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.

Caution

Mixing brands or using non-recommended oil may cause serious engine damage. We recommend the use of Premium 4 synthetic Oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands.

Oil check

1.      Position the ATV on a level surface.

2.      Start the engine and let it idle for 20-30 seconds.

3.      Stop the engine. Remove the dipstick and wipe it dry with a clean cloth.

Note: if the dipstick is equipped with a lever lock (3), lift the lock to remove the dipstick.

4.      Reinstall the dipstick completely, but do not lock it (if equipped). The dipstick must be completely seated to keep the angle and depth of the stick consistent.

5.      Remove the dipstick and check the oil level. Maintain the oil level in the normal or safe range (4), depending on the style of dipstick in your model. Do not overfill.

Note: due to the dipstick entry angle into the crankcase (600/700 models), the oil level will read higher on the bottom side of the dipstick. Always read the level on the upper surface (5) of the dipstick.

6.      After reinstalling the dipstick, be sure to seat the lever lock (if equipped).

Note: a rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil is over the full/ safe mark, change the oil immediately

Oil and filter change

 Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning

Oil change

1.      Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.

2.      Run the engine for two to three minutes, then turn it off.

3.      Place a drain pan beneath the oil tank and remove the drain plug (1). Allow the oil to drain completely.

4.      Install a new sealing washer (2) on the oil drain plug.

Note: the sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

5.      reinstall the drain plug and torque to 14-17 ft. lbs. (19-23 Nm)

6.      Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Clean and reinstall the fitting, torquing to 25 ft. lbs. reattach the oil line.

Note: the fitting threads must be sealed with Loctite TM PST 505 OR PTFE seal tape. The fitting must also line up with the mark (4) on the rear side of the oil tank.

Maintenance and lubrication

Oil change

1.      Place the vehicle on a level surface..

2．Run the engine for two or three minutes until warm. Stop the engine

2.      Clean the area around the drain plug.

4．Place a drain pan beneath engine crankcase and remove the drain plug

Caution

Hot oil can cause serious burns. Do not allow hot oil to touch skin  

5． Allow the oil to drain completely.        6． Replace the sealing washer on the drain plug.

Note: the sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7．Reinstall the drain plug and torque to 20 ft. lbs. (27 Nm)

8．Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove.

9．Using a clean dry cloth, clean the filter sealing surface on the crankcase.

10．Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.

11．Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

12．Remove the dipstick and fill the sump with two quarts (1.9.1) of recommended oil.

13．Place the gear selector in PARK and set the parking brake

14． Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks

15． Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

16． Dispose of used filter and oil properly.

Front and rear (rear brake) is the hydraulic disc brakes, through the hand toward the direction of the brake rod to pull a separate (with their feet after the brake pedal down the foot to move) operation. These brakes are self-regulating function, and foot release, the rear brake pedal after the brake is automatically reset to automatic release.

The following recommended inspection is used to maintain the braking system: always keep good operating conditions. If you use the brakes are heavier, and invites more examination.

Warning

Do not store or use part of the brake fluid. Brake fluid is hygroscopic, and that with it will quickly absorb the moisture in the air. The moisture can cause brake fluid dripping down the temperature of boiling, leading to premature brake failure and is likely to cause an accident or injury. When you open a bottle of brake fluid, the unused portion discarded. Always maintain the brake fluid agreed

Consists of a full brake master cylinder may cause overloading or is automatically locked, will lead to serious casualties. To maintain brake fluid in the proposed standard. Do not overflow.

Note: In normal operation, when fluid under the drip, the diaphragm will be extended to water office. If the fluid limit is low, the diaphragm does not stretch, it is likely to leak, it should be replaced by the diaphragm. Always filled with water when needed at both the lid is loose or removed the labels, and in order to ensure the normal operation of the diaphragm. Use DOT3 brake fluid. Do not overflow.

1． Check the brake system for fluid leaks.

2． Check the brakes for excessive travel or spongy feel.

3． Check the friction pads for wear, damage and looseness

4． Check the security and surface condition of the disc.

Note: pads should be changed when worn to 3/64”(.1 cm).

since this a rear brake only, it will not be as effective as the all-wheel single lever system.

Steering assembly

The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, contact your dealer for service before operating the vehicle.

Toe alignment

Warning

 Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8” to 1/4” toe out.

1． Set the handlebars in a straight-ahead position.

Note: the steering frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

2．Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration.

3．tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle(2).

4．Measure the distance from the string to the rim at the front and rear of the front rim(3). Rear measurement should be 1/16”-1/8” (.2 to .3 cm) more that the front measurement.

Note: if you discover improper alignment, contact your dealer for service

Footwell removal

1．Use screw driver loosen the 2 pieces of screw.

2．Use screw driver loosen the 2 pieces of screw

3．Remove the footwell.

Warning

 Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your ATV and in the owner’s manual.Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly.

Tire depth

 Always replace tires when the tread depth measures 1/8”(3cm) or less.

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized dealer.

Wheel removal

1.      Stop the engine, place the transmission in PARK and lock the parking brake.

2.      Loosen the wheel nuts slightly.

3.      Elevate the side of the vehicle by placing a suitable stand under the footrest frame

4.      Remove the wheel nuts and remove the wheel.

Warning

 Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Contact your dealer.

1． Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation.

2． Install the wheel nuts and finger tighten.    3． Lower the vehicle to the ground.

4． Torque the wheel nuts to specification

Wheel nut torque specifications

Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.

Filter Systems

Air filter Service

1.Open the seat, loosen the clip of the filter,then open the cap.

2.Loosen the clip,take out the air filter.

3.Remove the fabric from the main filter, put it in the soapsuds, clean and dry

4.Install the pre-filter onto the main filter

5.Install the air filter into the box, fasten the clip.

6.Closed up the box and seat.

Lights

Please don't use hand to maintenance the light. The oil on the hand will left some marks on the light and make the lift time of the light shorter.

WARNING

 When riding, the lights may cause accident if the lights have problem. There will be dust on the front light cover and tail light cover, please clean the cover before riding. When the light cooling down, clean the lights.

Headlight lamp replacement

1.      Brake up the cable of front lamp.

2.      Remove the cover, take out the screws.

3.      Remove the light

4.      Remove the light cover, screw out the light bubble.

5.      Install new light bubble housing. Caution: make sure the install the light bubble correctly.

6.      Reassemble the pod.

High beam adjustment

The front light can be adjusted up and down slightly.

Follow the process:

1. Park the vehicle on the flat ground,keep light 10 meters away from the wall.

2. Measure the middle distance between the ground and front light, make a mark on the wall.

3. Turn on the ignition switch, turn on the front light, adjust the high beam.

4. Observe the light point on the wall, the strongest light shall be 690mm lower than the mark we made before.

Caution: when measure, add the weight of rider on the vehicle.

5. Adjusting the screw (1) that behind the cover, adjust the screw to make the light in the right position.

After completing the adjustment of high beam, don't adjust the low beam.

Taillights /brake light /work light lamp replacement

1.      Remove the harness connector (1) from the back of the light assembly.

2.      Turn the lamp (2) counterclockwise to remove it.

3.      Apply dielectric grease to the socket and install the new lamp.

4.      Test the light for proper operation.

Spark Plug

Always use the spark plugs recommended for your ATV. Refer to the specification section beginning on page 39 for the recommended spark plug type and gap.

 CAUTION

 Using non-recommended spark plugs can result in serious engine damage. Always use -recommended spark plugs.

Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection.

1.      Normal

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustment.

2.      Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1.      remove the spark plug cap

2、Using the special wrench provided in tool pouch, rotate the spark plug counterclockwise to remove

3、Reverse the procedure for spark plug installation, using the recommended spark plug. Torque to 18 ft-lb.(24 Nm).

Vehicle Immersion

  CAUTION

  If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it is impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

1、move the ATV to dry land or at the very least, to water below the footrests.

2、check the air box for any water and dry it if water is present, filter replacement is required if water intrusion is evident.

3、turn the fuel valve off.    4、remove the spark plug   5、loosen the carburetor drain screw(1).

6、turn the engine over several times using the electric start.

7、dry the spark plug and reinstall, or replace it with a new plug.

8、tighten the carburetor drain screw.

9、turn the fuel valve on

10、try to start the engine. If necessary, repeat the drying procedure.

11、take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not.

Spark Arrestor

WARNING

Failure to heed the follow warnings while servicing the spark arrestor could result in serious injury or death.

Do not perform service on spark arrestor while the system is hot. Exhaust system temperatures can reach1000^o F .Allow components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.

Never go under the vehicle while it’s inclined.

Battery

Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filter caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup of water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes, or clothing.

Antidote:

External: Flush with water

Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes: flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gas, keep sparks, flame, cigarettes, etc. Anyway, keep ventilate when charging or using in an enclosed space, always protect eyes when working near batteries. KEEP OUT OF REACH BY CHILDREN.

Battery Removal

1.      Disconnect the hold-down strap holding the battery in position,and remove battery cover.

2.      On conventional batteries, remove the battery vent tube.

3.      Disconnect the black (negative) battery cable next.

4.      Disconnect the red (positive) battery cable next.

5.      Lift the battery out of the ATV. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.

BATTERY INSTALLION

1.      Set the battery in the battery holder.

2.      With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).

NOTE: the vent tube must be free of obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion. Avoid skin contact with electrolyte, which can cause severe burns.

3.      First connect and tighten the red(positive) cable.

4.      Second connect and tighten the black(negative) cable.

5.      Reinstall the battery cover and attach the hold-down strap.

6.      Verify that cables are properly routed.

NOTE:  When installing a new battery, make sure it’s fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.

Battery Storage

When the vehicle is placed in storage for three months or more, the battery should be removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take the battery to your dealer for testing and recharge.

Battery Charging (Traditional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks.

To refill use only distilled water. Tap water contains minerals that are harmful to a battery.

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

Battery Charging (Sealed Battery)

The following battery charging instruction apply only to the installation of a YUASA activated, sealed battery. Read all instructions before proceeding with the installation of this battery.

The YUASA activated, sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Do not ever pry the sealing strip off or add any other fluid to this battery.

YUASA The single most important thing to maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

Battery Charging (Sealed Battery)

For a refresh charge, follow all instruction carefully.

1.      check the battery voltage with a voltmeter or multimeter . a fully charged battery will register 12.8 V or higher.

2.      if the voltage is less than 12.8 volts,recharged the battery.

NOTE: When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When using a constant current charger, use the following guideline for recharging.

WARNING

An overheated battery could explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

Accessories

Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessories outlets are available for all models, also has a wide range of additional accessories available for your ATV. Contact your dealer.

Cleaning and Storage

Cleaning the ATV

Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots.

NOTE:  If warning and safety labels are damaged, contact your dealer for free replacement.

Does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system.

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax. avoid the use of harsh cleaner since they can scratch the body finish.

CAUTION

Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when using these products near plastic surface.

Storage Tips

Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergent or high pressure washers. Some detergents deteriorate rubber parts. Use dish soap type cleaner only. High pressure washers may force water past seals.

Stabilize the Fuel

Fill the fuel tank. Add Carbon Clean Fuel Treatment or Fuel Stabilizer. Follow the instruction on the container for the recommended amount.(Carbon clean will also reduce the possibility of bacterial growth in the fuel system.) allow 15-20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor.

      Turn the fuel valve off and drain the carburetor bowl

Oil and Filter

      Warm the engine and change the oil and filter.

Air Filter/ Air Box

Inspect and clean or replace the pre-cleaner and air filter, Clean the air box and drain the sediment tube.

Breather Filter

Inspect and clean or replace the breather filter.

Fluid Level

Inspect the following fluid level and change if necessary: front and rear gearcases; transmission and brake fluid (change every two years or as required if fluid looks dark or contaminated).

Fog the engine

1.      Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic OW40 engine oil. To access the plug hole, use a section of clear1/4’’ hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

   NOTE: Do this carefully! If you miss the plug hole, oil will drain from the spark plug cavity into the hole at the front of the cylinder head, and appear to be an oil leak.

2.      Reinstall the spark plug. Torque to 18ft,lbs.(24Nm)

3.      Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug.

4.      urn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

Alternative to Using Fogging Oil

If you choose not to use Fogging Oil, perform the following procedure.

1.      treat the fuel system with Carbon Clean, following the instruction on the can. Run the engine for several minutes so the Carbon Clean reaches the carburetor, turn the engine off.

2.      support the front end of the machine so the engine is level or tilted slightly rearward.

3.      remove the spark plug. Rotate the piston to BDC and pour approximately two ounces of recommended oil into the cylinder.

4.      reinstall the spark plug and torque to 18 ft.lbs(24Nm)

5.      apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug.

6.      turn the engine over several times to ensure coverage of piston rings, cylinder walls and crankshaft bearings.

7.      if fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. To eliminate any fuel remaining in the carburetor, run the engine until it stops.

Inspect and Lubricate

Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with  Premium All Season Grease.

Battery Maintenance (Conventional)

Remove the battery and add distilled water to the proper level. Do not use tap water, which may contain minerals the reduce battery life.

Apply dielectric grease to the terminal bolts and terminals. Charge the battery at 1.4 amps or less until the specific gravity of each cell is 1.265 or greater. Store the battery in a cool, dry place.

Charge can be maintained easily by using Battery Tender ^TM charge (PN 2871076) or by charging about once a month to make up for normal self-discharge. Battery Tender ^TM can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. Check the fluid level monthly.

Battery Maintenance (Sealed)

Remove the battery and recharge it as outlined on page 42. store the battery in a cool and dry place.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should be replaced every two years.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires 1-2’’ off the ground. Be sure the storage area is well ventilated, and cover the machine with a genuine ATV cover.

NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years.

Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime. Never use abrasive cleaners on plated or painted surfaces.

Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they’re exposed to salt or other corrosive elements.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool(# 0000-0TT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above.

Transporting the ATV

Follow these procedures when transporting the vehicle.

1.      Turn off the engine and remove the key to prevent loss during transporting.

2.      Place the transmission in PARK and lock the park brake.

3.      Turn the fuel valve off and be sure the fuel cap, oil cap and seat are installed securely.

4.      Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie strap to the front A-arm bolt pockets.

Camber and Caster

The camber and caster are non- adjustable.

Rear Spring

the rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension.

NOTE: Accessory springs are available through your dealer.

Handlebars

The handlebars can be adjusted for rider preference.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedure exactly, or ask your dealer for service.

1. Locate handlebar bolts (1) by removing the upper headlight pod.

2. loosen the four bolts.

3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

4. torque the front two bolts to 10-12 ft.lbs.(14-17 Nm), then torque the rear two bolts. A gap of up to 1/8’’ will remain at the rear bolts.

Carburetor/Idle RPM

Your ATV is calibrated at the factory for optimal performance at altitudes ranging form zero to 6,000 feet (1800m) and temperatures of +40 degrees F.(4 degree C.) or higher. Above 6,000 feet (1800m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (308m) increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation. Optional jets, available from your dealer, are required for operation above 6,000 feet and temperatures below +40 degrees F.(4 degree C.)

NOTE: Continuous operation of the engine without proper jetting when required can cause poor performance, overheating or engine damage. Ask your dealer for more information about jetting the ATV for condition in your area.

Throttle Cable Freeplay

1、Throttle cable freeplay is adjusted at the handlebar.

2、  Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3).

NOTE: While adjusting freeplay, be sure to flip the throttle lever back and forth.

3、Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster.

TROUBLE SHOOTING

Contact your BASHAN dealer for service if you’re unable to identify solutions using the following charts.

Engine Doesn’t Turn Over

Engine turns over, fails to start

Engine Pings or knocks

Engine Backfires 

Engine runs irregularly, stalls or misfires

Engine Stops or Loses Power

Engine Overheating 

unit specification：

engine specification

Electrical principle diagram