OPERATOR’S MANUAL - TRACKER OFF ROAD · Test your brakes after leaving water. If necessary, apply...

OPERATOR’S MANUAL

570/570EPS700EPS

Do not remove this Operator’s Manual from this ATV according to the guidelines and agreement with the U.S. Consumer Product Safety Commission.

Read this manual carefully. It contains important safety information.

p/n: 2263-0318/20

Your ATV Can Be Hazardous to Operate.A collision or rollover can occur quickly,even during routine maneuvers such asturning and driving on hills or over obsta-cles, if you fail to take proper precau-tions.For your safety, it is important to under-stand and follow all the warnings con-tained in this Operator’s Manual and thelabels on your ATV prior to riding.This Operator’s Manual should be con-sidered a permanent part of the ATV andmust remain with the ATV at the time ofresale. If the ATV changes ownershipmore than once, contact the manufacturerfor proper registration information.

Labels should be considered as perma-nent parts of the ATV. If a label comes offor becomes hard to read, contact yourauthorized dealer for a replacement.FAILURE TO FOLLOW THE WARN-INGS CONTAINED IN THIS MAN-UAL CAN RESULT IN SERIOUSINJURY OR DEATH.For your safety, it is important all opera-tors be properly trained to operate anATV. Training is available: U.S. owners,call 800-887-2887; Canadian owners,call 613-739-1535.Particularly important information is dis-tinguished in this manual by the follow-ing notations:

California Proposition 65

! The Safety Alert Symbol means ATTENTION!BE ALERT! YOUR SAFETY IS INVOLVED.

WARNING indicates a hazardous situationwhich, if not avoided, could result in death orserious injury.

! WARNING

CAUTION, without the safety alert symbol, isused to address practices not related to per-sonal injury.

CAUTION

NOTE: A NOTE provides key information to make pro-cedures easier or more clear.

! WARNINGThe Engine Exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects or other reproductive harm.

ForewordCongratulations and thank you for pur-chasing a Tracker Off RoadTM All-TerrainVehicle (ATV). Built with Americanengineering and manufacturing know-how, it is designed to provide superiorride, comfort, utility, and dependable ser-vice.You have chosen a quality vehicledesigned and built to give dependableservice. Be sure, as the owner/operator ofthis vehicle, to become thoroughly famil-iar with its basic operation, maintenance,and storage procedures. Read and under-stand the entire Operator’s Manualbefore operating the vehicle to ensuresafe and proper use. Always operate thevehicle within your level of skill and cur-rent terrain conditions.This Operator’s Manual is furnished toensure that the operator is aware of safeoperating procedures. It also includesinformation about the general care andmaintenance of your ATV.Carefully read the following pages. Ifyou have any questions regarding thisATV, contact an authorized dealer forassistance. Remember, only authorizeddealers have the knowledge and facilitiesto provide you with the best service pos-sible.

• Know all local, state/provincial ridinglaws,

• Respect your ATV,• Respect the environment, and• You will gain the respect of others.

The manufacturer advises you to strictlyfollow the recommended maintenanceprogram as outlined. This preventivemaintenance program is designed toensure that all critical components on thisATV are thoroughly inspected at variousintervals.All information in this manual is based onthe latest product data and specificationsavailable at the time of printing. The man-ufacturer reserves the right to make prod-uct changes and improvements which mayaffect illustrations or explanations withoutnotice.

Some illustrations used in this manual areused for clarity purposes only and are notdesigned to depict actual conditions.Because the manufacturer constantlyrefines and improves its products, no ret-roactive obligation is incurred.

Tracker Off Road and the ATV SafetyInstitute recommend that all ATV opera-tors ride the appropriate-sized ATVaccording to age.

Protect Your Sport

Parts and AccessoriesWhen in need of replacement parts,oil, or accessories for your ATV, besure to use only GENUINE PARTS,OIL, AND ACCESSORIES. Onlygenuine parts, oil, and accessoriesare engineered to meet the stan-dards and requirements of yourATV. For a complete list of accesso-ries, refer to the current ATV/ROVAccessory Catalog.To aid in service and maintenanceprocedures on this ATV, a ServiceManual and an Illustrated Parts Man-ual are available through your localauthorized dealer.

Category Age (Years)

Speed Limitations

in mph (km/h)

NOTES

Y-10+ 10 or Older

Limited 15 (24)

Maximum 30 (48)

Operate Under Adult Supervision

T-14 14 or Older

Limited 20 (32)Limited 30 (48)

Maximum38 (61)


G & S 16 or Older

According to Local

Regulations—

1

Table of ContentsForeword .................................................. 1Parts and Accessories............................ 1Division I — SafetyATV Safety Alert....................................... 4Rider Training Course............................. 5Hangtags ............................................... 6-7Warning Labels & Information ............ 8-9Warnings ........................................... 10-18Prevention......................................... 19-21

Safe Riding Clothing and Gear ............ 19ATV Condition ...................................... 20First Aid and Survival ........................... 21

Active Riding ......................................... 23Sound Judgment .............................. 24-27

Environment ......................................... 24Those Around You................................ 25Equipment ............................................ 25Load Capacity Ratings Chart ............... 26SpeedRack........................................... 26Personal Choices ................................. 26

Supervision............................................ 28Taking Responsibility............................ 28

Inexperienced/Untrained Riders ....... 28Experienced/Trained Riders ............. 28

Division II — Operation/ MaintenanceSpecifications ........................................ 29Location of Parts and Controls............ 30ATV Operation .................................. 31-39

Basic Operating Maneuvers................. 31Starting a Cold Engine...................... 31Starting the Engine ........................... 31

Handling the ATV (Active Riding Techniques) ...................................... 33

Tips ...................................................... 38

General Information ......................... 40-49Control Locations and Functions.......... 40Power Steering..................................... 42Speedometer/LCD Gauge.................... 43Oil Level Stick ...................................... 45Seat Latch ............................................ 46Safety Flag Bracket.............................. 46Rack Loading (Front and Rear)............ 46Trailering and Towing ........................... 46Transporting ......................................... 47Gasoline—Oil—Lubricant..................... 47Engine Break-In ................................... 48Burnishing Brake Pads......................... 49

General Maintenance ....................... 50-63Maintenance Schedule......................... 50Liquid Cooling System ......................... 51Shock Absorbers .................................. 52General Lubrication.............................. 52Hydraulic Hand Brake .......................... 54

Brake Fluid........................................ 54Brake Lever Lock .............................. 54Brake Hoses ..................................... 54Brake Pads ....................................... 54

Rear Foot Brake................................... 54Gas Hoses ........................................... 55Protective Rubber Boots ...................... 55Battery.................................................. 56Jump-Starting....................................... 57Spark Plug............................................ 58Throttle Cable Adjustment.................... 59Air Filter................................................ 59Air Filter Housing Drain ........................ 60Draining V-Belt Cover........................... 60Tires ..................................................... 60Wheels ................................................. 61Muffler/Spark Arrester .......................... 61Light Bulb Replacement ....................... 61Checking/Adjusting Headlight Aim ....... 62Fuses ................................................... 62Electrical Output Terminals .................. 63Storage Compartment/Tools ................ 63

Preparation for Storage ........................ 64Preparation after Storage ..................... 65Maintenance Record ........................ 66-67Warranty Procedure/Owner

Responsibility.................................... 68U.S. EPA Emission Control Statement/

Warranty Coverage (U.S. Only) ........ 69California Emission Control Statement/

Warranty Coverage — OHRV (U.S. Only) ................................................... 70

Change of Address, Ownership, or Warranty Transfer.............................. 71

Identification Numbers Record ............ 73

p/n: 2263-031

2

Division I — SafetyAN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

• Always go slowly and be extra careful when operating on unfamiliar terrain. Always bealert to changing terrain conditions when operating the ATV.

• Never operate on excessively rough, slippery, or loose terrain.• Always follow proper procedures for turning as described in this manual. Practice turning

at slow speeds before attempting to turn at faster speeds. Do not turn at excessive speed.• Always have the ATV checked by an authorized dealer if it has been involved in an acci-

dent.• Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on

smaller hills before attempting larger hills.• Always follow proper procedures for climbing hills as described in this manual. Check

the terrain carefully before you start up any hill. Never climb hills with slippery or loosesurfaces. Shift your weight forward. Never open the throttle suddenly or make suddengear changes. Never go over the top of any hill at high speed.

• Always follow proper procedures for going down hills and for braking on hills asdescribed in this manual. Check the terrain carefully before you start down any hill.Shift your weight backward. Never go down a hill at high speed. Avoid going down ahill at an angle which would cause the ATV to lean sharply to one side. Go straightdown the hill where possible.

• Always follow proper procedures for crossing the side of a hill as described in this man-ual. Avoid hills with slippery or loose surfaces. Shift your weight to the uphill side ofthe ATV. Never attempt to turn the ATV around on any hill until you have mastered theturning techniques described in this manual on level ground. Avoid crossing the side ofa steep hill if possible.

• Always be careful of skidding or sliding. On slippery surfaces, such as ice, go slowlyand be very cautious in order to reduce the chance of skidding or sliding out of control.

• Always use proper procedures if you stall or roll backward when climbing a hill. Toavoid stalling, maintain a steady speed when climbing a hill. If you stall or roll back-wards, follow the special procedure for braking described in this manual. Dismount onthe uphill side or to either side if pointed straight uphill. Turn the ATV around andmount following the procedure described in this manual.

• Always check for obstacles before operating in a new area. Never attempt to operate overlarge obstacles, such as large rocks or fallen trees. Always follow proper procedures whenoperating over obstacles as described in this manual.

• Never operate an ATV in fast flowing water or in water deeper than the footrests. Remem-ber that wet brakes may have reduced stopping capability. Test your brakes after leavingwater. If necessary, apply them lightly several times to let friction dry out the pads.

• Always be sure there are no obstacles or people behind you when you operate in reverse.When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

• Always use the size and type tires specified in this manual. Always maintain proper tirepressure as described in this manual.

• Never improperly install or improperly use accessories on this ATV.• Never install a twist grip throttle on this ATV.• Never exceed the stated load capacity for an ATV. Cargo should be properly distributed

and securely attached. Reduce speed and follow instructions in this manual for carryingcargo or pulling a trailer and allow greater distance for braking.

• No one under the age of 16 should operate this ATV. Some operators at the age of 16 maynot be able to operate an ATV safely. Parents should supervise the use of the ATV at alltimes. Parents should permit continued use only if they determine that the operator has theability to operate the ATV safely.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the ATV SafetyInstitute at 800-887-2887 (U.S.) or 613-739-1535 (Canada).

! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 3

ATV Safety AlertThe U.S. Consumer Product Safety Com-mission has concluded that ALL-TER-RAIN VEHICLES (ATVs) may present arisk of DEATH or SEVERE INJURY incertain circumstances:*** Each year, about 650 deaths and about

100,000 injuries (including children)related to off-road vehicles arereported.

*** Many people have become severelyparalyzed or suffered severe internalinjuries as a result of accidents asso-ciated with ATVs.

*** Every month thousands of people aretreated in hospital emergency roomsfor injuries received while riding anATV.

You should be aware that AN ATV ISNOT A TOY AND CAN BE HAZARD-OUS TO OPERATE. An ATV handlesdifferently from other vehicles, includingmotorcycles and cars. A collision or roll-over can occur quickly, even during rou-tine maneuvers such as turning anddriving on hills and over obstacles, if youfail to take proper precautions.TO AVOID DEATH OR SEVEREPERSONAL INJURY:

* Always read the Operator’s Manualcarefully and follow the operatingprocedures described. Pay specialattention to the warnings contained inthe manual and on all labels.

* Never operate an ATV without properinstruction. Take a training course.Beginners should complete a trainingcourse.

* Always follow these age recommen-dations:• A Y-10+ is intended for use by children

age 10 or older, and a T-14 is intendedfor use by an operator age 14 or older.

• A child under 16 years old shouldnever operate an ATV without adultsupervision. Children need to beobserved carefully because not all chil-dren have the strength, size, skills, orjudgment to operate an ATV safely.

* Never carry a passenger on an ATV.Carrying a passenger may upset thebalance of the ATV and may cause itto go out of control.

* Always avoid paved surfaces. ATVsare not designed to be used on pavedsurfaces and may seriously affecthandling and control.

* Never operate an ATV on a publicroad, even a dirt or gravel one,because you may not be able to avoidcolliding with other vehicles. Also,operating an ATV on a public roadmay be against the law.

* Never operate an ATV without anapproved motorcycle helmet, eyeprotection, boots, gloves, long pants,and a long-sleeved shirt or jacket.

* Never consume alcohol or drugsbefore or while operating an ATV.

* Never operate an ATV at excessivespeeds. Go at a speed which is properfor the terrain, visibility conditions,and your experience.

* Never attempt to do wheelies, jumps,or other stunts.

* Always be careful when operating anATV, especially when approachinghills, turns, and obstacles and whenoperating on unfamiliar or rough ter-rain.

* Never lend an ATV to anyone whohas not taken a training course or hasnot been driving an ATV for at least ayear.


Rider Training CourseThe manufacturer sponsors a free RiderTraining Course to teach ATV ridingskills or to reinforce current riding skills.First-time purchasers without any previ-ous ATV riding experience will receive a$100.00 coupon from the manufacturerthrough the Specialty Vehicle Institute ofAmerica/ATV Safety Institute after com-pleting the training course (U.S. ownersonly, one incentive, and free rider train-ing courses for appropriate immediatefamily members per ATV purchase). Seean authorized dealer for details or call800-887-2887 for training course infor-mation.In Canada, the Canada Safety Council(CSC) provides an ATV Rider’s Courseto teach safe ATV operating skills. Theyalso provide a special ATV Rider’sCourse for children under 14 years of agewith parental supervision. Call 613-739-1535 for more details. Also available aresafety training materials from the Cana-dian Off-Highway Vehicle DistributorsCouncil. Call toll-free at 877-470-2288.Au canada, le conseil canadien de lasécurité (CSC) offre un cours de conduitede VTT pour enseigner les habiletésd’opération sécuritaires de VTT. Uncours spécial de conduite de VTT estégalement offert aux enfants de moins de14 ans avec la surveillance d’un parent.Communiquez avec le CSC en com-posant le: 613-739-1535 pour de plusamples informations. Matériel de forma-tion à la sécurité est aussi disponible parConseil Canadien des Distributeurs deVéhicules Hors Route. Composez sansfrais le: 877-470-2288.

FOR MORE INFORMATIONABOUT ATV SAFETY in the U.S.,call the Consumer Product SafetyCommission at 800-638-2772 or theATV Safety Institute Safety Hotlineat 800-852-5344. In Canada, call theCanada Safety Council at 613-739-1535.


HangtagsThis vehicle comes with hangtags containing important safety information. Anyonewho rides the vehicle should read and understand this information before riding.


Hangtags


Warning Labels & Information This vehicle comes with several labels containing important safety information. Anyonewho rides the ATV should read and understand this information before riding. The labelsshould be considered as permanent parts of the ATV. If a label comes off or becomes hardto read, contact your authorized dealer for a replacement.NOTE: The location and content of labels on the ATV you have purchasedmay differ from those shown on this page.

XR WL2015XR_3


Warning Labels & Information

XR WL2015XR_1_TKR


Warnings

! WARNING POTENTIAL HAZARD Operating this ATV without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does not know how tooperate the ATV properly in different situations and on different types of terrain.HOW TO AVOID THE HAZARDBeginning and inexperienced operators should complete the certified trainingcourse offered. They should then regularly practice the skills learned in the courseand the operating techniques described in this Operator’s Manual.For more information about the training course, contact an authorized dealer orcall 1-800-887-2887 (U.S.) or 613-739-1535 (Canada).

! WARNINGPOTENTIAL HAZARDAllowing anyone under age 16 to operate this ATV.WHAT CAN HAPPENUse of an ATV by children can lead to severe injury or death of the child.Children under the age of 16 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 16 should never operate this ATV.

! WARNINGPOTENTIAL HAZARDCarrying a passenger on this ATV.WHAT CAN HAPPENGreatly reduces your ability to balance and control thisATV.Could cause an accident, resulting in injury or death toyou and/or your passenger.HOW TO AVOID THE HAZARDNever carry a passenger. The long seat is to allow the operator to shift positions asneeded during operation. It is not for carrying passengers.

! WARNINGPOTENTIAL HAZARDAttempting wheelies, jumps, and other stunts.WHAT CAN HAPPENIncreases the chance of an accident including a roll-over.HOW TO AVOID THE HAZARDNever attempt stunts, such as wheelies or jumps. Don’ttry to show off.


! WARNINGPOTENTIAL HAZARDOperating this ATV on paved surfaces.WHAT CAN HAPPENThe ATV’s tires are designed for off-road use only, notfor use on pavement. Paved surfaces may seriouslyaffect handling and control of the ATV and may causethe ATV to go out of control.HOW TO AVOID THE HAZARDWhenever possible, avoid operating the ATV on any paved surfaces includingsidewalks, driveways, parking lots, and streets. If operating on paved surfaces isunavoidable, travel slowly (less than 10 mph [16 km/h]) and avoid sudden turnsand stops.

! WARNINGPOTENTIAL HAZARDOperating this ATV without wearing an approved hel-met, eye protection, and protective clothing.WHAT CAN HAPPENOperating without an approved helmet increases yourchances of a severe head injury or death in the event ofan accident.Operating without eye protection can result in an acci-dent and increases your chances of a severe injury inthe event of an accident.Operating without protective clothing increases yourchances of severe injury in the event of an accident.HOW TO AVOID THE HAZARDAlways wear an approved helmet that fits properly.You should also wear: Eye protection (goggles or face shield)

GlovesBootsLong sleeved shirt or jacketLong pants

! WARNINGPOTENTIAL HAZARDFailure to use extra care when operating on rough, slippery,or loose terrain.WHAT CAN HAPPENCould cause loss of traction or ATV control, which couldresult in an accident including a rollover.HOW TO AVOID THE HAZARDDo not operate on rough, slippery, or loose terrain until you have learned and practicedthe skills necessary to control the ATV on such terrain.Always be especially cautious on these kinds of terrain.


! 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.

! WARNINGPOTENTIAL HAZARDOperating this ATV at excessive speeds.WHAT CAN HAPPENIncreases your chances of losing control of the ATV, which can result in an accident.HOW TO AVOID THE HAZARDAlways ride at a speed that is proper for the terrain, visibility and operating condi-tions, and your experience.

! WARNINGPOTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENIncreases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV each time you use it to make sure the ATV is in safeoperating condition.Always follow the inspection and maintenance procedures and schedulesdescribed in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDRemoving hands from handlebar or feet from footrests during operation.WHAT CAN HAPPENRemoving even one hand or foot can reduce your ability to control the ATV orcould cause you to lose your balance and fall off the ATV. If you remove a footfrom a footrest, your foot or leg may come into contact with the wheels, whichcould injure you or cause an accident.HOW TO AVOID THE HAZARDAlways keep both hands on the handlebar and both feet on the footrests of yourATV during operation.


! WARNINGPOTENTIAL HAZARDFailure to use extra care when operating the ATV onunfamiliar terrain.WHAT CAN HAPPENYou can come upon hidden rocks, bumps, or holeswithout enough time to react.Could result in the ATV overturning or going out ofcontrol.HOW TO AVOID THE HAZARDGo slowly and be extra careful when operating on unfamiliar terrain.Always be alert to changing terrain conditions when operating the ATV.

! WARNINGPOTENTIAL HAZARDImproperly crossing hills or turning on hills.WHAT CAN HAPPENCould cause loss of control or cause the ATV to over-turn.HOW TO AVOID THE HAZARDAvoid crossing the side of a hill or turning on a hillwhenever possible. Never attempt to turn the ATV around on any hill until youhave mastered the turning technique as described in this Operator’s Manual.Practice first on level ground. Be very careful when turning on any hill.If crossing the side of a hill or turning on a hill is unavoidable:Always follow proper procedures as described in this Operator’s Manual.Avoid hills with slippery or loose surfaces.Shift your weight to the uphill side of the ATV.

! WARNINGPOTENTIAL HAZARDGoing down a hill improperly.WHAT CAN HAPPENCould cause loss of control or cause the ATV to over-turn.HOW TO AVOID THE HAZARDAlways follow proper procedures for going down hills asdescribed in this Operator’s Manual.Always check the terrain carefully before you start down any hill.Shift your weight backward.Never go down a hill at high speed.Avoid going down a hill at an angle that would cause the ATV to lean sharply toone side. Go straight down the hill where possible.


NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 25°

! WARNINGPOTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENATV could go out of control, causing a collision or rollover.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in this Operator’s Man-ual.Practice turning at slow speeds before attempting to turn at faster speeds.Do not turn at excessive speed.

! WARNINGPOTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENCould cause loss of control or cause the ATV to over-turn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in this Operator’sManual.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 or make sudden gear changes. The ATV couldflip over backwards.Never go over the top of any hill at high speed. An obstacle, a sharp drop, oranother vehicle or person could be on the other side of the hill.

! WARNINGPOTENTIAL HAZARDFailure to release the brake lever lock before driving the ATVWHAT CAN HAPPENDriving the ATV with the brake lever lock engaged could cause a change in han-dling or loss of brakes and cause an accident.HOW TO AVOID THE HAZARDAlways release the brake lever lock before driving the ATV.


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

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

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

If you begin rolling backwards:Keep weight uphill.Apply the brakes while rolling backwards.When fully stopped, engage the brake lever lock.Dismount on uphill side or to a side if pointedstraight uphill.Turn the ATV around and mount following theprocedure described in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDOverloading the ATV or carrying or towing improperly.WHAT CAN HAPPENCould cause changes in ATV handling, which could lead to an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for the ATV.Cargo should be properly distributed and securely attached.Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.Always follow the instructions in this Operator’s Manual for carrying cargo or pull-ing a trailer.


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

! WARNINGPOTENTIAL HAZARDSkidding or sliding.WHAT CAN HAPPENYou may lose control of the ATV.You may also regain traction unexpectedly, which may cause the ATV to overturn.HOW TO AVOID THE HAZARDLearn to safely control skidding or sliding by practicing at slow speeds and onlevel, smooth terrain.On extremely slippery surfaces, such as ice, go slowly and be very cautious inorder to reduce the chance of skidding or sliding out of control.

! WARNINGPOTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of the ATV may causechanges in handling which could lead to an accident.HOW TO AVOID THE HAZARDNever modify the ATV through improper installation or improper use of accesso-ries. All parts and accessories added to this ATV should be genuine ATV compo-nents designed for use on the ATV and should be installed and used according toinstructions. Never install a twist grip throttle. If you have questions, consult anauthorized dealer.

! WARNINGPOTENTIAL HAZARDImproperly operating in reverse.WHAT CAN HAPPENYou could hit an obstacle or person behind you, resulting in serious injury.HOW TO AVOID THE HAZARDBefore you engage reverse gear, make sure there are no obstacles or peoplebehind you. When it is safe to proceed, go slowly.


! 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 public street, road, orhighway, even a dirt or gravel one.In many states it is illegal to operate an ATV on public streets, roads, or highways.

! WARNINGPOTENTIAL HAZARDOperating the ATV with improper tires or with improper or uneven tire pressure.WHAT CAN HAPPENUse of improper tires on the ATV or operation of the ATV with improper or uneventire pressure may cause loss of control increasing your risk of accident.HOW TO AVOID THE HAZARDAlways use the size and type tires specified in this Operator’s Manual for this ATV.Always maintain proper tire pressure as described in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDOperating the ATV through deep or fast flowing water.WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to anaccident.HOW TO AVOID THE HAZARDNever operate the ATV in fast flowing water or in water deeper than the footrests.Remember that wet brakes may have reduced stopping capability.Test your brakes after leaving water. If necessary, apply them several times to dryout the pads.

! WARNINGPOTENTIAL HAZARDApplication of excessive throttle.WHAT CAN HAPPENMay cause wheelies, flip-overs, or loss of controlresulting in serious injury or death.HOW TO AVOID THE HAZARDDo not accelerate rapidly or in an uncontrolled manneron any terrain. Use extra care when going uphill.Slowly apply throttle in a controlled manner. Release throttle lever as necessary tomaintain control.


California Proposition 65

! WARNINGPOTENTIAL HAZARDOperating the ATV with differential lock engaged.WHAT CAN HAPPENThe increased steering effort and reduced maneuverability caused by the lockeddifferential could result in loss of control and an accident.HOW TO AVOID THE HAZARDNever exceed 10 mph (16 km/h) with the differential lock engaged. Always disen-gage the differential lock as soon as not needed for additional traction.

! WARNINGThe Engine Exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects or other reproductive harm.


PreventionOverviewWhen using an ATV, prevention is thename of the game. “Had you onlyknown” something could go wrong, youwould have prevented it. If you don’tnotice your conditions and surroundingsbefore riding your ATV, you give up con-trol over the situation. Using ATV pre-vention techniques helps you forecastpotential hazards before they injure youor damage your ATV.Following the safety instructions andwarnings in this manual will help you“P.A.S.S.” the safety test. P.A.S.S. standsfor “Prevention,” “Active Riding,”“Sound Judgment,” and “Supervision.”Remembering P.A.S.S. and what it standsfor will help you have a safe, predictableride every time you go out on your ATV.

Always wear clothing suited to the typeof riding you are doing. ATV ridingrequires special protective clothingwhich will make you feel more comfort-able and reduce chances of injury.You’ll find it important to dress correctlyfor ATV riding in order to prevent scrapedskin and serious head injuries. It’s easyand could save you time in the long runnot having to contend with an injury. Ofcourse, it also makes sense to rememberthe seasons. Wear a hat under your helmetand a snowmobile suit in the winter andlighter, protective clothing in the summer.The following image shows the minimumprotection you need to wear during everyride:

ATV-0004A

HelmetYour helmet is the most important piece ofprotective gear for safe riding. A helmetcan prevent a severe head injury. Thereare several types of helmets on the market,but make sure you wear a helmet thatcomplies with the current standards of theU.S. Department of Transportation(DOT), The Snell Memorial Foundation,or the American National Standards Insti-tute (ANSI). Helmets that comply withone or more of these agency’s standardshave a sticker on the inside or outside ofthe helmet.

These helmets should provide full-faceprotection.If you drop or damage your helmet, get anew one immediately. Your helmet maynot protect your head from injury if it hascracks, fissures, or other damage to itsoutside or core padding.Remember, your helmet won’t do you anygood if the chin strap isn’t fastened.

Safe Riding Clothing and Gear

Helmets should have one of these:1. DOT label2. Snell label3. ANSI Z90.1 label


GlovesYour hands are targets for flying objectsand branches. Along with providing skinprotection, gloves will shield your handsfrom harsh weather. Wear gloves that areweather resistant and have a gripping sur-face to keep them from sliding off thehandlebars. Off-road style gloves withknuckle pads are the best for comfort andprotection.Boots/Ankle ProtectionWear a boot that covers the largest possi-ble area of your leg (preferably up toyour knee) and can handle significantimpact. Choosing boots with low heelsand a good tread will help prevent yourfeet from slipping off the footrests in wetor rugged conditions or getting hurt ifthey get hit by rocks, dirt, or branches.Eye ProtectionWear eye protection, such as goggles, tocompletely surround your eyes to preventgetting dirt or other items in your eyes.Do not depend on sunglasses for propereye protection. Sunglasses are not recom-mended; they don’t prevent objects fromflying in through the sides.Long Pants and Long Sleeved ShirtThe goal is to protect your body frombranches, long grass, airborne objects, oranything else that could scrape your skin.The more thick and durable the material,the better protection it’ll provide. Ridingpants with kneepads, a jersey, and shoul-der pads provide the best protection.

The second step in Prevention is check-ing the condition of your ATV. Chancesare good that you’ll be using your ATV insome rough terrain, and there’s no wayyou want your brakes to go out when rid-ing downhill. You need to check the fol-lowing parts on your ATV before everyride.

1. Tires and Wheels2. Controls and Cables3. Lights and Electric4. Oil and Fuel

5. Chassis6. Miscellaneous Items

1. Tires and WheelsCorrect tire pressure is crucial. Consultthe ATV Specifications section of thisOperator’s Manual for tire pressureguidelines. Incorrect tire pressure cancause poor handling, instability, and aloss of ATV control.

While checking the tire pressure, inspectthe tread and sidewalls of the tires forcracks, cuts, or other damage that couldindicate they need to be replaced.2. Controls and CablesWith the engine running and brakeapplied, check all transmission posi-tions: forward, neutral, and reverse.

A. BrakesSqueeze the hand brake lever. If it feels softor “squishy,” it could be low on fluid orhave a leak — refer to the General Mainte-nance section of this Operator’s Manual forinstructions. Don’t use the ATV until thebrakes are operating normally.Test the brake lever lock and see if it locksthe hand brake lever into position; thendisengage it to release the brake. Be surethe rear foot brake near the footrest isworking; your brakes could fail during aride if they’re not maintained.

ATV Condition

Check:1. Tire pressure2. Tire surface (tread and sidewalls)

Check:1. Forward2. Neutral3. Reverse

Check:1. Hand brake lever2. Rear foot brake 3. Brake lever lock


B. ThrottleBefore starting the ATV, push the throttlelever several times. The throttle shouldhave a free, smooth range of motion. If itseems to “stick” at any point, refer to theGeneral Maintenance section of thisOperator’s Manual for instructions. Driv-ing your ATV with a sticking throttle canturn your leisurely ride into an unwel-come accident. Don’t drive your ATV ifthe throttle sticks.

3. Lights and ElectricTurn the hi-beam and lo-beam on and offto make sure they work. At the sametime, check that the taillight and brakelight work. Also, check the status/warn-ing indicators (reverse, neutral, and hi-lobeam) on the handlebar when you startthe ATV. Don’t drive the ATV unless allsystems are working. Check the ignitionswitch and emergency stop switch.

4. Oil and FuelStart with a full tank of gas before everyride, and while you’re at it, top off the oil.Don’t forget to check for fluid leaks aroundthe ATV. Watch the overheat indicator toensure the engine coolant level is adequate.

5. ChassisGrass and leaves can gum-up your suspen-sion and shocks. Clear and clean the sus-pension arms, shock springs, and fenders.Check smoothness by turning the handle-bar full-left and full-right. Check that thereis no binding, restrictions, free-play, orlooseness in steering components.

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 anyloose parts, nuts, or bolts.

You need to prepare for the unexpected.Emergencies and accidents are traumaticenough, but they’re even worse whenyou’re not prepared for them. At the min-imum during every ATV ride, you shouldhave the following items on board:

• Tools• Water• Identification• First Aid Kit

For rides that are longer in duration anddistance, the following additional itemsare recommended:

• Cellular Phone• Maps/GPS• Emergency Kit with Flashlight and

First Aid Kit

Check:1. Hi-beam2. Lo-beam3. Taillight/brake light4. Status/warning indicators5. Ignition switch6. Emergency stop switch

Check:1. Free, smooth range of motion

Check:1. Gas2. Oil3. Fluid leaks

First Aid and Survival

Check:1. Suspension arms2. Shock springs3. Fenders4. Steering

Check:1. Air filter2. Battery3. Tighten parts, nuts, and bolts


ToolsRoutine maintenance will generally elim-inate the need for emergency repairs.Riding on rough terrain could cause loos-ening of nuts, bolts, and fasteners. Espe-cially on long rides, carrying the righttools can prevent an inconvenience frombecoming a crisis.

WaterWater is so important that you need tocarry it regardless of the duration of yourride. Heat exhaustion and heat stroke cancreep up suddenly and can take you outof commission. If you become dehy-drated, you could find yourself physi-cally unable to safely operate your ATV.IdentificationIf something does happen to you, theemergency personnel will want to knowwho you are and whom to contact. It’spossible you may be in no condition togive them that information. Put your I.D.in your pocket before you ride. Withoutit, you’re anonymous.

Cellular PhoneIt may be necessary to make an urgentphone call.Maps/GPS (Global Positioning System)Maps may be unnecessary when you’refamiliar with the area. But when you’reriding on unfamiliar trails, it’s good toknow where you are, what’s coming up,and how to get back.Emergency Kit with Flashlight and First Aid KitYou’ll need several items in your emer-gency kit including a flashlight. Thematches will come in handy if you needto start a fire to stay warm. Flares areappropriate for signaling help. A first aidkit is very important if an injury of sometype should happen. A good first aid kitshould include bandages, antisepticspray, gauze, tape, etc.

Carry these items on your ATV:1. Bulbs2. Duct tape3. Rope

4. Spark plugs5. Spare parts6. Tool Kit

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 understanding of howyour body weight, balance, gravity, and physical forces affect the handling of theATV. Knowing how to shift your weight is necessary to avoid rolling or flipping theATV.For complete operating instructions, see ATV Operation sub-section in this manual.


Sound JudgmentOverviewYou are not invincible. Knowing that thefirst “S” in “P.A.S.S.” stands for “SoundJudgment” means you need to use yours.

The environment you operate an ATV inis often harsh and sometimes dangerousif you don’t take proper precautions.WeatherYou need to consider the weather. It isdangerous to ride your ATV when theweather is bad or potentially bad. Keepabreast with weather forecasts.TerrainAlways pay close attention to the terrainyou’re on, even if it is familiar to you.You can’t assume that the landscapeyou’re used to doesn’t change. Changesto landscape can happen at nearly anytime. Fences can be constructed andexcavations dug in a short period of time.Weather, climate, and development taketheir toll. The thing about terrain is that sometimesyou don’t know it’s changed until you getthere. Whether it’s familiar or not, checkout your surroundings before and duringyour ride.Night RidingRiding at night can be very hazardous.Obstacles and other hazards (that are eas-ily identified during daytime) are muchmore difficult to see and avoid. Whennight riding, make sure the lights areproperly adjusted and in good workingorder. Reduce speed; do not over-drivethe headlights. Never travel in an unfa-miliar area or blaze a new trail at night.Always carry a flashlight or flare for sig-naling an emergency.Paved SurfacesAvoid whenever possible. The ATVisn’t designed for pavement. Its han-dling becomes more difficult on pavedsurfaces. If operating on paved surfacesis unavoidable, travel slowly (less than10 mph [16 km/h]) and avoid suddenturns and stops.

Trail RidingUse sound judgment when trail riding;that means riding on a trail that fits yourability level. If the trail is pretty rugged,standing up on your footrests will make iteasier for you to endure the rough terrain.Make yourself visible by using head-lights and taillights, and pull completelyoff the trail if you need to stop.Out-sloped trails (trails that slant to allowrain to run off) make trail riding a bitmore challenging. Keep your weightshifted into the slope. It also helps to know which trails you canlegally ride and who else might be onthose same trails. These are signs cur-rently used in some areas to designatetrail types and restrictions.

ATV-0068A

Environment

Trail Signs


People do all kinds of things that you can’tpredict or control.Riding CompanionsLeave a lot of space between you andother riders, especially in dusty and dirtyconditions, because it’ll be difficult to seethe riders in front of you stopping.Do not carry a passenger on any ATVdesigned for single-rider use. TheseATVs do not have appropriate equipment(hand-holds, footrests, etc) to accommo-date riders. Additionally, the addedweight and weight shift can make thevehicle difficult to control.Other VehiclesDepending on where you’re riding, youmight encounter other ATVs, bikes, ormotor vehicles on public lands. Respectthe presence of cars if you’re crossingroads or riding in public areas and makeyourself be seen. If you can’t see othervehicles coming, that means you’reinvisible, too.HikersWith the renewed interest in hiking,camping, and other outdoor activities,people can show up in remote areaswhere you would never expect them. Fortheir sake, keep your eyes open.Animals and NatureRespect the outdoors that you love. Don’tuse your ATV to chase animals or birds.Drive around young trees rather thanover them. Keep clear of streams andditches with standing water. Tread Lightly and leave it as you found it.

The last thing you expected was that yourATV would break down in the middle ofthe field ... it’s usually so reliable thatsometimes you forget the ATV has itslimits.

ATV MaintenanceYou have to maintain your ATV. TheGeneral Maintenance section of thisOperator’s Manual tells you about takingcare of your ATV. If, at any time, abnor-mal noises, vibrations, or improper func-tioning of any component of this ATV isdetected, DO NOT OPERATE THEATV. Take the ATV to an authorizeddealer for inspection and adjustment orrepair.Cargo LimitationsOne reason why passengers are prohib-ited on ATVs is because their presencethrows off the weight and balance of theATV. Cargo can do the same if it weighstoo much. Limit the ATV to the loadcapacity ratings identified in the follow-ing chart for the particular model beingoperated. So if you’re weighing in at over215 lb (97 kg) when you ride, leave someof that extra cargo at home. The com-bined weight limit, including you, yourrack cargo, and your trailer, is a specifiedamount, so consult the ATV Load Capac-ity Ratings chart and monitor it carefully.Extra weight on the ATV will also throwyou off balance if it’s not distributedevenly, side-to-side and front-to-rear. Ifyou have 160 lb (73 kg) on the rear rackonly and you’re heading up an incline,shifting your own weight forward isn’tgoing to do enough to compensate forthat cargo sitting over the back tires.Cargo has such a huge affect on ATVhandling that you need to pay a lot ofattention to your speed. Even on reallylevel areas, you should keep it under 10mph (16 km/h) if you’ve got a trailerattached. Avoid uneven terrain. Also,consider that your braking distance isgoing to increase with the more weightyou carry.

Those Around You

Equipment

Think about these when dealing with cargo:

1. Rack weight limit2. Trailer weight limit3. Weight distribution 4. ATV speed


Load Capacity Ratings Chart

Maximum Load Capacity — Totalweight of operator, accessories, tongueweight, and cargo on front and rear racks.Tongue Weight — Weight on trailertongue.Rear Rack and Tongue Weight — Totalweight on trailer tongue, SpeedRack, andrear rack.Towing Capacity — Total weight oftrailer and all cargo in the trailer.NOTE: Tongue and accessoryweight (winch, snowplow, SpeedRack,gun scabbard brackets, etc.) must beincluded as part of the front and rearrack weights.SpeedRackWhen installing SpeedRack accessories,read and carefully follow the instructionsprovided in each kit.NOTE: Use extra caution whenoperating an ATV with additionalloads such as accessories and/orcargo. Handling of the ATV may beadversely affected. Reduce speedwhen adding additional loads.

A safe, enjoyable ride is dependent onmany personal choices. An ATV, like allmotorized vehicles, can be dangerous tooperate if you choose to ignore safetyprecautions, take unnecessary chances, orride beyond your ability or your vehicle’scapability. Don’t allow the thrill of free-dom or adventure to affect your ability tomake good, safe choices.Alcohol and Drug ConsumptionIt’s extremely dangerous and often illegalto drink alcoholic beverages and ride.

ITEM Specifications

(lb) (kg)Maximum Load Capacity 515 233Front Rack (max) 100 45Rear Rack (max) 200 91Tongue Weight 35 16Rear Rack and Tongue Weight (max) 200 91

Towing Capacity 1050 477

! WARNINGPOTENTIAL HAZARDOverloading the ATV or carrying or tow-ing cargo improperly.WHAT CAN HAPPENCould cause changes in ATV handling,which could lead to an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacityfor the ATV.Cargo should be properly distributedand securely attached.Reduce speed when carrying cargo orpulling a trailer. Allow greater distancefor braking.Always follow the instructions in thisOperator’s Manual for carrying cargo orpulling a trailer.

Personal Choices

Substances to avoid when riding:1. Alcohol2. Over-the-counter or prescription

drugs3. Illegal/mood altering drugs


Be aware of prescription and over-the-counter medications. Drowsiness andimpaired judgment can be caused by awide variety of medications. The same istrue of allergy, cold, flu, and headachemedications. Your physical size and weightcan’t protect you ... just one antihistaminetablet can affect your judgment.Don’t use alcohol or drugs before orduring your ATV ride.

Your Physical ConditionYour physical condition is critical to safeATV operation. Don’t ride when tiredand consider your health when planninglonger rides.

Reckless RidingWhere excessive or high speed is a fac-tor, the potential for personal injury isgreatly increased. Ride within reason andyour skill level. Avoid maneuvers that arereckless. Don’t show off.Laws and RegulationsAny police officer will tell you that igno-rance of the law is no defense. Your bestdefense is to check out your local, state,or provincial ATV laws before riding.It’ll also make sure that you can continueto ride in your favorite areas. The quick-est way to have a land area closed is byriding over the regulations.

Group BehaviorWhen riding in a group, it is humannature to try to keep up with or out-dothose around you. We can all be competi-tive and that can lead to risk takingresulting in serious injury or equipmentdamage. Know your limitations and don'tbe afraid to slow the pace down.

Alcohol - Effects*The Number of Drinks that Impair

Mental and Physical Abilities1-2 DRINKS

Mental processes such as restraint,awareness, concentration, and judg-ment affected; reaction time slowed;inability to perform complicated tasks.

3-4 DRINKSDepth perception, glare recovery, eyemovement, and focus affected;decreased judgment and control.

5+ DRINKSCoordination deteriorates, loss of criti-cal judgment, and impaired memoryand comprehension.*According to the ATV Safety Institute.

Don’t ride:1. When you’re tired


SupervisionOverviewYou’re responsible for supervising thosewho ride your ATV. Your wisdom is valu-able ... it’ll bring them all back safely —your friends, your family, your relatives,and your ATV. It’s crucial that you con-sider yourself a supervisor for all riders ofyour ATV. Whether you accept responsi-bility or not, the truth is that you areresponsible for others riding your ATV.

You’re to the final “S” in P.A.S.S.:“Supervision.” You’ve just gone throughthe manual, and you’ve seen what’sinvolved. That puts you in a good posi-tion to be confident about what youknow. So now it’s time to use yourknowledge and supervise others who rideyour ATV.

Inexperienced/Untrained RidersYou can’t let people ride your ATV whodon’t know what they’re doing. Unlessthey’ve had over a year of experience withATV riding or taken an ATV trainingcourse, it’s your responsibility to keepthem off your ATV. It can be dangerous(especially for underage children) — allthe more reason for you to be firm.

Experienced/Trained RidersIf anyone is going to borrow your ATV,you are responsible for their supervision.Before they ride, have them take thetraining course, have them watch thesafety video, have Operator’s Manual,and train them.

ATVs are all a little different from thehandling to the stability to the controls.So regardless of how much experienceyour family members have with ATVs,they don’t have experience with yourATV. Let experienced riders get familiarwith your ATV — show them the basicsbefore they take off. You don’t want it onyour conscience that someone got hurtbecause you didn’t tell them how to useyour ATV.Remember that regardless of experi-ence, you should never let anyoneunder the age of 16 operate your ATV.The manufacturer and the ATV SafetyInstitute recommend that all ATV opera-tors ride the appropriate-sized ATVaccording to age.

Taking Responsibility

Category Age (Years)

Speed Limitations

in mph (km/h)

NOTES

Y-10+ 10 or Older

Limited 15 (24)

Maximum 30 (48)


T-14 14 or Older

Limited 20 (32)Limited 30 (48)

Maximum38 (61)


G & S 16 or Older

According to Local

Regulations—


Division II — Operation/MaintenanceSpecifications

Specifications subject to change without notice.

ENGINEType Four-Cycle/Liquid Cooled OHC Bore x Stroke 92 mm x 82 mm (3.62 x 3.22 in.) — 570

102 mm x 85 mm (4.01 x 3.35 in.) — 700Displacement 545 cc (33.6 cu in.) — 570

695 cc (42.4 cu in.) — 700Spark Plug Type NGK CPR8E — 570/700Spark Plug Gap 0.5-0.6 mm (0.019-0.024 in.) — 570/700CHASSISLength (Overall) 211 cm (83.4 in.) Height (Overall) 125.7 cm (49.5 in.) Width (Overall) 123 cm (48.5 in.)Suspension Travel (Front/Rear) 25.4 cm (10 in.)Tire Size (Front) 25 x 8-12 Tire Size (Rear) 25 x 10-12 Tire Inflation Pressure 68.9 kPa (10.0 psi) Brake Type Hydraulic w/Brake Lever Lock and Rear Foot BrakeMISCELLANEOUSDry Weight (Approx.) 333 kg (734 lb) — 570/700Gas Tank Capacity 22.7 L (6 U.S. gal.)Coolant Capacity 3.3 L (3.5 U.S. qt) — 570/700Differential Capacity 275 mL (9.3 fl oz) Rear Drive Capacity 250 mL (8.5 fl oz)Engine Oil Capacity (Approx.) 1.9 L (2.0 U.S. qt) — 570/700Gasoline (Recommended) 87 Octane Regular UnleadedEngine Oil (Recommended) ACX All Weather (Synthetic)Front Differential/Rear Drive Lubricant SAE-Approved 80W-90 HypoidBrake Fluid DOT 4Taillight/Brake Light LEDHeadlight HalogenStarting System Electric

29

Location of Parts and Controls

XR481

XR482

XR484B

XR483

1. Battery 2. Headlights 3. Hand Brake Lever 4. Power Distribution Module 5. Radiator Access Panel 6. Seat Latch 7. Storage Compartment8. Reverse Override Switch 9. Rear Foot Brake

10. Brake Lever Lock11. Key Switch12. Shift Lever13. Throttle Limiter14. Throttle Lever15. DC Power Outlet16. Taillight/Brake Light17. Operator’s Manual Location18. Headlight HI/LO Switch19. Starter Button20. Emergency Stop Switch21. Drive Select Switch22. Winch Switch (if equipped)

NOTE: Your ATV may differ slightlyfrom those shown in this manual.

30

ATV Operation

Active riding and basic maneuvers arethe foundation of your ATV ride. Withoutbasic skills, it’s impossible to move tothis level — active riding. These are yourbasic maneuvers:

• Mounting the ATV• Starting the Engine• Starting a Cold Engine• Shifting• Braking/Stopping• Parking• Dismounting the ATV

Mounting the ATVTo get seated:

1. From the left side, grab the left-sidehandlebar, apply the brake, and putyour 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-sidefootrest.

4. Get seated in a comfortable position.5. Always keep your feet planted on the

footrests.

Starting the EngineAlways start with the ATV on a flat, levelsurface. Carbon monoxide poisoning cankill you, so keep your ATV outside while it’srunning. Follow these steps to start it up:

1. Mount the ATV and sit down.2. Engage the brake lever lock.3. Turn on the ignition.4. Shift into neutral.5. Move the emergency stop switch to

RUN.6. Press the starter button.

7. Let the engine warm up.

Starting a Cold EngineNOTE: It is very important not totouch or compress the throttle leverduring the starting procedures.

1. Turn off all electrical accessories(hand warmer, lights, etc.); thenrotate the ignition switch key to thefirst position (ON) leaving the head-lights OFF. Note that the N is indi-cated on the LCD.

2. Press on the starter button.

NOTE: Do not touch the throttlelever until the engine has run for atleast 3 minutes.

3. Allow the engine to warm up forapproximately 2-3 minutes or until theATV will accelerate without hesitating.

Shifting 1. To engage any gear position from

park, move the shift lever upward tothe desired position. R (reverse), N(neutral), H (high range), or L (lowrange).

Basic Operating Maneuvers

CAUTIONDo not run the starter motor for morethan eight seconds per startingattempt. The starter motor may over-heat causing severe starter motordamage. Allow 15 seconds betweenstarting attempts to allow the startermotor to cool.

CAUTIONDo not run the starter motor for morethan eight seconds per startingattempt. The starter motor may over-heat causing severe starter motordamage. Allow 15 seconds betweenstarting attempts to allow the startermotor to cool.

31

XR004A

2. To engage the P (park), come to acomplete stop; then shift the trans-mission into park.

NOTE: The high range is for nor-mal riding with light loads. The lowrange is for carrying heavy loads ortrailer towing. Compared to HIGHrange, the LOW range position pro-vides slower speed and greatertorque to the wheels.

Braking/StoppingAlways allow plenty of room and time tostop safely. Sometimes quick stops areinevitable, so always be prepared.Whether you’re stopping slowly or stop-ping quickly, do this:

1. Squeeze the brake lever on the lefthandlebar to apply both the front andrear brakes.

2. If your wheels lock, release them fora second; then apply them again.

3. Never “ride” the brake. Even main-taining minimal pressure on the brakelever will cause the brake pads todrag on the disc and may overheat thebrake fluid.

ParkingParking involves following the previousrules for braking; then:

1. After the ATV stops, shift into neutral.2. Stop the engine using the emergency

stop switch.3. Turn off the ignition.4. If you have to park on a hill, shift the

ATV into park.5. Engage the brake lever lock.

Dismounting the ATVAfter you’ve followed the procedure forparking, it’s time to dismount:

1. Double check that the brake leverlock is engaged.

2. Swing your right leg over to the leftside of the seat.

3. Step to the ground on the left side ofthe ATV.

CAUTIONAlways shift into low range when oper-ating on wet or uneven terrain, whentowing or pushing heavy loads, andwhen using a plow. Failure to followthis caution may result in prematureV-belt failure or in damage to relateddrive system components.

CAUTIONAlways come to a complete stop beforeattempting to shift from one range tothe other or into reverse. Always shifton level ground, or engage the brakelever lock before shifting into anotherrange or into reverse.

! WARNINGExcessive repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only approved brake fluid. Neversubstitute or mix different types orgrades of brake fluid. Brake loss canresult. Check brake fluid level andpad wear before each use. Brake losscan result in severe injury or evendeath.

32

Active riding involves moving your body.You must learn to lean and shift yourweight into your turns to maintain control.Your safety depends on using safe ridingtechniques. Statistics from the U.S. Con-sumer Product Safety Commission(CPSC) say that inexperienced riderswho don’t use safe riding techniques are13 times more likely to have an ATVaccident than riders who have more thanone month of experience.Safe riding techniques include:

• Riding• Leaning, Weight Shift, and Balance• Wide Turns• Sharp Turns• K-Turns• Riding Uphill• Riding Downhill• Sidehilling/Traversing• Swerving• Crossing Obstacles

RidingOnce the engine’s warm, the ATV isready to go.

ATV-0012

1. Keep your feet on the footrests andboth hands on the handlebar.

2. Hold the brake lever, and release thebrake lever lock.

3. Shift into gear.4. Release the brake slowly and apply

the throttle.

Leaning, Weight Shift, and BalanceWhen you turn, the trick is to move for-ward and slide over to the side of the seatthat’s on the inside of the turn. Supportyour body weight on the outside footrest.At the same time, lean your body to theinside of the turn. Pay attention to thehandling — if you feel the tires comingoff the ground, reduce speed, shift moreof your body weight to the side that’s lift-ing, and make the turn wider if possible.

ATV-0013

ATV-0024

ATV-0025

Handling the ATV (Active Riding Techniques)

33

Wide TurnsMany ATV accidents happen during turns.If you don’t understand turning techniques,it’s easy for the ATV to get away from youby losing traction, plowing, or tipping. Usethis method for wide turns:

ATV-0046

ATV-0045

ATV-0044

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

2. Use the principles of leaning, weightshifting, and balancing — shift yourbody weight to the inside of the turn.

3. Gradually increase your speed as youcome out of the turn.

Sharp TurnsAfter mastering wide turns, practice theadvanced skill of sharp turns.

ATV-0038

ATV-0039

ATV-0040

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

2. Use the principles of leaning, weightshifting, and balancing — shift yourbody weight to the inside of the turn.

3. You might have to lean into the turnmore than you do in a wide turn.

4. If shifting your weight and balancearen’t enough to keep the ATV tireson the ground, straighten out the han-dlebar as much as you can.

5. Gradually increase your speed as youcome out of the turn.

34

K-TurnsUse K-turns if you accidentally stallwhile riding uphill; you need to takeaction before the ATV rolls backwarddown the hill.

ATV-204

1. Stop where you are, apply the brakes,and shift to neutral.

2. Shut off the engine.3. Keep your body weight shifted for-

ward.

4. Get off the ATV on the uphill side.5. If you’re to the left of the ATV, turn

the handlebar all the way left.6. Partially release the brake, but lightly

hold the brake lever.7. Let the ATV roll to your right side

until it faces slightly downhill.8. Reapply the brakes.9. Get back on the ATV from the uphill

side, and keep your weight shifteduphill when you sit down.

10. Start the engine and follow themethod for riding downhill.

Riding UphillMany accidents happen while riding onhills and as a result of the ATV rolling orflipping. So, obviously, use extreme cau-tion and follow this method for ridinguphill.

ATV-0019

ATV-0032

ATV-0033

35

1. Shift down and accelerate before youstart climbing; then maintain a steadypace.

2. Lean as far forward as possible. Forsteeper hills, come off your seat tostand and lean forward.

3. If you lose speed, release the throttle(so your front tires don’t lift), OR

4. If that doesn’t work and you still haveforward motion and the terrain per-mits, do a U-turn, go back down, andtry climbing again, OR

5. If you have lost all forward motion,follow the K-turn procedure.

NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 25°

Riding DownhillSuccess in riding downhill depends onhow well you know your brakes — takeit easy on them, or you could flip over.

ATV-0018

ATV-0030

ATV-0031

1. Shift your body weight as far back onthe seat as possible.

2. Keep it in a low gear; stay out of neu-tral.

3. Lightly apply the brake and ease upon the throttle.

Sidehilling/TraversingSidehilling is considered an advancedskill; it’s really tricky and unpredictable.So, whether your skills are advanced ornot, try to avoid this kind of riding. Ifyou’re in a situation where you absolutelyhave to sidehill, follow this method:

ATV-0017

ATV-0028

ATV-0029

36

1. Keep your speed low and consistent.2. Shift all your body weight to the

uphill side of the seat; also, supportyour weight on the uphill footrest.

3. Steer like you’re driving into the hill.4. If the ATV feels like it’s tipping, turn

the handlebar downhill. If that’s notpossible because of the terrain orother conditions or if it just doesn’twork, stop and get off. Dismount theATV on the uphill side.

SwervingSwerving is usually an emergency reac-tion to avoid an obstacle.

ATV-0043

1. Ease off the throttle as you approachthe obstacle.

2. Turn the handlebar. At the same time,shift your weight and balance as youswerve. Use the principles of leaning,weight shifting, and balancing —shift your body weight to the inside ofthe turn.

3. Keep your hand off the brake until theemergency is over and you’re back incontrol.

Crossing ObstaclesCrossing obstacles is risky; avoid it ifpossible. Riding over logs, rocks, andruts means combining all the active rid-ing skills into one big motion. Your ATVwill respond differently for differentobstacles (logs, ruts, etc.), but these aregeneral guidelines for overcoming two-track (both tires contacting the obstacle atthe same time) obstacles:

ATV-0016

ATV-0026

ATV-0027

1. Keep your speed way down; less than5 mph (8 km/h).

2. Approach the obstacle head-on.3. Come up off the seat.4. Keep your weight on the footrests.5. Apply a little throttle when the front

tires make contact with the obstacle.6. Lean forward and release the throttle

when the front tires clear the obstacle.

37

7. Keep your body loose to absorb anyshock.

8. If the ATV starts tipping, shift yourweight to keep it in balance.

To clear a single-track (only one tire con-tacts) obstacle, follow the same rulesexcept:

1. Use the ATV’s momentum to clearthe obstacle.

2. Don’t pull up on the handlebar.3. Don’t apply the throttle.

Driving an ATV and a car have somesimilarities; however, there are a few sit-uations that require special attention:

• Reversing• Skidding or Sliding• Parking on a Hill• Stalling on a Hill• Crossing Water• Crossing Roads• Stopping the ATV• Stopping the Engine

ReversingIt’s tough to see things behind you.

1. Go slowly. It’s hard to see behindyou.

2. Keep your handlebar straight.3. Backing down hills is a bad idea; do a

U-turn or K-turn instead to turnaround.

Skidding or SlidingIf you lose control after hitting sand, ice,mud, or water:

1. Turn your handlebar into the directionof the slide.

2. Keep your hand off the brakes untilyou’re out of the skid.

3. Shift your weight forward.Sometimes your ATV may not respondand goes straight ahead instead of lettingyou turn. Here’s how to handle it:

1. Slow down.2. Move forward on the seat.3. Lean to inside of turn.4. Turn handlebar.

Parking on a HillThis shouldn’t be necessary, but if it is:

1. Keep it in gear.2. Engage the brake lever lock.3. Find something to block the rear tires.

Stalling on a HillIf you use the right method for ridinguphill, this shouldn’t happen. But if youhave a problem, do this:

1. If the ATV hasn’t started rollingbackwards yet, follow the procedurefor the K-Turn, OR

2. If the ATV is already rolling back-ward, lean as far forward as possiblestanding up on the footrests.

3. Nice and easy, apply the hand brakelever.

4. When you come to a stop, follow theprocedure for the K-turn.

5. If the ATV continues to roll back-ward, dismount immediately on theuphill side.

Crossing WaterYour ATV can only handle water up to itsfootrests. Any more than that and yourisk engine damage and/or personalinjury. Stay away from fast moving riv-ers. ATV tires can be buoyant, so if thewater is too deep, you might find theATV suddenly afloat.

Tips

! WARNINGNever activate the override while thethrottle is open as a loss of controlmay result. Use caution when usingthe override switch as reverse speedcan greatly increase.

38

1. Physically check the depth and cur-rent of the water, especially if youcan’t see the bottom. You’re alsochecking for boulders, logs, or anyother 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 surethey work.

Crossing RoadsCrossing roads on your ATV is also a badidea, so avoid it. If you can’t:

1. Stop completely on the shoulder ofthe road.

2. Check both directions for traffic.3. Crossing near a blind corner or inter-

section is dangerous; don’t do it.4. Drive straight across to the opposite

shoulder.5. Take into account that your ATV

could stall while crossing; give your-self enough time to get off the road.

6. You have to assume that oncomingcars don’t see you, and if they do,they won’t be able to predict youractions.

7. It’s illegal to cross public roads insome places. Know your local laws.

Stopping the ATVTo stop the ATV, first release the throttlelever. Next, apply the brake.

Stopping the EngineTo stop the engine, turn the ignitionswitch key to the OFF position or set theemergency stop switch to the OFF posi-tion.NOTE: Leaving the ignition switchkey in the ON position could result ina discharged battery.

! WARNINGDo not operate this vehicle on a fro-zen body of water unless you havefirst verified the ice is sufficientlythick to support the vehicle, cargo,and participants. The vehicle couldbreak through the ice causing seri-ous injury or death.

39

General InformationControl Locations and FunctionsIgnition Switch KeyTwo keys come with the ATV. Keep thespare key in a safe place. An identifyingnumber is stamped on each key. Use thisnumber when ordering a replacement key.Ignition SwitchThe ignition switch has three positions.

ATV-0056

OFF position — All electrical circuitsexcept the accessory plug are off. Theengine will not start. The key can beremoved in this position.NOTE: The accessory plug is pow-ered by the battery at all times.ON position — The ignition circuit iscomplete and the engine can run. The keycannot be removed in this position.LIGHTS position — The ignition circuit iscomplete and headlights and taillight are on.The key cannot be removed in this position.

Shift Lever

XR004A

This ATV has a dual-range automatictransmission with reverse and park.Drive Select Switch

XR472_TKR

This switch allows the operator to operatethe ATV in either two-wheel drive (rearwheels) or four-wheel drive (all wheels). Fornormal riding on flat, dry, hard surfaces,two-wheel drive should be sufficient. In sit-uations of aggressive trail conditions, four-wheel drive would be the desired choice.To either engage or disengage the frontwheels, pull the switch toward the rear ofthe vehicle and release. This will togglebetween 4WD and 2WD. The 4WD positionor the 2WD position will be indicated viathe window on the assembly.

CAUTIONLeaving the ignition switch in the ONor LIGHTS position for a long periodof time when the engine is not run-ning may cause the battery to dis-charge. Always leave the ignitionswitch in the OFF position whenengine is not running.

40

Hand Brake Lever/Brake Lever Lock

CF301A

The hand brake is considered to be thenormal operating (main) brake. It shouldbe applied whenever a braking situationis needed.Apply the brake by compressing thebrake lever toward the handlebar.To engage and release the brake leverlock, use the following procedure:

1. Squeeze the hand brake two or threetimes and release it.

2. Depress and hold the brake leverlock.

3. While holding in on the brake leverlock, squeeze the brake lever.

NOTE: It will click as it engagesand the brake lever will not return toits released position.

4. Attempt to push the ATV. Check tomake sure the brake lever lockengages properly and that the brake(when engaged) locks the wheels.

NOTE: The brake lever lock mustlock the wheels. If it doesn’t, take theATV to an authorized dealer for ser-vice.

5. Release the brake lever lock bysqueezing the brake lever. It willreturn to its released position.

Headlight Switch

CF295C

With the ignition switch in the LIGHTSposition, use the headlight switch toselect the high or low headlight beam.

XR071A

Emergency Stop SwitchOFF position — The ignition circuit is off.The engine cannot be started or will notrun. If the emergency stop switch is usedto stop engine without turning off ignitionswitch, the battery may discharge.RUN position — The ignition circuit ison. The engine can start and run.

! WARNINGAlways check to be sure that thebrake lever lock has been disengagedbefore operating the ATV. An accidentcould result if the brake lever lock isleft engaged while the ATV is oper-ated. The brake may relax if leftengaged for a long period of time.This could cause an accident; there-fore, do not leave the ATV on a hilldepending on the brake lever lock.Always block the downhill side of thewheels if leaving the ATV on a hill orpark the ATV in a sidehill position.

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In an emergency, slide the switch to theOFF position to stop the engine. Applythe brakes to stop the wheels.Starter Button Pushing in on this button activates thestarter motor. Before starting the engine,make sure the ignition switch is in theON position, the transmission is in neu-tral, and the brake lever lock is engaged.NOTE: This ATV has safety interlockswitches which prevent the startermotor from activating when the trans-mission is not in neutral. To start theATV while in gear, depress the rearfoot brake or compress the brakelever; then depress the starter button.Reverse Override SwitchThis ATV is equipped with a reversespeed limiter system. When additionalRPM is needed in reverse, depress andhold the override switch.NOTE: The reverse overrideswitch is active in 4WD only.

Throttle Lever

XR068D

Control engine RPM with the position ofthe throttle lever. Operate this lever withthe thumb. Pushing it forward increasesengine RPM and allowing it to retractdecreases engine RPM.

Throttle Limiter Screw

CF297B

Throttle lever travel may be limited byadjusting the throttle limiter screw. The throt-tle limiter should be adjusted according to theoperator’s skill and experience. To adjust thethrottle limiter, use the following procedure:

1. Loosen the jam nut.2. Turn the throttle limiter screw clock-

wise to decrease engine RPM maxi-mum or counterclockwise to increaseengine RPM maximum.

3. Tighten the jam nut securely.NOTE: The ATV is equipped withan RPM limiter that retards ignitiontiming when maximum RPM isapproached. When the RPM limiter isactivated, it could be misinterpretedas a high-speed misfire.Rear Foot Brake Pressing the rear foot brake downwardwill apply the brake to the rear wheels.

Power SteeringCertain ATV models were produced withan Electronic Power Steering (EPS) sys-tem to reduce steering effort and driverfatigue over a broad range of operatingconditions. The EPS system engages when the igni-tion switch is turned to the ON positionand disengages after approximately fiveminutes (to conserve battery power) ifthe engine is not running.This system is entirely maintenance-free:no adjustment or servicing is required.There are no fluids to check or change,and the EPS system is entirely self-con-tained and sealed to protect it from theelements.

! WARNINGNever activate the override switchwhile the throttle is open as a loss ofcontrol may result. Use caution whenusing the override switch as reversespeed can greatly increase.

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The EPS system is battery system pow-ered; therefore, the battery must be ingood condition and fully charged. Powerdelivery and overload protection is pro-vided by an EPS relay and 30-amp fuselocated under the passenger seat in thePower Distribution Module (PDM).The system is self-monitored and willdisplay a malfunction code on the LCDgauge/speedometer should an EPS sys-tem control circuit problem occur. Do notoperate the vehicle with an EPS malfunc-tion code displayed.

NOTE: Turn the key switch to theOFF position then back to the ON posi-tion to reset the malfunction code. Ifthe code continues to be displayed,take your ATV to an authorized dealerfor EPS system servicing beforeresuming operation.

In the event of electrical power failure,the EPS system becomes disabled (simi-lar to an automobile with the engine shutoff). Steering effort increases but steeringcontrol can be maintained.

Speedometer/LCD Gauge

WT103C_TKR

1. Left Button — Shifts top displaythrough speedometer, RPM, and clock.

2. Middle Button — Shifts middle dis-play through speedometer, RPM,clock, odometer, trip 1, trip 2, andengine hours.

3. Right Button — Shifts bottom displaythrough coolant temperature, batteryvoltage, intake air temperature, fuellevel, and tachometer.

Code Fault DescriptionC1301 Over CurrentC1302 Excessive Current ErrorC1303 Torque Sensor Range FaultC1304 Torque Sensor Linearity FaultC1305 Rotor Position EncoderC1306 System Voltage LowC1307 System Voltage HighC1308 Temperature Above 110° CC1309 Temperature Above 120° CC1310 Vehicle Speed HighC1311 Vehicle Speed LowC1312 Vehicle Speed FaultyC1313 Engine RPM HighC1314 Engine RPM LowC1315 Engine RPM FaultyC1316 EEPROM ErrorC1317 CAN Bus ErrorC1318 Internal CRC ErrorC1319 Boot Counter ExceededC1320 Incorrect Vehicle Speed-to-RPM

RatioC1321 Vehicle Speed ErraticC1322 Engine RPM LostC1323 “EPS OFF” Gauge DisplayC1324 Loss of CAN communication with

EPS unitC1325 Dual LossC1326 Rotor Position EncoderC1327 Voltage Converter Error (Low)C1328 Voltage Converter Error (High)C1329 Internal Data Error

CAUTIONNever operate this ATV with an EPScode indicated on the LCD gauge/speedometer. This indicates a mal-function in the EPS system controlcircuit and could result in a loss ofpower steering assist.

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4. Speedometer/Tachometer/Clock Dis-play — Indicates approximate vehiclespeed in MPH or KM/H when speed-ometer function is selected, RPM whentachometer function is selected, or timewhen clock is selected. Press the LeftButton to change which parameter isbeing displayed. With speedometerselected, press and hold the Left Buttonto shift between standard (mph/miles/Fahrenheit) and metric (km/h/kilome-ters/Celsius).To set the clock, use the following pro-cedure:A. With the clock mode selected, press

and hold the Middle Button to setthe clock. Press the Left or RightButton to alternate between 12-hour or 24-hour modes.

B. Press the Middle Button to set thehours. Press the Left button todecrease the hours or the RightButton to increase the hours.

C. Press the Middle Button to set theminutes. Press the Left Button todecrease the minutes or the RightButton to increase the minutes.

D. When the proper time has been set,press the Middle Button to return tothe main gauge display.

5. Engine Hour Meter/Odometer/TripMeter/Speedometer/Tachometer/Clock Display — Displays enginehours, odometer, trip meter, speedom-eter, tachometer, or clock. Press theMiddle Button to change whichparameter is being displayed. TheEngine Hour Meter and Odometercannot be reset. To reset the tripmeter, select the Trip Meter; thenpress and hold the Middle Buttonuntil the trip meter display reads 0.

NOTE: The engine hour meter willnot activate until engine speedexceeds 500 RPM.NOTE: An item can only be dis-played in this position if it is notalready being displayed in the topdisplay. To set the clock when theclock is in this position, press andhold the Middle Button; then use theprocedure found in number 4.

6. Coolant Temperature/Battery Volt-age/Intake Air Temperature/FuelLevel Display — Displays coolanttemperature, battery voltage, intakeair temperature, fuel quantity, andRPM. Press the Right Button tochange which parameter is being dis-played. Press and hold the Right But-ton to see the actual values associatedwith the mode selected.

7. Gear Position Indicator — Indicateswhich gear is selected.

8. EFI Malfunction Indicator — A diag-nostic code (see list below) andengine icon will be displayed on theLCD whenever an EFI error isdetected. The LCD will be normal,but the code and engine icon will con-tinue to be displayed on the LCDuntil the error is corrected.

Diagnostic Trouble Codes

Display Fault DescriptionC0063 Tilt Sensor Circuit HighC0064 Tilt Sensor Circuit Low/SG/OpenC1263 Backup/Reverse-Light Circuit OpenC1264 Backup/Reverse-Light Circuit HighC1265 Backup/Reverse-Light Circuit Low/

SGC1400 Fuel Level Sender OpenC1418 Memory Power FailureP0030 O2 Heater Intermittent/OpenP0031 O2 Heater Low/SGP0032 O2 Heater High/SPP0107 MAP Sensor Circuit Low/SG/OpenP0108 MAP Sensor Circuit High/SPP0112 Intake Air Temp Sensor Circuit Low/

SGP0113 Intake Air Temp Sensor Circuit High/

OpenP0114 Intake Air Temp Sensor Circuit Inter-

mittentP0116 Engine Coolant Temp Sensor Circuit

Range/PerformanceP0117 Engine Coolant Temp Sensor Circuit

Low/SGP0118 Engine Coolant Temp Sensor Circuit

High/Open/SPP0119 Engine Coolant Temp Sensor Circuit

IntermittentP0121 Throttle Position Sensor Range/Per-

formanceP0122 Throttle Position Sensor Circuit Low/

SG

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NOTE: Take the vehicle to anauthorized dealer to have the errorcorrected and the system error resetas soon as possible.Oil Level StickThere is an oil level stick for checkingthe engine oil level. To check the oillevel, use the following procedure:NOTE: The ATV should be on levelground when checking the engine oillevel.

1. Unscrew the oil level stick and wipeit with a clean cloth.

2. Install the oil level stick and threadinto the engine case.

NOTE: The oil level stick shouldbe threaded in for checking pur-poses.

3. Remove the oil level stick; the engineoil level should be within the operatingrange as indicated.

XR075A

P0123 Throttle Position Sensor Circuit HighP0130 O2 Sensor Intermittent/OpenP0131 O2 Sensor Low/SG or Air-LeakP0132 O2 Sensor High/SPP0171 O2 Feedback Below Minimum Cor-

rectionP0172 O2 Feedback Exceeds Maximum

CorrectionP0219 Engine Over-Speed ConditionP0231 Fuel Pump Relay Circuit Low/SG/

OpenP0232 Fuel Pump Relay Circuit HighP0233 Fuel Pump Relay CircuitP0261 Cylinder #1 Fuel injector Circuit Low/

SGP0262 Cylinder #1 Fuel injector Circuit HighP0263 Cylinder #1 Fuel injector Balance/

OpenP0264 Cylinder #2 Fuel injector Circuit Low/

SGP0265 Cylinder #2 Fuel injector Circuit HighP0266 Cylinder #2 Fuel injector Balance/

OpenP0336 Crankshaft Angle Sensor Synchroni-

zationP0337 Crankshaft Angle Sensor Circuit/SGP0339 Crankshaft Angle Sensor Intermittent/

ErraticP0340 Camshaft Angle Sensor Synchroniza-

tionP0341 Camshaft Angle Sensor Circuit/SGP0342 Camshaft Angle Sensor Intermittent/

ErraticP0480 Fan-Primary/Right Relay Control Cir-

cuitP0481 Fan-Secondary/Left Relay Control

Circuit HighP0482 Fan-Secondary/Left Relay Control

Circuit Low/SG/OpenP0483 Fan-Secondary/Left Relay Control

CircuitP0484 Fan-Primary/Right Relay Control Cir-

cuit HighP0485 Fan-Primary/Right Relay Control Cir-

cuit Low/SG/OpenP0500 Vehicle Speed-SensorP0508 Idle Air Control System Circuit Low/

SGP0509 Idle Air Control System Circuit High/

OpenP0520 Engine Oil Sensor/SwitchP0562 System Voltage LowP0563 System Voltage HighP0601 ECM CAN Communication Shutdown

Display Fault DescriptionP0615 Starter Relay CircuitP0616 Starter Relay Circuit LowP0617 Starter Relay Circuit HighP0630 VIN Not Programmed or IncompatibleP0642 Sensor Power Circuit LowP0643 Sensor Power Circuit HighP2300 Ignition Coil #1 Primary Circuit Low/

SG/OpenP2301 Ignition Coil #1 Primary Circuit HighP2303 Ignition Coil #2 Primary Circuit Low/

SG/OpenP2304 Ignition Coil #2 Primary Circuit HighP2531 Ignition Switch Circuit LowP2532 Ignition Switch Circuit HighFUEL OFF

Tilt Sensor Activation Code

Display Fault Description

570/700

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Seat Latch

XR473

1. To remove the seat, lift up on thelatch release (located at the rear of theseat); then raise the rear of the seatand slide it rearward.

2. To lock the seat into position, slidethe front of the seat into the seatretainers and push down firmly on therear of seat. The seat should automat-ically lock into position.

Safety Flag BracketA bracket is provided for mounting a flagat the rear of the ATV.

Rack Loading (Front and Rear)The front rack and rear rack are designedto carry specified load capacities. Alwaysrefer to the ATV Load Capacity Ratingschart for proper capacities.

Trailering and Towing

This vehicle is equipped with a frame-mounted receiver for a standard 5.1 cm(2 in.) receiver hitch. The standardreceiver hitch must be purchased sepa-rately.

XR474

When loading a trailer properly, twoitems are critical: Gross Trailer Weight(the weight of the trailer plus cargo) andTrailer Tongue Weight.

Trailer Tongue Weight is the downwardforce exerted on the hitch by the trailercoupler when the trailer is fully loadedand the coupler is at its normal towingheight. Refer to the Load Capacity Rat-ings chart for tongue weight information.

CAUTIONDo not overfill the engine with oil.Always make sure the oil level iswithin the operating range.

! WARNINGMake sure the seat is secure beforemounting the ATV. Severe personalinjury may result if the seat is notproperly secured.

! WARNINGMake sure the loads on the front andrear racks will not interfere with theATV controls or obstruct the view ofthe operator. Also, make sure theloads are evenly distributed, properlysecured, and will not shift while oper-ating the ATV.

! WARNINGNever use the racks as a towing ortrailering point.

! WARNINGMake sure that the load in the traileris properly secured and will not shiftwhile the ATV is moving. Also, do notoverload the trailer.

! WARNINGNever exceed any of the ATV weightrestrictions.

46

Always maintain a slow speed whentrailering and towing and avoid suddenaccelerations, quick maneuvers, and sud-den stops. Braking distance will beaffected when towing a trailer. Whentowing a trailer, always maintain slowspeed and allow more stopping distancethan when not towing a trailer.

TransportingWhen transporting the ATV, the ATVmust be in its normal operating position(on all four wheels) and the following pro-cedure must be used:

1. Engage the brake lever lock and placethe transmission in park.

2. Secure the ATV with load rated hold-down straps.

NOTE: Suitable hold-down strapsare available from your authorizeddealer. Ordinary rope is not recom-mended because it can stretchunder load.

XR475

XR474A

Gasoline—Oil—LubricantFilling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled toits rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area.Allow the engine to cool before filling thegas tank. Care must be taken not to over-fill the tank. If overfilled, gas may leakonto the engine creating a fire hazard.

! WARNINGRiding an ATV without extra cautionwhen towing a trailer will be hazard-ous. Trailer towing can affect the han-dling and braking of the ATV. Never towa trailer without a rigid tongue andnever exceed 10 mph (16 km/h). Avoidsudden accelerations and stopping ofthe ATV. Do not make quick maneu-vers. Avoid uneven surfaces and donot tow on hills.

! WARNINGNever tow people in or on any deviceexcept when towing a disabled vehi-cle with operable brakes and steeringor on a trailer designed for passen-gers that has a rigid tow bar.

CAUTIONFailure to engage the brake lever lockand place the transmission in parkcould result in the ATV rolling off thetrailer in the event of tie-down strapfailure.

CAUTIONIf using additional hold-down strapsin any other areas, care must betaken not to damage the ATV.

! WARNINGAlways fill the gas tank in a well-ven-tilated area. Never add gasoline to theATV gas tank near any open flames orwith the engine running or hot. DONOT SMOKE while filling the gastank.

! WARNINGDo not over-flow gasoline when fill-ing the gas tank. A fire hazard couldmaterialize. Always allow the engineto cool before filling the gas tank.

47

Tighten the gas tank cap securely afterfilling the tank.Recommended GasolineThe recommended gasoline to use in thisATV is 87 minimum octane regularunleaded. In many areas, oxygenates areadded to the gasoline. Oxygenated gaso-lines containing up to 10% ethanol or 5%methanol are acceptable gasolines.When using ethanol-blended gasoline, it isnot necessary to add a gasoline antifreezesince ethanol will prevent the accumula-tion of moisture in the fuel system.

Recommended Engine/Transmission Oil

The recommended oil to use is ACX AllWeather Synthetic engine oil, which hasbeen specifically formulated for use inthis engine. Although ACX All WeatherSynthetic engine oil is the only oil recom-mended for use in this engine, use of anyAPI-certified SM 0W-40 oil is acceptable.

OILCHARTJ

Recommended Front Differential/Rear Drive Lubricant NOTE: The manufacturer recom-mends the use of genuine lubricants.The recommended lubricant (front differen-tial and rear drive) is SAE-approved 80W-90 hypoid. This lubricant meets all of thelubrication requirements of the ATV.

Engine Break-In After the completion of the break-inperiod, the engine oil and oil filter shouldbe changed. Other maintenance afterbreak-in should include checking of allprescribed adjustments and tightening ofall fasteners. At the discretion andexpense of the owner/operator, the ATVmay be taken to an authorized dealer forthis initial serviceNew ATVs and renewed ATV enginesrequire a “break-in” period. The firstmonth is most critical to the life of thisATV. Proper operation during this break-in period will help ensure maximum lifeand performance from the ATV.During the first 10 hours of operation,always use less than 1/2 throttle. Varyingthe engine RPM during the break-inperiod allows the components to “load”(aiding the engine/transmission compo-nent mating process) and then “unload”(allowing components to cool). Althoughit is essential to place some stress on theengine components during break-in, careshould be taken not to overload theengine too often. Do not pull a trailerduring the break-in period.When the engine starts, allow it to warmup properly. Idle the engine several min-utes until the engine has reached normaloperating temperature. Do not idle theengine for excessively long periods oftime.

! WARNINGDo not overfill the gas tank.

CAUTIONDo not use white gas. Only approvedgasoline additives should be used.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage. Do not use oilswhich contain graphite or molybde-num additives. These oils canadversely affect clutch operation.Also, not recommended are racing,vegetable, non-detergent, and castor-based oils.

CAUTIONAny lubricant used in place of the rec-ommended lubricant could cause seri-ous front differential/rear drive damage.

48

Burnishing Brake PadsBrake pads must be burnished to achievefull braking effectiveness. Braking dis-tance will be extended until brake padsare properly burnished.

To properly burnish the brakes, use fol-lowing procedure:

1. Choose an area sufficiently large tosafely accelerate ATV to 30 mph (48km/h) and to brake to a stop.

2. Accelerate to 30 mph (48 km/h);then compress brake lever to decel-erate to 0-5 mph (0-8 km/h).

3. Repeat procedure 20 times. ! WARNINGFailure to properly burnish the brakepads could lead to premature brakepad wear or brake loss. Brake losscan result in severe injury.

! WARNINGDo not attempt sudden stops or putyourself into a situation where a sud-den stop will be required until thebrake pads are properly burnished.

49

General MaintenanceNOTE: Proper maintenance of theATV is important for optimum perfor-mance. Follow the MaintenanceSchedule and all ensuing maintenanceand care instructions/information.NOTE: Proper maintenance proce-dures for each item can be found onthe corresponding page indicated.

If, at any time, abnormal noises, vibrations,or improper functioning of any componentof this ATV is detected, DO NOT OPER-ATE THE ATV. Take the ATV to an autho-rized dealer for inspection and adjustmentor repair.If the owner/operator does not feel quali-fied to perform any of these maintenanceprocedures or checks, take the ATV to anauthorized dealer for professional ser-vice.

I = Inspect and clean, adjust, lubricate, replace as necessary; T = Tighten; R = Replace; C = Clean* Dealer maintenance ** When using ACX All Weather Synthetic oil, oil change interval can be increased to every 1,000 miles or

every year.

Maintenance Schedule

Item PageInitial

Service (100 miles)

1 month 3 months 6 months

Battery 56 I I* Engine nuts and bolts — I I* Valve clearance — I ISpark plug 58 I I I

58, 29 Replace every 4000 miles or 18 monthsLiquid cooling system 51 I Inspect every time before ridingThrottle cable 52, 59 I Inspect every time before ridingGas Hoses 55 I Inspect every time before ridingEngine/transmission oil and filter 52, 29 R R**Air filter 59 I Inspect every time before ridingAir filter housing drain 60 I Inspect every time before ridingGear lubricant (Front differential/ rear drive)

53, 29 R I53, 29 Replace every 2 years or 2000 miles

V-Belt 60 I ISpark arrester/muffler 61 CTires/air pressure 60, 29 I Inspect every time before riding* Brake components 54 I Inspect every time before ridingBrake fluid 54 I Inspect every time before ridingBrake hoses 54 I Inspect every time before riding* Steering — I Inspect every time before riding* Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) — I Inspect every time before riding* Chassis nuts and bolts — I TFrame/welds/racks — I IElectrical connections — I IHeadlight/taillight-brake light 61 I Inspect every time before ridingWheel nuts 61 I I

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Liquid Cooling SystemNOTE: Debris in front of the engineor packed between the cooling fins ofthe radiator can reduce cooling capa-bility. Using a garden hose, wash theradiator to remove any debris pre-venting air flow.

The cooling system capacity can befound in the specifications chart. Thecooling system should be inspected dailyfor leakage and damage. If leakage ordamage is detected, take the vehicle to anauthorized dealer for service. Also, thecoolant level should be checked periodi-cally.

NOTE: High engine RPM, low vehi-cle speed, or heavy load can raiseengine temperature. Decreasingengine RPM, reducing load, andselecting an appropriate transmis-sion gear can lower the temperature.When filling the cooling system, use acoolant/water mixture which will satisfythe coldest anticipated weather condi-tions of the area in accordance with thecoolant manufacturer’s recommenda-tions. While the cooling system is beingfilled, air pockets may develop; there-fore, run the engine for five minutes afterthe initial fill, shut the engine off, andthen fill the cooling system to the bottomof the stand pipe in the radiator neck.Checking/Filling

1. Remove the rubber access plug fromthe front fender.

XR477

2. Carefully rotate the radiator capcounterclockwise to release pressure;then remove the cap.

XR478

3. Add coolant as necessary; then installthe radiator cap and access plug.

NOTE: Use a good quality, biode-gradable glycol-based, automotive-type antifreeze.

MaintenanceWhen operating in muddy conditions, it isextremely important to clean the radiatorcore frequently. The manufacturerrequires inspecting and/or flushing theradiator core before each use to preventoverheating resulting in severe enginedamage. After cleaning, shine a lightthrough the radiator core while observingfrom the opposite side to determine if alldirt and debris have been removed.

CAUTIONDo not use a pressure washer toclean the radiator core. The pressuremay bend or flatten the fins causingrestricted air flow, and electrical com-ponents on the radiator could bedamaged. Use only a garden hosewith spray nozzle at normal tap pres-sure.

CAUTIONContinued operation of the ATV withhigh engine temperature may resultin engine damage or premature wear.

! WARNINGNever check the coolant level whenthe engine is hot or the cooling sys-tem is under pressure.

CAUTIONAfter operating the ATV for the initial 5-10 minutes, stop the engine, allow theengine to cool down, and check thecoolant level. Add coolant as necessary.

51

NOTE: It is necessary to removefour machine screws securing theprotective screen to the front of theradiator and move it forward to prop-erly flush the radiator core. Makesure to secure the screen to the radi-ator after cleaning.

Shock AbsorbersEach 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 operated inextremely cold weather (-23°C/-10°F orcolder), a small amount of leakage maybe present. Unless the leakage is exces-sive, replacement is not necessary.The shock absorber has a spring forceadjustment sleeve with five adjustmentpositions to allow the spring to be adjustedfor different riding and loading conditions.If the spring action is too soft or too stiff,adjust it according to the chart.

XR063

NOTE: Before attempting to adjustsuspension, clean dirt and debrisfrom the sleeve and remove loadfrom the suspension; then use thespanner wrench to adjust the sleeveto the desired position.

General LubricationCablesNone of the cables require lubrication;however, it is advisable to lubricate theends of the cables periodically with agood cable lubricant. Engine/Transmission Oil and FilterChange the engine oil and oil filter at thescheduled intervals. The engine shouldalways be warm when the oil is changedso the oil will drain easily and completely.

1. Park the ATV on level ground.2. Loosen the oil level stick. Be careful

not to allow contaminates to enter theopening.

XR016A

3. Remove the drain plug from the bot-tom of the engine and drain the oilinto a drain pan.

CAUTIONFailure to remove dirt and debrisfrom the radiator prior to operatingthe ATV may cause overheatingresulting in severe engine damage.

CAUTIONDo not use a pressure washer toclean the radiator core. The pressuremay bend or flatten the fins causingrestricted air flow, and electrical com-ponents on the radiator could bedamaged. Use only a garden hosewith spray nozzle at normal tap pres-sure.

Position Spring Force Setting Load

1

Stronger

Soft

Stiff

Light

Heavy

2

3

4

5

52

733-441A

4. Using the oil filter wrench and a ratchethandle (or a socket or box-end wrench),remove the old oil filter and dispose ofproperly. Do not re-use oil filter.

NOTE: Clean up any excess oilafter removing the filter.

5. Apply oil to the new filter O-ring andcheck to make sure it is positionedcorrectly; then install the new oil fil-ter. Tighten securely.

6. Install the engine drain plug and newgasket; then tighten to 16 ft-lb (21.8N-m). Remove the oil filler plugbeing careful not to let contaminatesenter the opening; then pour ACX AllWeather Synthetic oil in the fillerhole. Install the level stick.

7. Start the engine (while the ATV isoutside on level ground) and allow itto idle for a few minutes.

8. Turn the engine off and wait approxi-mately one minute. Recheck the oillevel.

9. Inspect the area around the drain plugand oil filter for leaks.

Front Differential and Rear Drive Gear Lubricant (Inspecting/Changing)Inspect and change the gear lubricant ineach according to the MaintenanceSchedule. When changing the lubricant,use approved SAE 80W-90 hypoid oiland use the following procedure:

1. Place the ATV on level ground.2. Remove each oil filler plug.3. Drain the oil into a drain pan by remov-

ing in turn the drain plug from each.

XR019A

XR017A

4. After all the oil has been drained,install the drain plugs and new O-rings; then tighten to 45 in.-lb (5 N-m).

5. Pour recommended oil into each fillerhole.

XR022A

NOTE: The manufacturer recom-mends the use of manufacturer-approved lubricants.

6. Install the filler plugs.

CAUTIONInspect the oil for any signs of metalfilings or water. If found, take the ATVto an authorized dealer for servicing.

Front

Rear

53

Hydraulic Hand Brake

Brake FluidCheck the brake fluid level in the brakefluid reservoir. If the level in the reser-voir is not visible in the sight glass, addDOT 4 brake fluid.

CF295A

NOTE: If the sight glass appearsdark, there is a sufficient amount offluid in the reservoir.

Brake Lever LockNOTE: The brake lever lock mustlock the wheels. If it doesn’t, take theATV to an authorized dealer for ser-vice.Brake HosesCarefully inspect the hydraulic brakehoses for cracks or other damage. Iffound, take the ATV to an authorizeddealer to have the brake hoses replaced.Brake PadsThe clearance between the brake padsand brake discs is adjusted automaticallyas the brake pads wear. The only mainte-nance that is required is replacement ofthe brake pads when they show excessivewear. Check the thickness of each of thebrake pads as follows:

1. Remove a front wheel.

2. Measure the thickness of each brakepad.

3. If thickness of either brake pad is lessthan 1.0 mm (0.039 in.), take the ATVto an authorized dealer to have brakepads replaced.

PR376B

4. Install the wheel; then using a criss-cross pattern, tighten the wheel nutsin 20 ft-lb (27.2 N-m) increments toa final torque of 40 ft-lb (54.4 N-m)(steel wheel), 60 ft-lb (81.6 N-m)(aluminum wheel w/black nuts), or80 ft-lb (108.8 N-m) (aluminumwheel w/chrome nuts).

Rear Foot BrakeThe rear foot brake must be maintainedto be fully functional.

1. Check the brake fluid level in the res-ervoir. The fluid level must be main-tained between the MAX and MINlevel marks. If the level in the reser-voir is low, add DOT 4 brake fluid.

XR479

! WARNINGBe sure to inspect the hydraulicbrake system before each use.Always maintain brakes according tothe Maintenance Schedule.

CAUTIONBe careful not to spill any fluid whenfilling the brake fluid reservoir. Wipeaway spilled fluid immediately. ! WARNING

Be sure to inspect the rear foot brakesystem before each use. Alwaysmaintain brakes according to theMaintenance Schedule.

54

NOTE: The brake fluid reservoir islocated in the right rear fender well. 2. Press the rear foot brake several times

to check for firmness. 3. If the brake is not firm, the system

must be bled.NOTE: Take the ATV to an autho-rized dealer for this service.Gas HosesInspect the gas hoses. Damage fromaging may not always be visible.

Protective Rubber BootsThe protective boots should be inspectedperiodically according to the Mainte-nance Schedule.Ball Joint Boots (Upper and Lower/Right and Left)

XR486A

XR487A

1. Secure the ATV on a support stand toelevate the front wheels.

2. Remove both front wheels.3. Inspect the four ball joint boots for

cracks, tears, or perforations.

4. Check the ball joint for free-play bygrasping the steering knuckle andturning it from side to side and up anddown.

5. If boot damage is present or ball jointfree-play seems excessive, contact anauthorized dealer for service.

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

XR057A

1. Secure the ATV on a support stand toelevate 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 andattempting to move it up and down.

5. If boot damage is present or tie rodend free-play seems excessive, con-tact an authorized dealer for service.

Drive Axle Boots

XR488

1. Inspect all drive axle boots for cracks,tears, or perforations.

2. If boot damage is present, contact anauthorized dealer for service.

55

BatteryThe battery is located under the seat.After being in service, batteries requireregular cleaning and recharging in orderto deliver peak performance and maxi-mum service life. The following proce-dures are recommended for cleaning andmaintaining a sealed battery. Always readand follow instructions provided withbattery chargers and battery products.NOTE: Refer to all warnings andcautions provided with the battery orbattery maintainer/charger.Loss of battery charge may be caused byambient temperature, ignition OFF currentdraw, corroded terminals, self discharge,frequent start/stops, and short engine runtimes. Frequent winch usage, snowplow-ing, extended low RPM operation, shorttrips, and high amperage accessory usageare also reasons for battery discharge.Charging/Maintenance Charging NOTE: Use of the CTEK Multi US 800for charging or the CTEK Multi US 3300for battery maintenance charging isrecommended. Maintenance chargingis required on all batteries not used formore than two weeks or as required bybattery drain.

800A

NOTE: When charging a battery inthe vehicle, be sure the ignitionswitch is in the OFF position.

1. Clean the battery terminals with asolution of baking soda and water.

NOTE: The sealing strip shouldNOT be removed and NO fluidshould be added.

2. Be sure the charger and battery are ina well-ventilated area. Be sure thecharger is unplugged from the 110-volt electrical outlet.

3. Connect the red terminal lead fromthe charger to the positive terminal ofthe battery; then connect the blackterminal lead of the charger to thenegative terminal of the battery.

NOTE: Optional battery chargingadapters are available from yourauthorized dealer to connect directlyto your vehicle from the recom-mended chargers to simplify themaintenance charging process.Check with your authorized dealerfor proper installation of thesecharging 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 buttons to push. Ifusing the CTEK Multi US 3300, pressthe Mode button (A) at the left of thecharger until the Maintenance ChargeIcon (B) or Normal Charge Icon (E)at the bottom illuminates. the NormalCharge Indicator (C) should illumi-nate on the upper portion of the bat-tery charger.

3300C

56

NOTE: For optimal charge and per-formance, leave the charger connectedto the battery for a minimum 1 hourafter the Maintenance Charge Indicator(D) illuminates. The maintainer/char-ger will charge the battery to 95%capacity at which time the Mainte-nance Charge Indicator (D) will illu-minate and the maintainer/chargerwill change to pulse/float mainte-nance. If the battery falls below 12.9DC volts, the charger will automati-cally start again at the first step ofthe charge sequence. If the batterybecomes hot to the touch, stopcharging. Resume after it has cooled.NOTE: Not using a battery chargerwith the proper float maintenancewill damage the battery if connectedover extended periods.

6. Once the battery has reached fullcharge, unplug the charger from the110-volt electrical outlet.

NOTE: If, after charging, the bat-tery does not perform to operatorexpectations, bring the battery to anauthorized dealer for further trouble-shooting.Jump-StartingNOTE: Do not jump-start a vehiclewith a dead battery. Instead, removethe battery, service it, and correctlycharge it; however, in an emergency,it may be necessary to jump-start avehicle. If so, use the following pro-cedure to carefully and safely com-plete this procedure:

1. On the vehicle to be jump-started,remove the battery cover and any ter-minal boots.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, orbulging sides. Leaking or bulging bat-tery cases may indicate a frozen orshorted battery.

3. Inspect the vehicle to be used forjump-starting to determine if voltageand ground polarity are compatible.The vehicle must have a 12-volt DC,negative ground electrical system.

4. Move the vehicle to be used for thejump-start close enough to ensure thejumper cables easily reach; then shiftinto neutral, set and lock the brakes,shut off all electrical accessories, andturn the ignition switch OFF.

NOTE: Make sure all switches onthe vehicle to be jump-started areturned OFF.

! WARNINGImproper handling or connecting of abattery may result in severe injuryincluding acid burns, electrical burns,or blindness as a result of an explosion.Always remove rings and watches.

! WARNINGAny time service is performed on abattery, the following must beobserved: keep sparks, open flame,cigarettes, or any other flame away.Always wear safety glasses. Protectskin and clothing when handling abattery. When servicing battery inenclosed space, keep the area well-ventilated. Make sure battery ventingis not obstructed.

! WARNINGIf any of these conditions exist, DONOT attempt a jump-start, boost, orcharge the battery. An explosioncould occur causing serious injury.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electri-cal damage may occur.

57

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive (red)jumper cable to the positive (+) termi-nal (1) of the dead battery (C) beingcareful not to touch any metal with theother clamp; then attach the otherclamp of the positive (red) jumpercable to the positive (+) terminal (2) ofthe good battery (B).

0744-527

NOTE: Some jumper cables maybe the same color but the clamps orends will be color-coded red andblack.

7. Attach one clamp of the negative(black) jumper cable to the negative(-) terminal (3) of the good battery(B); then attach the other clamp of thenegative (black) jumper cable (4) toan unpainted metal surface (A) on theengine or frame well away from thedead battery and fuel system compo-nents.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle to runfor several minutes applying somecharge to the dead battery.

9. Start the vehicle with the dead batteryand allow it to run for several minutesbefore disconnecting the jumper cables.

10. Remove the jumper cables in oppo-site order of hook-up (4, 3, 2, 1). Becareful not to short cables againstbare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the vehicle again.Spark PlugThe ATV comes equipped with a specifiedspark plug. See the specifications chart forthe correct spark plug. To help preventcold weather fouling, make sure to thor-oughly warm up the engine before operat-ing.To maintain a hot, strong spark, keep theplug free of carbon.Before removing the spark plug, be sureto clean the area around the spark plug. Ifyou do not, dirt could enter engine whenremoving or installing the spark plug.

ATV-0051

Adjust the gap to specified amount (seeappropriate specifications chart) forproper ignition. Use a feeler gauge tocheck the gap.

ATV0052B

CAUTIONFailure to disconnect electronicaccessories during jump-startingmay cause system damage due topower spikes.

! WARNINGNever make the final connection to abattery as a spark could ignite hydro-gen gases causing an explosion ofthe battery resulting in acid burns orblindness.

58

A new spark plug should be tightened 1/2turn once the washer contacts the cylin-der head. A used spark plug should betightened 1/8-1/4 turn once the washercontacts the cylinder head.

Throttle Cable AdjustmentTo adjust the throttle cable free-play:

1. Loosen the jam nut from the throttlecable adjuster.

2. Slide the rubber boot away and turn theadjuster until the throttle lever hasproper free-play of 3-6 mm (1/8-1/4 in.).

CF297C

3. Tighten the jam nut against the throt-tle cable adjuster securely; then slidethe rubber boot over the adjuster.

Air FilterThe air filter inside the air filter housingmust be clean to provide good enginepower and gas mileage. If the ATV is usedunder normal conditions, service the filterat the intervals specified in the Mainte-nance Schedule. If operated in dusty, wet,or muddy conditions, inspect and servicethe filter more frequently.

1. Remove the seat; then remove theclips securing the air filter housingcover.

XR002A

2. Loosen the clamp securing the air fil-ter to the inside of the housing; thenremove the filter.

XR029A

3. Carefully remove the pre-filter fromthe air filter. If the air filter is dirty, itmust be replaced.

XR049

4. Using an air hose, clean the pre-filter. 5. Slide the pre-filter over the closed end

of the new filter and install into thehousing. Tighten the clamp securely.

6. Install the air filter housing cover andsecure with the clips.

7. Install the seat.

CAUTIONFailure to inspect the air filter fre-quently if the ATV is used in dusty,wet, or muddy conditions can dam-age the engine.

59

Air Filter Housing DrainInspect the drain beneath the main hous-ing for debris and for proper sealing.

XR489

Draining V-Belt CoverNOTE: If the ATV has been driventhrough water, the V-belt cover mustbe drained of any water.

1. Place the ATV on a level surface.2. Remove the drain bolt from the cover

and allow the water to drain out.

XR014B

XR493_TKR

3. Shift the range lever to the neutralposition; then start the engine.

4. Increase and decrease engine RPMseveral times to “blow out” anywater; then stop the engine.

5. Install the drain bolt and tightensecurely.

NOTE: The V-belt and pulleysshould be inspected every 500 milesand the belt replaced (if necessary).

Tires

Tire Tread ConditionThe use of worn-out tires on an ATV isvery dangerous. A tire is considered to beworn out when the depth of the tread isless than 3 mm (1/8 in.). Be sure toreplace the tires before reaching this min-imum specification.

0732-649

Tire Replacement

The ATV has low-pressure tubeless tires.Have this maintenance performed by aqualified tire repair station.

! WARNINGAlways use the size and type of tiresas specified. Refer to the appropriateSpecifications Chart for proper tireinflation pressure, and always main-tain proper tire inflation pressure.

! WARNINGThe use of worn-out tires can be dan-gerous and can increase the risk ofan accident.

! WARNINGUse only approved tires whenreplacing tires. Failure to do socould result in unstable ATV opera-tion.

60

Tubeless Tire RepairShould a leak or flat tire occur due to apuncture, the tire may be repaired using aplug-type repair. If the damage is from acut or if the puncture cannot be repairedusing a plug, the tire must be replaced.When operating the ATV in areas wheretransportation or service facilities are notreadily available, it is strongly recom-mended to carry a plug-type repair kitand a tire pump along.

Wheels1. Park the ATV on level ground and

engage the brake lever lock.2. Loosen the lug nuts on the wheel to

be removed.3. Elevate the ATV.4. Remove the lug nuts.5. Remove the wheel.6. Install the wheel and install the lug

nuts.7. Install the wheel; then using a criss-

cross pattern, tighten the wheel nutsin 20 ft-lb (27.2 N-m) increments toa final torque of 40 ft-lb (54.4 N-m).

8. Remove the jack.

Muffler/Spark ArresterThe muffler has a spark arrester whichmust be periodically cleaned. At theintervals shown in the MaintenanceSchedule, clean the spark arrester usingthe following procedure.

1. Remove the cap screws securing thespark arrester assembly to the muffler.

CF105A

CF104

2. Using a suitable brush, clean the car-bon deposits from the screen takingcare not to damage the screen.

NOTE: If the screen or gasket isdamaged in any way, it must bereplaced.

3. Install the spark arrester assemblyand secure with the cap screws.Tighten cap screws to 48 in.-lb (5.4N-m).

Light Bulb ReplacementTo replace the headlight bulb, use the fol-lowing procedure:

1. Rotate the back of the headlight bulbcounterclockwise, disconnect the wir-ing harness, and discard the bulb.

XR494A

! WARNINGWait until the muffler cools to avoidburns.

61

2. Connect the new headlight bulb to thewiring harness and insert into head-light assembly. Turn clockwise tosecure the bulb.

To replace the taillight, use the followingprocedure:NOTE: The taillight is a non-ser-viceable component; it must bereplaced as an assembly.

1. Disconnect the wiring harness andremove the three screws securing thetaillight; then discard the taillight.

XR020A

2. Insert the taillight into position andsecure with existing screws. Tightenthe screws securely; then connect thewiring harness.

Checking/Adjusting Headlight AimThe headlights can be adjusted verticallyand horizontally. The geometric center ofthe HIGH beam light zone is to be usedfor vertical and horizontal aiming.

1. Position the ATV on a level floor sothe headlights are approximately 6.1m (20 ft) from an aiming surface(wall or similar aiming surface).

0748-548

NOTE: There should be an averageoperating load on the ATV whenadjusting the headlight aim.

2. Measure the distance from the floor tothe mid-point of each headlight.

3. Using the measurements obtained instep 2, make horizontal marks on theaiming surface.

4. Make vertical marks which intersectthe horizontal marks on the aiming sur-face directly in front of the headlights.

5. Switch on the lights. Make sure theHIGH beam is on. DO NOT USELOW BEAM.

6. Observe each headlight beam aim.Proper aim is when the most intensebeam is centered on the vertical mark 5cm (2 in.) below the horizontal markon the aiming surface.

7. To adjust the headlights, loosen theadjustment knob. After proper adjust-ment is achieved, tighten the knobsecurely.

XR494B

FusesThe fuses are located in a power distribu-tion module on the right side of the ATVbehind the access panel. If there is any typeof electrical system failure, always checkthe fuses first.

XR001

62

NOTE: To remove the fuse, com-press the locking tabs on either sideof the fuse cover and lift out.

4411-131

Electrical Output TerminalsTwo output terminals for electrical acces-sories are located on the front and rearwiring harnesses. The accessory plug islocated on the instrument pod.

Storage Compartment/ToolsA basic tool kit is provided with the ATV.Maintain the tool kit with the ATV at alltimes.

XR002B

The storage compartment is above theengine in front of the seat.

CAUTIONAlways replace a blown fuse with afuse of the same type and rating. Ifthe new fuse blows after a shortperiod of use, consult an authorizeddealer immediately.

CAUTIONAlways use electrical accessoriesless than 180W.

63

Preparation for Storage

The manufacturer recommends the fol-lowing procedure to prepare the ATV forstorage:

1. Clean the seat cushion (cover and base)with a damp cloth and allow to dry.

2. Clean the ATV thoroughly by washingdirt, oil, grass, and other foreign matterfrom the entire ATV. Allow the ATV todry thoroughly. DO NOT get water intoany part of the engine or air intake.

3. Either drain the gas tank or add a fuelstabilizer to the gas in the gas tank.

4. Clean the interior of the air filterhousing.

5. Plug the hole in the exhaust systemwith a clean cloth.

6. Apply light oil to the upper steeringpost bushing and plungers of theshock absorbers.

7. Tighten all nuts, bolts, cap screws,and screws. Make sure rivets holdingcomponents together are tight.Replace all loose rivets. Care must betaken that all calibrated nuts, capscrews, and bolts are tightened tospecifications.

8. Fill the cooling system to the bottomof the stand pipe in the radiator neckwith properly mixed coolant.

9. Disconnect the battery cables (nega-tive cable first); then remove the bat-tery, clean the battery posts andcables, and store in a clean, dry area.

NOTE: For storage, use a batterymaintainer or make sure the batteryis fully charged (see Battery sectionin this manual).10. Store the ATV indoors in a level posi-

tion.

CAUTIONPrior to storing the ATV, it must beproperly serviced to prevent rustingand component deterioration.

CAUTIONAvoid storing outside in direct sun-light and avoid using a plastic coveras moisture will collect on the ATVcausing rusting.

64

Preparation after StorageTaking the ATV out of storage and cor-rectly preparing it will ensure many milesand hours of trouble-free riding. Themanufacturer recommends the followingprocedure to prepare the ATV:

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 ifnecessary.

4. Change the engine/transmission oiland filter.

5. Check the coolant level and add prop-erly mixed coolant as necessary.

6. Charge the battery; then install. Con-nect the battery cables making sure toconnect the positive cable first.

7. Check the entire brake systems (fluidlevel, pads, etc.), all controls, head-lights, taillight, brake light, and head-light aim; adjust or replace if necessary.

8. Check the tire pressure. Inflate to rec-ommended pressure as necessary.

9. Tighten all nuts, bolts, cap screws,and screws making sure all calibratednuts, cap screws, and bolts are tight-ened to specifications.

10. Make sure the steering moves freelyand does not bind.

11. Check the spark plug. Clean orreplace as necessary.

12. Check the air filter and the air filterhousing. Clean or replace as necessary.

CAUTIONBefore installing the battery, makesure the ignition switch is in the OFFposition.

65

Maintenance RecordDATE MILEAGE SERVICE PERFORMED/NOTES

66

Maintenance RecordDATE MILEAGE SERVICE PERFORMED/NOTES

67

Warranty Procedure/Owner ResponsibilityAt the time of sale, an ATV Rider Training Certificate and Owner Registration form is to be completedby the selling dealer and consumer. The receipt of the form by the Company is a condition precedent towarranty coverage. It is the selling dealer’s responsibility to retain and/or submit appropriate copies ofthe form to the appropriate place(s) to initiate warranty coverage.

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

When warranty repair is suspected, the ATV should be taken to the selling dealer, who has the primaryresponsibility to perform warranty repairs. Subject to the limitations set forth in the Limited Warranty, inthe event the selling dealer has ceased to do business, you have moved, or you are in a location awayfrom your selling dealer, warranty may be performed by any authorized dealer.

The authorized dealer will examine the vehicle or part to determine if, in his opinion, a warrantablecondition exists. If a warrantable condition appears to exist, the dealer will repair or replace, at ouroption, free of charge, including any related labor costs, all parts that are found to be warrantable andany other parts which the warrantable part caused to be damaged. You, the owner, will then be askedto sign a warranty form to ensure the Company that the warranty work was actually performed.

It is the owner’s responsibility to maintain and service the vehicle in accordance with this Operator’sManual. To protect yourself and your ATV, follow all safety and service tips. We will NOT warrant non-emissions related repairs required as a result of not performing standard operator maintenance,storage procedures, and service as outlined in the Operator’s Manual.

Should you have any questions concerning the warranty, contact an authorized dealer.

68

U.S. EPA Emission Control Statement/Warranty Coverage (U.S. Only)

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

Your authorized dealer will repair or replace any defective emission-related component at no cost to youduring the warranty period. You may have non-warranty service performed by any repair establishment thatuses equivalent components. The regulations provide significant civil penalties for tampering that causesyour vehicle to no longer meet U.S. EPA emission standards.

Tracker Off Road further warrants that the engine and its emission-related components are free from defectsin materials or workmanship that could cause the engine to fail to comply with applicable regulations duringthe warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contact yourauthorized dealer.

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

COMPONENTS COVEREDI. For exhaust emissions, emission-related components include any engine parts related to the followingsystems:

Air-induction system. Fuel system.Ignition system. Exhaust gas recirculation systems.

II. The following parts are also considered emission-related components for exhaust emissions:Aftertreatment devices. Crankcase ventilation valves.Sensors. Electronic control units.

III. The following parts are considered emission-related components for evaporative emissions:Fuel Tank. Fuel Cap.Fuel Line. Fuel Line Fittings.Clamps*. Pressure Relief Valves*.Control Valves*. Control Solenoids*.Electronic Controls*. Vacuum Control Diaphragms*.Control Cables*. Control Linkages*.Purge Valves. Vapor Hoses.Liquid/Vapor Separator. Carbon Canister.Canister Mounting Brackets. Carburetor Purge Port Connector.

*As related to the evaporative emission control system.

OWNER’S RESPONSIBILITIESThe owner of any vehicle warranted under this Emission Control Statement is responsible for the propermaintenance and use of the vehicle as stated in the Operator's Manual. Proper maintenance generallyincludes replacement and service, at the owner's choosing, such items as air filter, oil and oil filter, or anyother part, item, or device related to emissions control as specified in the Operator's Manual. It is the owner'sresponsibility to ensure that the vehicle is used in a manner for which it was designed.

For U.S. EPA Emission Control Warranty coverage questions, contact Tracker OffRoad at 877-394-6727.

69

California Emission ControlStatement/Warranty Coverage — OHRV

(U.S. Only)

STATEMENT/WARRANTYThe California Air Resources Board is pleased to explain the emission control system warranty on yourOHRV. In California, new off-highway recreational vehicles must be designated, built and equipped tomeet the State's stringent anti-smog standards. Tracker Off Road must warrant the emission controlsystem on your OHRV for the periods of time listed below provided there has been no abuse, neglector improper maintenance of your OHRV.

Your emission control system may include parts such as the carburetor or fuel-injection system, fueltank, fuel hoses, carbon canister, and engine computer. Also included may be hoses, belts, connectorsand other emission-related assemblies. Where a warrantable condition exists, Tracker Off Road willrepair your OHRV at no cost to you including diagnosis, parts and labor.

WARRANTY PERIODFor 30 months, or 2500 miles, or 250 hours, whichever comes first, except for evaporative componentsover the OHRV high-priced warranty value, which are covered for 60 months, or 5000 miles, or 500hours, whichever comes first.

If any emission-related part on your OHRV is defective, the part will be repaired or replaced by Tracker OffRoad.

OWNER’S RESPONSIBILITIESAs the OHRV owner, you are responsible for the performance of the required maintenance listed inyour owner's manual. Tracker Off Road recommends that you retain all receipts covering maintenanceon your OHRV, but Tracker Off Road cannot deny warranty solely for the lack of receipts or for yourfailure to ensure the performance of a scheduled maintenance.

As an owner you are responsible for presenting your OHRV to a Tracker Off Road dealer as soon as aproblem exists. The warranty repairs should be completed in a reasonable amount of time, not toexceed 30 days.

As an OHRV owner, you should also be aware that Tracker Off Road may deny you warranty coverageif your OHRV or a part has failed due to abuse, neglect, improper maintenance or unapprovedmodifications.

If you have any questions regarding your warranty rights and responsibilities, you should contact TrackerOff Road at 877-394-6727 or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA91731.

70

Change of Address, Ownership, or Warranty Transfer

Tracker Off Road keeps on file the current name and address of theowner of this vehicle. This allows us to reach the current owner withany important safety information which may be necessary to protectcustomers from personal injury or property damage. Please make surea copy of this form is completed and returned to us if you move or if thevehicle is sold to another party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty, fill outthis form completely; then return a copy of this form to us. We will thenprocess the application and issue warranty for the balance of the timeremaining of the original warranty. Warranty coverage is only availablein the country in which the original retail purchase occurs to the originalretail purchaser resident in that country or to a transferee resident inthat country of the balance of the remaining warranty.

Address ChangeOwnership Change

Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name _________________________________________Address _______________________________________City/State (Province) ______________________________Zip Code (Postal Code)____________________________Phone ( ) ____________________________________Email __________________________________________Year and Model _________________________________Vehicle Identification Number (VIN) __________________

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CHANGE OF ADDRESS/OWNERSHIP

TRACKER OFF ROAD1451 MARVIN GRIFFIN RDAUGUSTA GA 30906-3852 USA

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Identification Numbers RecordThis ATV has two identification numbers: Vehicle Identification Number (VIN) and EngineSerial 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 or mutilated in any way.Always provide the ATV name, Vehicle Identification Number, and Engine Serial Numberwhen contacting an authorized dealer for parts, service, accessories, or warranty. If a com-plete engine must be replaced, ask the dealer to notify the manufacturer for correct registra-tion information.Record the Vehicle Identification Number and Engine Serial Number in the spaces providedto assist you in ordering parts from your authorized dealer or for reference in case the ATV isstolen.

1. KEY IDENTIFICATION NUMBER:

The key identification number is stampedon the key. Record this number in thespace provided for reference if you everneed a new key.

2. VEHICLE IDENTIFCATION NUMBER:

The VIN is located on the frame supportrail.

3. ENGINE SERIAL NUMBER:

The ESN is located on the left-side rearof the engine crankcase.

XR006A

XR016A

MANUFACTURER INFORMATION:Textron Specialized Vehicles, Inc.1451 Marvin Griffin RoadAugusta, Georgia 30906-3852 USADealer: 800-296-4804Consumer: 877-394-6727www.trackeroffroad.com

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OPERATOR’S MANUAL - TRACKER OFF ROAD · Test your brakes after leaving water. If necessary, apply...

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