Coleman HS500ATV User manual

POWERSPORTS OWNER’S MANUAL
[phone] Coleman Powersports
1775 E. University Dr., Tempe, AZ 85281
colemanpowered.com
No one under the
age of 16 should
operate this ATV
HS500ATV
Model:

Owner Manual

Owner Manual
INTRODUCTION
Congratulations on your purchase of the HS500ATV-4. This Owner’s / Operator’s manual will
provide you information regarding safe operation, operational instructions, maintenance and care.
Fully understanding this manual and following all of the instructions herein will provide the
knowledge needed to have safe and enjoyable ATV operation.
If you have any questions regarding the operation or maintenance of your ATV, please
consult the dealer.
IMPORTANT SAFETY MESSAGES
●READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE
SURE YOU UNDERSTAND ALL INSTRUCTIONS.
●PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
●NEVER OPERATE THE ATV WITHOUT PROPER TRAINING OR INSTRUCTION.
●THIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.

Owner Manual
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. Particularly important information is distinguished in this manual by the
following notations:
The Safety Alert Symbol means ATTENTION!
YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or
death to the machine operator, a bystander or a person inspecting or
repairing the machine.
A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
NOTE:

Owner Manual
IMPORTANT NOTICE
Turning speed must be slower than 30km/h. (19 mph)
This ATV is designed and manufactured for OFF - ROAD use only. It is illegal and unsafe
to operate this ATV on any public street, road or highway.
This ATV complies with all applicable OFF - ROAD noise level and spark arrester laws and
regulations in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
When the temperature is below -20℃ (-4°F), please park the ATV in the place where the
temperature is higher than -20℃ (-4°F). After the ATV has warmed up, the ATV can be started.
Please see page 6-3 on the warming up process.
When the temperature is higher than 38℃ (100°F), and when you park the ATV after it has
ran at high rpms, keep engine running for 3 minutes at idle. This will allow the radiator fan to
work for 3 minutes to prevent coolant from boiling. Once ATV has ran for 3 minutes at idle, turn
ignition switch completely off. When parking the ATV and turning off engine, turn ignition
switch completely off making sure the console meter is turned off. If the ignition switch is not
turned completely off, the console will illuminate and the electric fuel pump in the fuel tank will
continue to work. If the fuel pump runs while the engine is off for a long period of time, it will
result in loss of battery power and the ATV will not start.

Owner Manual
Coleman Limited Warranty
0-1
Location of the Warning and
Specification Labels
1-1
Safety Information
2-1
Description and Vehicle
Identification
3-1
Identification Number Records
3-2
Vehicle Identification Number
3-2
Control Functions
4-1
Main Switch
4-1
Indicator and Warning Lights
4-2
Use of EPS system
4-3
Speedometer Unit
4-5
Clock time adjustment
4-6
Four-wheel drive indicator
4-6
Differential gear lock indicator
4-7
Fault code indicator
4-8
Fuel level indicator
4-8
Handlebar Switches
4-9
Throttle Lever
4-14
Speed Limiter
4-15
Front Brake Lever
4-17
Brake Pedal and Rear Brake
Lever
4-17
Drive Select Lever
4-18
Fuel Tank Cap
4-18
Seat
4-19
Storage Compartment
4-19
Front Carrier
4-20
Rear Carrier
4-21
Front and Rear Shock Absorber
Adjustment
4-21
Auxiliary DC Jack
4-23
Pre Operation Checks
5-1
Front and Rear Brakes
5-2
Fuel
5-4
Engine Oil
5-6
Final Gear Oil
5-6
Differential Gear Oil
5-7
1
2
3
4
5

Owner Manual
Coolant
5-7
Throttle lever
5-8
Fittings and Fasteners
5-8
Lights
5-8
Switches
5-8
Tires
5-9
How to Measure Tire Pressure
5-10
Tire Wear Limit
5-11
Operation
6-1
Starting a Cold Engine
6-1
Starting a Warming Engine
6-2
Warming Up
6-2
Drive Select Lever Operation
and Reverse Driving
6-2
Engine Break-In
6-5
Parking
6-7
Parking on a Slope
6-7
Accessories and Loading
6-8
Your Vehicle
7-1
Driving Your Vehicle
7-1
Ride With Care and Good
Judgment
7-1
Apparel
7-4
Speed Limiter
7-8
Loading and Accessories
7-8
During Operation
7-9
Modifications
7-11
Exhaust System
7-11
Be Careful Where You Ride
7-12
Turning Your ATV
7-18
Climbing Uphill
7-21
Riding Downhill
7-26
Crossing a Slope
7-28
Crossing Through Shallow
Water
7-29
Riding Over Rough Terrain
7-32
Sliding and Skidding
7-33
Periodic Maintenance and
Adjustment
8-1
6
7
8

Owner Manual
Owner’s Manual and Tool Kit
8-1
Periodic Maintenance Chart for
the Emission Control System
8-3
General Maintenance and
Lubrication Chart
8-4
Panel Removal and Installation
8-6
EFI System
8-13
EFI System Inspection
8-17
Engine Oil and Oil Filter
Cartridge
8-17
Final Gear Oil
8-21
Differential Gear Oil
8-23
Cooling System
8-24
Changing the Coolant
8-26
Axle Boots
8-29
Spark Plug Inspection
8-30
Air Filter Elements Cleaning
8-32
Spark Arrester Cleaning
8-35
V-belt Cooling Duct Check Hose
8-36
V-belt Case Drain Plug
8-37
Valve Clearance Adjustment
8-37
Select Lever Safety System
Cable Adjustment
8-38
Throttle Lever Adjustment
8-38
Front Brake Pad Check
8-38
Checking the Rear Brake Pads
8-39
Checking the Brake Fluid Level
8-39
Brake Fluid Replacement
8-41
Front Brake Lever Free Play
8-41
Adjusting the Rear Brake Lever
8-42
Adjusting the Brake Pedal
8-43
Adjusting the Rear Brake Light
Switch
8-44
Cable Inspection and Lubrication
8-45
Lubricating the Brake Levers
and Brake Pedal
8-45
Rear Knuckle Upper and Lower
Pivot Lubrication
8-46
Wheel Removal
8-47
Wheel Installation
8-47
Battery
8-48
Battery Maintenance
8-49

Owner Manual
Fuse Replacement
8-49
Replacing A Headlight Bulb
8-51
Headlight Beam Adjustment
8-53
Tail/Brake Light Bulb
Replacement
8-53
Check and Solution to Common
Problems in Vehicle
8-55
Cleaning and Storage
9-1
Cleaning
9-1
Storage
9-3
Specifications
10-1
Fault code of Electronic
Injection System
11-1
USA EPA Emissions Limited
Warranty
12-1
9
10
11
12

Warranty 0-1
COLEMAN POWERSPORTS LIMITED WARRANTY
This Warranty is NOT the Emissions Control Warranty. Please note this is a general Limited Warranty for this product. It IS
NOT an Emissions Control Warranty. Please see the Emissions Control Warranty in section 12-1 of this manual.
The Warranty
Coleman Powersports Inc., distributor of Coleman ATVs, offers the following warranty to the initial purchaser of this new
Coleman product. The initial purchaser is defined as the first person to purchase a new Coleman ATV from an authorized
retailer of Coleman Powersports.
The limited warranty period for this product is 1 year from the date of purchase shown on the original sales receipt.
What is a defect?
The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 1 year from
the date of purchase shown on the sales receipt. During this period of time Coleman Powersports will, at its option, either
repair or replace any original Coleman Powersports part that is covered by this warranty and is proven to be defective in
workmanship or material.
To qualify for this warranty the part:
1. Must have been purchase from Coleman Powersports or from an authorized Coleman Powersports retailer.
2. This warranty does not apply to any vehicle, which is used in competition or used in a manner not consistent with the
normal and proper intended use for the vehicle. This vehicle is not intended for rental or commercial use.

Warranty 0-2
Who can perform repairs under this warranty?
Repairs under this warranty should be performed by an authorized Coleman Powersports retailer or comparable servicing
dealer.
How to get service under this warranty
To get warranty service call Coleman Powersports at 888-405-8725 or visit www.colemanpowered.com for the location of
your local servicing retailer / dealer. Please do not return the product to the retailer where the product was purchased unless
instructed to do so by Coleman Powersports. The retailer of this product does not make any warranty of its own and has no
authority to implement this warranty on behalf of Coleman Powersports without the approval of Coleman Powersports. A
COPY OF YOUR SALES RECEIPT IS REQUIRED FOR WARRANTY SERVICE.
What this warranty does not cover
This warranty does not cover the following:
1. Damage due to lack or improper maintenance as described in this manual.
2. Damage that is caused by normal use and not caused by a defect in materials or workmanship.
3. Use of the product that is not consistent with the intended use as described in the operating instructions.
4. Any expendable maintenance item which need replacement or service as part of normal maintenance, unless such
items have defects in material or workmanship that cause failure or premature wear.
5. Any product that has been altered or modified in a manner not consistent with the original design of the product or in a
manner not approved by Coleman Powersports.
6. Tires
7. Damage or failures due to abuse, neglect, or misuse of the product.

Warranty 0-3
Limitations of this warranty
This warranty does not cover and Coleman Powersports disclaims any responsibility for:
1. Loss of time or loss of use of the product.
2. Transportation costs to and from the authorized service center.
3. Other loss or damage to other equipment or personal items.
Length of implied warranties
Any implied warranties are limited to the duration set forth in this warranty. Coleman Powersports does not make any claim
as to the merchantability or fitness for a particular purpose that would extend longer than the duration of this written
warranty.
Check your state laws as some state laws do not allow limitations as to the duration of an implied warranty. Some states
may also not allow limitation or exclusions based on incidental or consequential damages.

Location of the Warning and Safety Labels 1-1
LOCATION OF THE WARNING AND SPECIFICATION LABELS
②
⑫
⑪

1-2 Location of the Warning and Safety Labels
Read and understand all of the labels on
your machine. They contain important
information for safe and proper operation of
your ATV.
Never remove any labels from your ATV. If a
label becomes difficult to read or comes off, a
replacement label is available from your
dealer.
①
②
③

Location of the Warning and Safety Labels 1-3
④ ⑤
⑥

1-4 Location of the Warning and Safety Labels
⑦ ⑧

Location of the Warning and Safety Labels 1-5
⑨ ⑩
⑪
⑫

2-1 Safety Information
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles
differently from other vehicles including motorcycles and cars. A collision or rollover can occur
quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if
you fail to take proper precautions.
 SEVERE INJURY OR DEATH can result if you do not follow these instructions:
 Read this manual and all labels carefully and follow the operating procedures described.
 Never operate an ATV without proper training or instruction. Take a Training Course.
Beginners should receive training from a certified instructor.
 Always follow the age recommendation:
A child under 16 years old should never operate an ATV with engine size greater
than 90cc.
 Never allow a child under age 16 to operate an ATV without adult supervision, and never
allow continued use of an ATV by a child if he or she does not have the abilities to operate
it safely.
SAFETY INFORMATION

Safety Information 2-2
 Never operate an ATV without wearing an approved motorcycle helmet that fits properly.
You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved
shirt or jacket, and long pants.
 Never consume alcohol or drugs before or while operating this ATV.
 Never operate at speeds too fast for your skills or the conditions. Always go at a speed that
is proper for the terrain, visibility and operating conditions, and your experience.
 Never attempt wheelies, jumps, or other stunts.
 Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in this
manual.
 Always keep both hands on the handlebars and both feet on the footboards of the ATV
during operation.
 Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert
to changing terrain conditions when operating the ATV.
 Never operate on excessively rough, slippery or loose terrain until you have learned and
practiced the skills necessary to control the ATV on such terrain. Always be especially
cautious on these kinds of terrain.

2-3 Safety Information
 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.
 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 excessively slippery or
loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over
the top of a hill at high speed.
 Always follow proper procedures for going down hills and for braking on hills as described
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 a hill at an angle that
would cause the vehicle to lean sharply to one side. Go straight down the hill where
possible.
 Always follow proper procedures for crossing the side of a hill as described in this manual.
 Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of
the ATV. Never attempt to turn the ATV around on any hill until you have mastered the
turning technique described in this manual on level ground. Avoid crossing the side of a