Crossfire HS800ATV-2 Manual

FOREWORD
Brief introduction to maintenance handbook of HS800ATV-2
The handbook is edited by Technical Center of Chongqing Huansong Industries
(Group) Co., Ltd., and is supplied to dealers and technicians as document of technique.
Mainly, the handbook gives methods to check, maintain and repair four wheel
all-terrain vehicles （ATV）, and supplies some relevant technique and performance data.
Some techniques and method inside may be used to check, maintain and repair other
models of ATV, although it is mainly for HS800ATV-2.
Please read the handbook through and fully understand it; otherwise, any improper
repairing and amounting would bring you problems, and accident may occur in your use.
Proper use and maintenance can guarantee ATV being driven safely, reduce its
malfunction, and help the vehicle remain its best performance.
The standards, performances and specifications mentioned in interpretation are
based on the sample in design, and they are subject to changes according to the
product’s improvement without prior notice.
First version , November 15, 2012
Published by Chongqing Huansong Industries (Group) Co., Ltd.
Chongqing Huansong Industries (Group) Co., Ltd holds the copy right.
No publishing and reprinting without permission.

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CONTENT
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION……………………………………………………………………1
WATNINGS, CAUTIONS AND NOTES……………………………………………………1
DESCRIPTION……………………………………………………………………………………2
IDENTIFICATION CODE……………………………………………………………………… 3
Frame No. ………………………………………………………………………………… 3
Engine No. ………………………………………………………………………………… 3
SAFETY ………………………………………………………………………………………… 4
Handing gasoline safely…………………………………………………………………… 4
Cleaning parts……………………………………………………………………………… 5
Warning labels……………………………………………………………………………… 5
SERIAL NUMBERS…………………………………………………………………………… 6
FASTENERS…………………………………………………………………………………… 6
Torque specifications ……………………………………………………………………… 6
Self-locking fasteners……………………………………………………………………… 6
Washers…………………………………………………………………………………… 6
Cotter pins…………………………………………………………………………………… 7
Snap rings and E-clips …………………………………………………………………… 7
SHOP SUPPLIES……………………………………………………………………… 8
Lubricants and Fluids……………………………………………………………………… 8
Engine oils…………………………………………………………………………………… 8
Greases……………………………………………………………………………………… 9
Brake fluid…………………………………………………………………………………… 9
Coolant……………………………………………………………………………………… 9
Cleaners, Degreasers and solvents …………………………………………………… 9
Gasket sealant…………………………………………………………………………… 10
Gasket remover ………………………………………………………………………… 10
Thread locking compound……………………………………………………………… 10
BASIC TOOLS ………………………………………………………………………………… 10
Screwdrivers……………………………………………………………………………… 11

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Wrenches ………………………………………………………………………………… 11
Adjustable wrenches …………………………………………………………………… 12
Socket wrenches, ratchets and handles ……………………………………………… 12
Impact drivers …………………………………………………………………………… 13
Allen wrenches…………………………………………………………………………… 13
Torque wrenches………………………………………………………………………… 14
Torque adapters ………………………………………………………………………… 14
Pliers……………………………………………………………………………………… 15
Snap ring pliers…………………………………………………………………………… 16
Hammers ………………………………………………………………………………… 16
Ignition grounding tool…………………………………………………………………… 16
PRECISION MEASURING TOOLS ………………………………………………………… 17
Feeler gauge ……………………………………………………………………………… 17
Calipers…………………………………………………………………………………… 17
Micrometers……………………………………………………………………………… 18
Adjustment ……………………………………………………………………………… 19
Care ……………………………………………………………………………………… 19
Metric micrometer………………………………………………………………………… 20
Standard inch micrometer……………………………………………………………… 20
Telescoping and small bore gauges…………………………………………………… 21
Dial Indicator……………………………………………………………………………… 22
Compression gauge……………………………………………………………………… 22
Multimeter………………………………………………………………………………… 22
ELECTRICAL SYSTEM FUNDAMENTALS……………………………………………… 23
Voltage …………………………………………………………………………………… 23
Resistance………………………………………………………………………………… 23
Amperage………………………………………………………………………………… 24
BASIC SERVICE METHODS……………………………………………………………… 24
Removing frozen fasteners………………………………………………………………24
Removing broken fasteners ……………………………………………………………25
Repairing damaged threads ……………………………………………………………25
Stud Removal/Installation ………………………………………………………………26
Removing hoses …………………………………………………………………………27
Bearings……………………………………………………………………………………27

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Removal…………………………………………………………………………………… 27
Installation…………………………………………………………………………………28
Interference fit ……………………………………………………………………………29
Seal replacement…………………………………………………………………………30
STORAGE………………………………………………………………………………………31
Storage area selection……………………………………………………………………31
Preparing the motorcycle for storage ……………………………………………………31
Returning the UTV to service……………………………………………………31
TROVBLESHOOTING………………………………………………………………………32
ENGINE PRINCIPLES AND OPERATING REQUIREMENTS…………………………33
STARTING THE ENGINE …………………………………………………………………33
Engine is cold ……………………………………………………………………………33
Engine is warm……………………………………………………………………………33
Starting the engine after a fall or after the engine stalls………………………………34
Flooded engine……………………………………………………………………………34
Engine cold with air temperature ………………………………………………………34
Engine cold with air temperature above 35℃（95°F）………………………………34
Cold engine with air temperature below 10℃(50°F) ………………………………34
Engine is hot………………………………………………………………………………35
Starting the engine after a fall or after the engine stalls………………………………35
Flooded engine……………………………………………………………………………35
ENGINE WILL NOT START ………………………………………………………………36
Identifying the problem …………………………………………………………………36
Spark test…………………………………………………………………………………37
Starter does not turn over or turns over slowly ………………………………………38
POOR ENGINE PERFORMANCE…………………………………………………………38
Engine starts but stalls and is hard to restart……………………………………………38
Engine backfires, cuts out or misfires during acceleration……………………………39
Engine backfires on deceleration………………………………………………………39
Poor fuel mileage…………………………………………………………………………40
Engine will not idle or idles roughly ……………………………………………………40
Low engine power …………………………………………………………………………40
Poor idle or low speed performance……………………………………………………41
Poor high speed performance …………………………………………………………42

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FUEL SYSTEM……………………………………………………………………………… 42
Rich mixture……………………………………………………………………………… 42
Lean mixture……………………………………………………………………………… 43
ENGINE………………………………………………………………………………………… 43
Engine smoke……………………………………………………………………………… 43
Black smoke ……………………………………………………………………………… 43
Blue smoke………………………………………………………………………………… 43
White smoke or steam…………………………………………………………………… 43
Low engine compression ………………………………………………………………… 44
High engine compression ……………………………………………………………… 44
Engine overheating (cooling system) ………………………………………………… 44
Engine overheating (engine)…………………………………………………………… 45
Preignition…………………………………………………………………………………45
Detonation………………………………………………………………………………… 45
Power loss ……………………………………………………………………………… 45
engine noises……………………………………………………………………………… 45
ENGLNE LUBRICATION…………………………………………………………………… 46
HIGH OIL CONSUMPTION OR EXCESSIVE……………………………………………… 46
Exhaust smoke…………………………………………………………………………… 46
Low oil pressure ………………………………………………………………………… 46
High oil pressure ………………………………………………………………………… 47
No oil pressure…………………………………………………………………………… 47
Oil level too low…………………………………………………………………………… 47
Oil contamination………………………………………………………………………… 47
CYLINDER LEAK DOWN TEST…………………………………………………………… 47
ELECTRICAL TESTING…………………………………………………………………… 50
Preliminary checks and precautions …………………………………………………… 50
Intermittent problems…………………………………………………………………… 50
Electrical component replacement ……………………………………………………… 51
Test equipment …………………………………………………………………………… 52
Ammeter …………………………………………………………………………………… 52
Self-powered test light …………………………………………………………………… 52
Ohmmeter ………………………………………………………………………………… 52
Jumper wire……………………………………………………………………………… 53

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TEST PROCEDURES………………………………………………………………………… 54
Voltage test……………………………………………………………………………… 54
Voltage drop test………………………………………………………………………… 54
Peak voltage test………………………………………………………………………… 55
Continuity test……………………………………………………………………………… 55
Testing for a short with a self-powered test light or ohmmeter……………………… 55
Testing for a short with a test light or voltmeter………………………………………… 56
BRAKE SYSTEM……………………………………………………………………………… 56
Soft or spongy brake lever or pedal…………………………………………………… 56
Brake drag………………………………………………………………………………… 57
Hard brake lever or pedal operation…………………………………………………… 58
Brake Grabs……………………………………………………………………………… 58
Brake squeal or chatter ………………………………………………………………… 58
Leaking brake caliper …………………………………………………………………… 58
Leaking master cylinder………………………………………………………………… 59
CHAPTER 2
SPECIFICATIONS
HOW TO USE CONVERSION TABLE OF UNIT…………………………………………… 60
How to use conversion table…………………………………………………………… 60
Definition of unit ………………………………………………………………………… 60
GEBERAR SPECIFICATIONS ……………………………………………………………… 61
ENGINE SPECIFICATIONS ………………………………………………………………… 64
CHASSIS SPECIFICATIONS………………………………………………………………… 70
ELECTRICAL SPECIFICATIONS…………………………………………………………… 72
TIGHTENING TORQUES …………………………………………………………………… 74
Engine tightening torques………………………………………………………………… 74
Chassis tightening torques ……………………………………………………………… 77
GENERAL TIGHTENING TORQUE SPECIFICATIONS ………………………………… 79
LUBRICATION PIONTS AND LUBRICANT TYPES……………………………………… 80
Engine……………………………………………………………………………………… 80
Chassis……………………………………………………………………………………… 81

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HYDROGRAPHIC CHART…………………………………………………………………… 82
LUBRICATION OIL WAY…………………………………………………………………… 83
CHAPTER 3
MAINTENCE AND ADJUSTMENT OF THE ATV
MAINTENANCE SCHEDULE……………………………………………………………… 84
ENGINE
Adjusting the valve clearance…………………………………………………………… 86
Checking the spark plug ………………………………………………………………… 89
Checking the ignition timing……………………………………………………………… 90
Measuring the compression pressure………………………………………………… 91
Checking the engine oil level …………………………………………………………… 92
Changing the engine oil ………………………………………………………………… 93
CHASSIS
Cleaning the air filter………………………………………………………………… 96
Checking the coolant level …………………………………………………………… 97
Changing the coolant…………………………………………………………………… 98
Checking the coolant temperature warning light …………………………………… 101
Checking the v-belt……………………………………………………………………… 102
Cleaning the spark arrester …………………………………………………………… 103
Adjusting the brake pedal……………………………………………………………… 104
Checking the brake fluid level ………………………………………………………… 105
Checking the front brake pads………………………………………………………… 106
Checking the rear brake pads………………………………………………………… 106
Checking the brake hoses and brake pipes………………………………………… 107
Bleeding the hydraulic brake system…………………………………………………107
Adjusting the select lever shift rod …………………………………………………… 109
Checking the final gear oil level ……………………………………………………… 109
Changing the final gear oil……………………………………………………………… 110
Checking the differential gear oil……………………………………………………… 110
Changing the differential gear oil……………………………………………………… 111
Checking the constant velocity joint dust boots……………………………………… 112

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Checking the steering system………………………………………………………… 112
Adjusting the toe-in ……………………………………………………………………… 114
Adjusting the rear shock absorbers…………………………………………………… 115
Checking the tires ……………………………………………………………………… 116
Checking the wheels…………………………………………………………………… 118
Checking and lubricating the cables ………………………………………………… 118
ELECTRICAL
Checking and charging the battery…………………………………………………… 119
Checking the fuses ……………………………………………………………………… 125
Adjusting the headlight beam ………………………………………………………… 127
Changing the headlight bulb …………………………………………………… 127
Changing the tail/brake light bulb …………………………………………………… 128
CHAPTER 4
ENGINE
ENGINE NOTE……………………………………………………………………………… 130
ENGINE REMOVAL………………………………………………………………………… 131
CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 134
ROCKER ARMS AND CAMSHAFT……………………………………………………… 139
VALVES AND VALVE SPRINGS………………………………………………………… 142
CYLINDER AND PISTON………………………………………………………………… 147
ENGINE COOLING FAN AND A.C. MAGNETO ……………………………………… 151
STARTER MOTOR AND OIL FILTER…………………………………………………… 155
PRIMARY AND SECONDARY SHEAVES………………………………………………… 159
CRANKCASE COVER AND OIL PUMP………………………………………………… 163
CRANKCASE AND MIDDLE DRIVEN SHAFT…………………………………………… 167
OUTPUT SHAFT…………………………………………………………………………… 173
GEARCASE………………………………………………………………………………… 177
Shift lever and oil pump………………………………………………………………… 177
Gearcase transmission………………………………………………………………… 179

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CHAPTER 5
CHASSIS
MALFUNCTION INSPECTION…………………………………………………………… 184
STEERING OPERATION SYSTEM……………………………………………………… 187
The structure of steering………………………………………………………………… 187
The steering handle and cable………………………………………………………… 190
The handle switch and lever…………………………………………………………… 191
BRAKE SYSTEM…………………………………………………………………………… 200
Preparation for checking before the maintenance of the brake system …………… 200
Brake system……………………………………………………………………………… 201
Disk brake components ………………………………………………………………… 201
Front brake pads………………………………………………………………………… 203
Front brake caliper……………………………………………………………………… 204
Rear brake caliper (option 1)…………………………………………………………… 211
Rear brake caliper (option 2)…………………………………………………………… 212
FOOTREST ASSEMBLY…………………………………………………………………… 221
WHEEL AND TYRE PARTS ……………………………………………………………… 222
Front wheels……………………………………………………………………………… 222
Rear wheels……………………………………………………………………………… 223
Front and rear wheel rim (different model) …………………………………………… 224
TRANSMISSION SYSTEM ………………………………………………………………… 229
Axle, front wheel………………………………………………………………………… 229
Front bridge……………………………………………………………………………… 230
Axle, rear wheel………………………………………………………………………… 237
Rear bridge ……………………………………………………………………………… 238
REVERSE MECHANISM PARTS………………………………………………………… 243
SUSPENSION ……………………………………………………………………………… 247
Front Suspension and arm …………………………………………………………… 247
Rear suspension ……………………………………………………………………… 252
Rear arm shaft…………………………………………………………………………… 257
COOLING SYSTEM………………………………………………………………………… 257
Water pump……………………………………………………………………………… 262

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SEAT ………………………………………………………………………………………… 269
FUEL TANK………………………………………………………………………………… 272
Fuel tank cover parts …………………………………………………………………… 247
Fuel tank parts…………………………………………………………………………… 252
CHAPTER 6
ELECTRICAL COMPONENTS
ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 277
ELECTRICAL………………………………………………………………………………… 278
ELECTRICALCOMPONENTS……………………………………………………………… 278
IGNITION SYSTEM………………………………………………………………………… 283
Circuit diagram………………………………………………………………………… 283
ELECTRIC STARTING SYSTEM ……………………………………………………… 287
Circuit diagram………………………………………………………………………… 287
STARTER MOTOR………………………………………………………………………… 291
CHARGING SYSTEM……………………………………………………………………… 294
Circuit diagram………………………………………………………………………… 294
LIGHTING SYSTEM………………………………………………………………………… 297
Circuit diagram………………………………………………………………………… 297
SIGNALING SYSTEM……………………………………………………………………… 301
Circuit diagram………………………………………………………………………… 301
COOLING SYSTEM………………………………………………………………………… 313
Circuit diagram…………………………………………………………………………… 313
2WD/4WD SELECTING SYSTEM………………………………………………………… 317
Circuit diagram…………………………………………………………………………… 317
CHAPTER 7
ENGINE MANAGEMENT SYSTEM
INTRODUCTION…………………………………………………………………………… 319

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EMS (Engine Management System) …………………………………………………… 319
Typical Components Of EMS…………………………………………………………… 319
Layout of EMS Components…………………………………………………………… 320
COMPONENTS OF EMS…………………………………………………………………… 321
Electronic Control Unit…………………………………………………………………… 321
Multec 3.5 Injectors……………………………………………………………………… 322
Throttle Body Assembly(with stepper motor) ………………………………………… 326
Engine Coolant Temperature Sensor………………………………………………… 327
Intake Air Pressure and Temperature Sensor………………………………………… 328
Ignition Coil……………………………………………………………………………… 329
Fuel Pump Module……………………………………………………………………… 333
EMS FAULT DIAGNOSIS………………………………………………………………… 339
EME Fault Diagnosis…………………………………………………………………… 339
Fault code list…………………………………………………………………………… 339
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING………………………………………………… 341
Fuel system ……………………………………………………………………………… 341
Electrical system ………………………………………………………………………… 341
Compression system …………………………………………………………………… 342
POOR IDLE SPEED PERFORMANCE ………………………………………………… 342
Poor idle speed performance…………………………………………………………… 342
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… 342
Poor medium and high-speed performance………………………………………… 342
FAULTY GEAR SHIFTING………………………………………………………………… 343
Shift lever does not move ……………………………………………………………… 343
Jumps out of gear……………………………………………………………………… 343
OVERHEATING……………………………………………………………………………… 343
Overheating……………………………………………………………………………… 343
FAULTY BRAKE…………………………………………………………………………… 344
Poor braking effect……………………………………………………………………… 344
SHOCK ABSORBER MALFUNCTION………………………………………………… 344

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Malfunction ……………………………………………………………………………… 344
UNSTABLE HANDLING…………………………………………………………………… 344
Unstable handling ……………………………………………………………………… 344
LIGHTING SYSTEM………………………………………………………………………… 345
Head light is out of work………………………………………………………………… 345
Bulb burnt out…………………………………………………………………………… 345
CHAPTER 9
HS800ATV-2 WIRING DIAGRAM
HS800ATV-2 WIRING DIAGRAM………………………………………………………… 346
HS800ATV-2 WIRING EFI DIAGRAM…………………………………………………… 347

GENERALINFORMATION
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GENERAL INFORMATION
The text provides complete information on maintenance，tune-up repair and overhaul，Hundreds of
photographs and illustrations created during the complete disassembly of four wheel all-terrain
vehicles (ATV) guide the reader through every job，All procedures are in step-by-step format and
designed for the reader who may be working on the ATV for the first time.
WARNINGS, CAUTIONS AND NOTES
The terms WARNING, CAUTION and NOTE have specific meaning in this manual.
WARNING: emphasizes areas where injury or even death could result from negligence.
Mechanical damage may also occur. WARNINGS are to be taken seriously.
CAUTION: emphasizes areas where equipment damage could result. Disregarding a
CAUTION could cause permanent mechanical damage. though injury is unlikely.
NOTE: provides additional information to make a step or procedure easier or clearer.
Disregarding a NOTE could cause inconvenience. but would not cause
equipment damage or injury.

GENERALINFORMATION
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DESCRIPTION
1. Headlights
2. Radiator part
3. Shock absorber comp
4. Meter
5. Left handle bar
6. Air filter
7. Front seat
8. Rear seat
9. Back rest
10. Carrier
11. Rear bumper
12. Front bumper
13. Front carrier
14. Front sundry box
15. Ignition switch
16. Auxiliary dc plug
17. Steering bar part
18. Gearshift bracket
19. Range gear shift lever
20. Fuel tank cap
21. Rear shock absorber comp
22. Rear sundry box
23. Rear turning light
24. Taillight comp
NOTE:
The vehicle you have purchased may differ slightly from those in the figures
of this manual.

GENERALINFORMATION
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IDENTIFICATION CODE
Frame No.
Frame No. is carved on the right of the rear
frame
Engine No.
Engine NO. Is carved on the right side of the
engine, Figure.

GENERALINFORMATION
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SAFETY
Professional mechanics can work for years and never sustain a serous injury or mishap. Follow
these guidelines and practice common sense to safely service the utility terrain venires.
1. Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain
carbon monoxide. an odorless, colorless and tasteless poisonous gas. Carbon monoxide levels
build quickly in small enclosed areas and can cause unconsciousness and death in a short time.
Make sure to properly ventilate the work area or operate the ATV side.
2. Never use gasoline or any extremely flammable liquid to clean parts. Refer to cleaning parts and
handling Gasoline Safely in this section.
3. Never smoke or use a torch in the vicinity of flammable liquids, such as gasoline or cleaning
solvent.
4. If welding or brazing on the ATV the fuel tank to a safe distance at least 50ft.(15m) away.
5. Use the correct type and size of tools to avoid damaging fasteners.
6. Keep tools clean and in good condition. Replace or repair worn or damaged equipment.
7. When loosening a tight fastener, be guided by what would happen if the tool slips.
8. When replacing fasteners, make sure the new fasteners are the same size and strength as the
original ones.
9. Keep the work area clean and organized.
10. Wear eye protection anytime the safety of the eyes is in question. This includes procedures that
involve drilling, grinding, hammering, compressed air and chemicals.
11. Wear the correct clothing for the job. Tie up or cover long hair so it does not get caught in moving
equipment.
12. Do not carry sharp tools in clothing pockets.
13. Always have an approved fire extinguisher available. Make sure it is rated for gasoline (Class B)
and electrical (Class C) fires.
14. Do not use compressed air to clean clothes, the ATV or the work area. Debris may be blown into
the eyes or skin. Never direct compressed air at anyone. Do not allow children to use or play with
any compressed air equipment.
15. When using compressed air to dry rotating parts, hold the part so it does not rotate. Do not allow
the force of the air to spin the part. The air jet is capable of rotating parts at extreme speed. The
part may disintegrate of become damaged, causing serious injury.
16. Do not inhale the dust created by brake pad and clutch wear. These particles may contain
asbestos. In addition, some types of insulating materials and gaskets may contain asbestos.
Inhaling asbestos particles is hazardous to one’s health.
17. Never work on the ATV while someone is working under it.
Handling Gasoline Safely
Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop.
Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel
for gasoline internal combustion engines. Keep in mind when working on the machine, gasoline is

GENERALINFORMATION
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always present in the fuel tank, fuel line and carburetor. To avoid a disastrous accident when
working around the fuel system, carefully observe the following precautions:
1. Never use gasoline to clean parts. Refer to Cleaning Parts in this section.
2. When working of the fuel system, work outside or in a well-ventilated area.
3. Do not add fuel to the fuel tank or service the fuel system while the ATV is near open flames,
sparks or where someone is smoking .Gasoline vapor is heavier than air, it collects in low areas
and is more easily ignited than liquid gasoline.
4. Allow the engine to cool completely before working on any fuel system component.
5. Do not store gasoline in glass containers. If the glass breaks, a serious explosion of fire may
occur.
6. Immediately wipe up spilled gasoline with rags. Store the rags in a metal container with a lid until
they can be properly disposed of, or place them outside in a safe place for the fuel to evaporate.
7. Do not pour water onto a gasoline fire. Water spreads the fire and makes it more difficult to put out.
Use a class B, BC or ABC fire extinguisher to extinguish the fire.
8. Always turn off the engine before refueling. Do not spill fuel onto the engine or exhaust system.
Do not overfill the fuel tank. Leave an air space at the top of the tank to allow room for the fuel to
expand due to temperature fluctuations.
Cleaning Parts
Cleaning parts is one of the more tedious and difficult service jobs performed in the home garage.
Many types of chemical cleaners and solvents are available for shop use. Most are poisonous and
extremely flammable. To prevent chemical exposure, vapor buildup, fire and serious injury, observe
each product warning label and note the following:
1. Read and observe the entire product label before using any chemical. Always know what type of
chemical is being used and whether it is poisonous and/or flammable.
2. Do not use more than one type of cleaning solvent at a time. If mixing chemicals is required,
measure the proper amounts according to the manufacturer.
3. Work in a well-ventilated area.
4. Wear chemical-resistant gloves.
5. Wear safety glasses.
6. Wear a vapor respirator if the instructions call for it.
7. Wash hands and arms thoroughly after cleaning parts.
8. Keep chemical products away from children and pets.
9. Thoroughly clean all oil, grease and cleaner residue from any part that must be heated.
10. Use a nylon brush when cleaning parts. Metal brushes may cause a spark.
11. When using a parts washer, only use the solvent recommended by the manufacturer. Make sure
the parts washer is equipped with a metal lid that will lower in case of fire.
Warning Labels
Most manufacturers attach information and warning labels to the ATV. These labels contain
instructions that are important to personal safety when operating, servicing, transporting and storing
the ATV. Refer to the owner’s manual for the description and location of labels. Order replacement
labels from the manufacturer if they are missing or damaged.

GENERALINFORMATION
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SERIAL NUMBERS
Serial and identification numbers are stamped on various locations on the frame, engine and
carburetor body. Record these numbers in the Quick Reference Data section in the front of the manual.
Have these numbers available when ordering parts.
FASTENERS
Proper fastener selection and installation is important to ensure the motorcycle operates as
designed and can be serviced efficiently. The choice of original equipment fasteners is not arrived at
by chance. Make sure replacement fasteners meet all the same requirements as the originals
Many screws. Bolts and studs are combined with nuts to secure particular components. to indicate
the size of a nut. Manufactures specify the internal diameter and the thread pitch
The measurement across two flats on a nut or bolt indicates the wrench size
WARNING
Do not install fasteners with a strength
classification lower than what was originally
installed by the manufacturer doing so may cause
equipment failure and or damage
Torque Specifications
The material used in the manufacturing of the ATV may be subjected to uneven stresses if the
fasteners of the various subassemblies are not installed and tightened correctly. Fasteners that are
improperly installed or work loose can cause extensive damage. it is essential to use an accurate
torque wrench as described in this chapter
Self-Locking Fasteners
Several types of bolts. Screws and nuts incorporate a system that creates interference between
the two fasteners. Interference is achieved in various ways. The most common types are the nylon
insert nut and a dry adhesive coating on the threads of a blot.
Self-locking fasteners offer greater holding strength than standard fasteners, which improves their
resistance to vibration.All self-locking fasteners cannot be reused. The materials used to from the lock
become distorted after the initial installation and removal. Discard and replace self-locking fasteners
after removing them. Do not replace self-locking fasteners with standard fasteners.
Washers
The two basic types of washers are flat washers and lock washers. Flat washers are simple discs
with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose.
Washers can be used as spacers and seals. Or can help distribute fastener load and prevent the
fastener from damaging the component

GENERALINFORMATION
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As with fasteners. When replacing washers make sure the replacement washers are of the same
design and quality
Cotter Pins
A cotter pin is a split metal pin inserted into a hole or slot to prevent a fastener from loosening. In
certain applications, such as the rear axle on an ATV or motorcycle, the fastener must be secured in
this way. For these applications. A cotter pin and castellated (slotted) nut is used.
To use a cotter pin, first make sure the diameter is correct for the hole in the fastener. Aster
correctly tightening the fastener and aligning the holes, insert the cotter pin through the hole and bend
the ends over the fastener, Unless instructed to do so, never loosen a tightened fastener to align the
holes. If the holes do not align. Tighten the fastener enough to achieve alignment
Cotter pins are available in various diameters and lengths. Measure the length from the bottom of
the head to the tip of the shortest pin
Snap Rings and E-clips
Snap rings (Figure 1) are circular-shaped metal
retaining clips. They secure parts in place on parts
such as shafts. External type snap rings are used to
retain items on shafts. Internal type snap rings secure
parts within housing bores. In some applications. in
addition to securing the component(s). snap rings of
varying thicknesses also determine endplay. These
are usually called selective snap rings.
The two basic types of snap rings are machined
and stamped snap rings. Machined snap rings (Figure
2) can be installed in either direction. Because both
faces have sharp edges. Stamped snap rings (Figure
3) are manufactured with a sharp and a round edge.
When installing a stamped snap ring in a thrust
application, install the sharp edge facing away from
the part producing the thrust.
E-clips are used when it is not practical to use a
snap ring. Remove E-clips with a flat blade
screwdriver by prying between the shaft and E-clip. To
install an E-clip. Center it over the shaft groove and
push or tap it into place
Observe the following when installing snap rings:
1. Remove and install snap rings with snap rings
pliers. Refer to Basic Tools in this chapter
2. In some applications. it may be necessary to
replace snap rings after removing them

GENERALINFORMATION
- 8 -
3. Compress or expand snap rings only enough to install them. If overly expanded. Lose their
retaining ability
4. After installing a snap ring. Make sure it seats completely
5. Wear eye protection when removing and installing snap rings
SHOP SIPPLIES
Lubricants and Fluids
Periodic lubrication help ensure a long service life for any type of equipment. Using the correct
type of lubricant is as important as performing the lubrication service. Although in an emergency the
wrong type is better than not using one, The following section describes the types of lubricants most
often required. Make sure to follow the manufacturer’s recommendations for lubricant types
Engine oils
Engine oil for four-stroke the ATV engine use is classified by two standards: the American
Petroleum Institute (API) service classification. The Society of Automotive Engineers (SAE) viscosity
rating Standard classification
The API and SAE information is on all oil container labels. Two letters indicate the API service
classification. The number or sequence of numbers and letter (10W-40SG for example) is the oil’s
viscosity rating. The API service classification and the SAE viscosity index are not indications of oil
quality.
The APL service classification standards, The first letter in the classification S indicates that the oil
is for gasoline engines. The second letter indicates the standard the oil satisfies .
The classifications are: MA (high friction applications) and MB( low frication applications).
NOTE
Refer to Engine Oil and Filter in
Chapter Three for further information
on API, SAE classifications.
Always use an oil with a classification recommended by the manufacturer, Using an oil with a
different classification can cause engine damage.
Viscosity is an indication of the oil’s thickness. Thin oils have a lower number while thick oil have a
higher number. Engine oils fall into the 5-to50-weight range for single-grade oils.
Most manufactures recommend multi-grade oil. These oils perform efficiently across a wide
range of operating conditions. Multi-grade oils are identified by a W after the first number, which
indicates the low-temperature viscosity.
Engine oils are most commonly mineral (petroleum) based, but synthetic and semi-synthetic types
are used more frequently. When selecting engine oil, follow the manufacturer’s recommendation for
type, classification and viscosity.