Massimo 800atv User manual

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INTRODUCTION

Congratulations on your purchase of the 800ATV. It represents the result of many years of

experience in the production of fine sporting, touring, and pace-setting racing machines. With the

purchase of this, you can now appreciate the high degree of craftsmanship and reliability. This

800ATV adopts the EFI system, enjoying the advantages of more power, less emission, higher

reliability.

This manual will provide you with a good basic understanding of the features and operation of

this ATV. This manual includes important safety information. It provides information about special

techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection

procedures. If you have any questions regarding the operation or maintenance of your ATV, please

consult the dealer.

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IMPORTANT SAFETY INSTRUCTIONS:

zREAD THIS MANUAL TOGETHER WITH TIPS CAREFULLY AND COMPLETELY BEFORE

OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.

zPAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.

zNEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION.

zTHIS ATV, AND ANY OTHER ATV OVER 90cc, SHOULD NOT BE RIDDEN BY ANYONE

UNDER 16 YEARS OF AGE.

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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:

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:

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IMPORTANT NOTICE

The turning speed of this ATV should not exceed 25km/h.

This ATV is designed and manufactured 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 check P6-3 on the warming up process.

When the temperature is higher than 38℃(100°F), and when you park the ATV after it runs at

a high speed, please turn off flameout switch firstly, while make the radiator fan still work for at

least 3 minutes, then turn off the power switch to save the battery.

As long as the ATV key switch is on, the oil pump of the EFI system is in working status, which

will consume the storage of the battery. When the battery is short of electricity, the electric start

system would not work. So, if you want to stop ATV working for a long time, please always

keep the key switch off.

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CONTENTS

LOCATION OF THE WARNING AND

SPECIFICATION LABELS…………1-1

SAFETY INFORMATION……………2-1

DESCRIPTION AND MACHINE

IDENTIFICATION…………………3-1

Identification number records………3-2

Vehicle identification number………3-2

EC signs ……………………………3-3

Model label…………………………3-3

CONTROL FUNCTIONS.................. 4-1

Main switch…………………………4-1

Indicator and warning lights…………4-2

Speedometer unit……………………4-5

Clock mode……………………………4-6

Fault code indicator …………………4-6

1 Fuel meter……………………………4-7

Left handlebar switches……………4-7

Throttle lever .................................. 4-13

2 Speed limiter…………………………4-14

Front brake lever……………………4-15

3 rear brake pedal ……………………4-16

Fuel tank cap………………………4-17

Seat …………………………………4-18

Storage box…………………………4-18

Front and rear carrier………………4-19

Front/rear shock absorber

adjustment…………………………4-20

4 Auxiliary DC jack……………………4-21

Steering Lock ………………………4-23

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PRE-OPERATION CHECKS ………5-1

Brake System…………………………5-3

Fuel …………………………………5-4

Gasohol ………………………………5-5

Engine oil…………………………… 5-6

Differential gear oil ………………… 5-7

Coolant………………………………5-7

Throttle lever …………………………5-9

Fittings and fasteners………………5-9

Lights…………………………………5-9

Switches………………………………5-9

Idling…………………………………5-9

Turn-off Switch………………………5-9

Tire……………………………………5-10

How to measure tire pressure……5-11

Tire wear limit………………………5-12

OPERATION…………………………6-1

Starting a cold engine………………6-1

Starting a warm engine………………6-2

5 Warming up …………………………6-2

Engine’s turning off…………………6-2

Recommended procedure of turning off

the engine……………………………6-2

Neutral to Reverse……………………6-4

Braking………………………………6-6

Parking braking………………………6-7

Parking on a slope……………………6-8

ATV brake-in…………………………6-9

Engine brakie-in……………………6-10

Braking system break-in …………6-11

Modifications………………………6-11

Loading ……………………………6-12

HOW TO RIDE YOUR ATV ………7-1

7Getting to know your ATV……………7-1

Ride with care and good

6 judgment ……………………………7-1

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Apparel………………………………7-4

Pre-operation checks………………7-6

Speed limiter…………………………7-6

Loading and accessories……………7-7

During operation……………………7-8

No Attempting to modify your

ATV……………………………………7-9

Modifications……………………….7-10

Exhaust system ……………………7-10

Pay attention to the road

condition……………………………7-11

Turning your ATV …………………7-15

Climbing uphill………………………7-17

Crossing a slope……………………7-18

Riding downhill………………………7-22

Crossing through shallow wat……7-24

Riding over rough terrain…………7-26

Sliding and skidding………………7-27

PERIODIC MAINTENANCE

8AND ADJUSTMENT ………………8-1

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

EFI System……………………………8-5

EFI system examination……………8-8

Engine oil and oil filter………………8-8

Checking the engine oil level ………8-9

Replacing the engine oil

(with or without oil filter cartridge

replacement) ………………………8-10

Final gear oil…………………………8-12

Differential gear oil…………………8-14

Replacing the differential gear oil…8-14

Cooling system……………………8-15

Coolant replacement………………8-17

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Axle boots……………………………8-19

Spark plug inspection………………8-20

Installation……………………………8-21

Air filter element cleaning…………8-22

Spark arrester cleaning……………8-24

V-belt cooling duct check hose……8-26

Valve clearance adjustment…8-26

Select lever safety system cable

adjustment…………………………8-27

Throttle lever adjustment…………8-27

Front/rear brake pad checking……8-27

Brake fluid level checking…………8-28

Brake fluid replacement……………8-29

Front brake lever free play…………8-30

Adjusting the brake lever…………8-31

Adjusting the rear brake light

switch………………………………8-31

Lubricating the park lever and brake

pedal…………………………………8-32

Rear knuckle upper and lower pivot

lubrication……………………………8-34

Wheel removal………………………8-34

Wheel installation…………………8-35

Battery………………………………8-36

Battery maintenance………………8-37

Fuse replacement…………………8-37

Replacing a headlight bulb…………8-38

Headlight beam adjustment………8-40

Tail/brake light bulb replacement…8-40

ATV common fault inspection and

measures table……………………8-42

CLEANING AND STORAGE………9-1

9A. Cleaning …………………………9-1

B. Storage ……………………………9-2

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SPECIFICATIONS…………………10-1

10

EFI system fault code……………11-1

11

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LOCATION OF THE WARNING AND SPECIFICATION LABELS

1-1

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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

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④

⑤

1-3

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1-4

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SAFETY INFORMATION

ATV is a special vehicle, which is different from other vehicles as 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:

zRead this manual and all labels carefully and follow the operating procedures described.

zNever operate an ATV without proper training or instruction. Take a Training Course.

Beginners should receive training from a certified instructor.

zAlways follow the age recommendation:

A child under 16 years old should never operate an ATV with engine size greater than

90cc.

zNever 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.

zNever carry more than one passenger on an ATV.

zNever 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.

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zNever take alcohol or drugs before or while operating this ATV.

zNever 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.

zNever attempt wheelies, jumps, or other stunts.

zAlways inspect your ATV each time when 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.

zAlways keep both hands on the handlebars and both feet on the footboards of the ATV

during operation.

zAlways go slowly and be extra careful when operating on unfamiliar terrain. Always be alert

to changing terrain conditions when operating the ATV.

zNever 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.

zAlways follow proper procedures for turning as described in this manual. Practice turning

at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

zNever operate the ATV on hills too steep for the ATV or operate ATV beyond your control.

Practice on smaller hills before attempting larger hills.

zAlways follow proper procedures for climbing hills as described in this manual. Check the

terrain carefully before you starting up any hill. Never climb hills with excessively slippery

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or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go

over the top of a hill at high speed.

zAlways follow proper procedures for going down hills and for braking on hills as described

in this manual. Check the terrain carefully before you start to go down any hill. Shift your

weight backward. Never go down a hill at a 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. Please carefully brake when necessary, since braking when going down may

easily cause rolling over.

zAlways 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. Avoid crossing the side of a steep hill if

possible.

zAlways use proper procedures if you stall or roll backwards when climbing a hill. To avoid

stalling, use proper gear range and maintain a steady speed when climbing a hill. If you

stall or roll backwards, follow the special procedure for braking described in this manual.

Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and

remount, following the procedure described in this manual.

zAlways check for obstacles before operating in a new area. Never attempt to operate over

large obstacles, such as large rocks or fallen trees. Always follow proper procedures when

operating over obstacles as described in this manual.

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zAlways be careful when skidding or sliding. Learn to safely control skidding or sliding by

practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces,

such as ice, go slowly and be very cautious in order to reduce the chance of skidding or

sliding out of control. NEVER ride your ATV on frozen road.

zNever operate an ATV in fast flowing water or in water deeper than that recommended in

this manual. Remember that wet brakes may reduce the stopping ability. Test your brakes

after leaving water. If necessary, apply them several times to let friction dry out the linings.

zAlways 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.

zAlways use the size and type tires specified in this manual.

zAlways maintain proper tire pressure as described in this manual.

zNever modify an ATV through improper installation or accessories.

zNever exceed the stated load limit for an ATV. Cargo should be properly distributed and

securely attached. Reduce speed and follow instructions in this manual for carrying cargo

or pulling a trailer. Prepare greater distance for braking.

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WARNING

Improper handling of gasoline may cause fire

and you could be burned.

Remember: Always turn off the engine when

refueling. Do not refuel right after the engine

has been stopped which is still very hot.

Do not spill gasoline on the engine or exhaust

pipe/muffler when refueling.

No smoking while refueling.

Never refuel in the vicinity of sparks, open

flames, or other sources of ignition such as

the pilot lights of water heaters and clothes

dryers.

When transporting the ATV in another vehicle,

be sure it is kept position of upright.

Otherwise, fuel may leak out of the fuel tank.

Gasoline is poisonous and can cause injuries.

If you swallow some gasoline or inhale a lot of

gasoline vapor, or get some gasoline in your

eyes, see your doctor immediately. If gasoline

spills on your skin, wash with soap and water.

If gasoline spills on your clothing, change

your clothes.

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WARNING

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may cause

loss of consciousness and death within a short

time.

HOW TO AVOID THE HAZARD

Always operate your ATV in an area with good

ventilation.

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Massimo 800ATV User manual

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