ATV700 700EFI T3 Owner's Manual

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ATV-700/700EFI T3 OWNER’S MANUAL

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FOREWORD

May we, the manufacturer, take this opportunity to thank you for choosing our ATV-700 to

serve you.

This Owner’s Manual is prepared for you to properly operate in safety. It also includes

information about the general care and maintenance of your ATV-700. Therefore, we would

like you to read the manual before operating the vehicle.

It is our sincere wish that you enjoy operating the ATV-700 and receive fun from it. Should you

have any problems, please feel free to contact our local dealer in your area.

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CONTENTS

Page

Foreword --------------------------------------------------------------------------------------------------------- 1

Contents ---------------------------------------------------------------------------------------------------------- 2

Operation Warning --------------------------------------------------------------------------------------------- 3

Safety Information ---------------------------------------------------------------------------------------------- 4

Specifications ---------------------------------------------------------------------------------------------------- 6

Periodical Check and Services ------------------------------------------------------------------------------ 9

Pre Operating Inspection -------------------------------------------------------------------------------------12

Operation -------------------------------------------------------------------------------------------------------- 15

Inspection and Maintenance -------------------------------------------------------------------------------- 38

Correct Way of Driving --------------------------------------------------------------------------------------- 57

Abnormalities and Trouble Shooting ---------------------------------------------------------------------- 59

VIN number and Identification ------------------------------------------------------------------------------ 62

Pre-Delivery Inspection ---------------------------------------------------------------------------------------63

Maintenance and Service record -------------------------------------------------------------------------- 64

Abnormalities Service Record ------------------------------------------------------------------------------ 66

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OPERATION WARNING

READ OWNER’S MANUAL CAREFULLY BEFORE OPERATING VEHICLE.

DON’T CARRY MORE THAN ONE PASSENGER ON A 2-UP VEHICLE.

THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.

NEVER OPERATE THIS VEHICLE WITHOUT PROPER INSTRUCTION.

THIS VEHICLE IS NOT FOR YOUTH UNDER 16 YEARS OLD.

ALWAYS WEAR A HELMET. AND PROTECTIVE CLOTHING.

IT’S DANGEROUS TO DRIVE ON AN UNCLEAR ROAD CONDITION.

TO LOWER YOUR SPEED WHEN DRIVING AT NIGHT.

NEVER CONSUME ALCOHOL OR DRUGS BEFORE OR DURING RIDING.

NEVER OPERATE THIS VEHICLE ON HILLS TOO STEEP.

ALWAYS INSPECT YOUR VEHICLE EACH TIME YOU USE IT.

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SAFETY INFORMATION

Don’t allow your child to ride.

Read all warning sticks on vehicle and follow the instruction.

Keep a safe distance between your vehicle and other vehicles.

Take a training course if you are a beginner.

This vehicle is designed to be operated only on level, off road surfaces, free of obstacles.

If this vehicle is not equipped with differential, do not make sharp turns with high speed.

When operate this vehicle on public streets, follow all safety rules that required.

ALWAYS�

Keep hands and feet inside vehicle.

Reduce speed and use extra caution when carrying a passenger.

Operate slowly in reverse gear - avoid sharp turns or sudden braking.

Make sure passenger reads and understands all safety labels.

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SAFETY INFORMATION

Clothing Actual weather condition should help you decide how to dress. However, it is important that the operator always protective clothing and apparel, including an approved helmet, eye protection, boots, gloves, long sleeved shirt and pants. This type of clothing will provide you protection from some of the minor hazards you may encountered.

Operator must never wear loose clothing such as a scarf that may get entangled in the vehicle or on tree branches and shrubs.

Depending on conditions, antifogging goggles or sunglasses may be required. Different colored lenses available for goggles or sunglasses help you distinguish terrain variations. Sun glasses shall only be worn during the daytime.

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SPECIFICATIONS MODEL ATV-700 ATV-700 EFI T3 OVERALL LENGTH 2150 mm OVERALL WIDTH 1280 mm OVERALL HEIGHT 1250 mm WHEEL BASE 1320 mm NET WEIGHT 358 kg 400 kg MAX. WEIGHT CAPACITY 560 kg FRONT TOWING CAPACITY N/A 280 kg (see pag.34) REAR TOWING CAPACITY 350 kg (see pag.35) DISPLACEMENT 695 cc TYPE 4-stroke, 4 Valve, DOHC FUEL SYSTEM Mikuni BSR42 Delphi Electronic Fuel Injection FUEL Unleaded (octane 90 or higher) COMPRESSION RATIO 10.3� 1 STARTING Electric TRANSMISSION CVT SPARK PLUG NGK, CR8E PERFORMANCE 15KW 36KW COOLING TYPE Water-cooled AIR CLEANER Paper filter STEERING SYSTEM Handle bar Handle bar (EPS Option)

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SPECIFICATIONS MODEL ATV-700 ATV-700 EFI T3 GEARS L / H / N / R / P BATTERY 12 volts, 12 Ah FRONT DRIVE 4x4 with Differential Lock REAR DRIVE Shaft drive FUEL TANK 17 Liter

OIL CAPACITY 3.0L

(2.4L routine oil change / 2.7L with oil filter replace)

FRONT DIFF. GEAR OIL 150cc (SAE 80W or 85W-140)

REAR GEAR OIL 250cc (SAE 80W or 85W-140)

FRONT LIGHT BULB(HIGH / LOW) H3 12V 55W x2 / H7 12V 55W x2 H3 12V 55W x 2

FRONT POSITION LIGHT 12V 0.5W x 2 LED BRAKE LIGHT BULB(TAIL LIGHT) 12V 5W / 21W x 2 12V 0.2W / 2.2W x 2 LED LICENSE LIGHT BULB 12V 5W x 1 TURN SIGNAL LIGHT BULB(F/R) 12V 10W x 4 12V 2.4W x 2/1.8W x 2 LED FRONT SUSPENSION Double A-Arm REAR SUSPENSION Independent Rear Suspension FRONT TIRE 25x8-12, (Opt. 26x8-14) REAR TIRE 25x10-12, (Opt. 26x10-14) TIRE PRESSURE Front: 3.8~5.0psi / Rear: 3.8~5.0psi WINCH (Opt.) Front Installed, 3000 lbs Capacity(see pag.36~38) OPERATOR PRESENCE CONTROL N/A Saddle Switch

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GROSS VEHICLE WEIGHT CHART MAXIMUM TECHNICALLY ERMISSIBLE MASS (GVW)

DISTRIBUTION OF GVW BETWEEN AXLES FRONT REAR

560 kg 250 kg 310 kg

GVW Includes: curb weight and cargo weight and person weight.

Suggest the maximum GVW be within the limits set forth.

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PERIODICAL CHECK & SERVICES Maintenance

kilometer First

300km Every 500km

Every 1000km

Every 2000km

Every 4000km

Remarks

Check Item

Maintenance Interval

1 Month 3 Month 6 Month 1 Year

Air cleaner element(Remark) I C R

Oil filter R Replacement for every 1,000KM or 3 months

Engine oil change R Replacement for every 1,000KM or 3 months

Tire and pressure I I

Battery inspection I I

Brake & free ply check I I

Steering handle check I I

Cushion operation check I I

Every screw tightening check I I

Gear oil check for leaking I I

Spark Plug check or change I I R

Differential gear oil R Replacement for every 4,000KM or 12 months

Final gear oil R Replacement for every 4,000KM or 12 months

Frame lubrication L

Exhaust pipe I I

Ignition timing I I

Emission check in idling A I

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PERIODICAL CHECK & SERVICES Maintenance

kilometer 300km

Every 500km

Every 1000km

Every 2000km

Every 4000km

Remarks

Check Item

Maintenance Interval

1 Month 3 Month 6 Month 1 Year

Throttle operation I I

Engine bolt tightening I I

CVT driving device(belt) I R

CVT driving device(roller) C

Engine Drive Shaft I / L I / L C I/R

Light/electrical equipment / multi-meters

I I

Fuel lines I I

Cam chain I I

Valve Clearance I C

Lines & connections in cooling system

I I

Coolant reservoir I I

Coolant I I R

� The above maintenance schedule is established by taking the monthly 1,000KM kilometers as a reference whichever comes first. Code� I� inspection, cleaning, and adjust R� Replacement

C� Cleaning (replaced if necessary) L� Lubrication A� Have your ATV checked and adjusted periodically by your ADLY authorized dealer

or to maintain the ATV at the optimum condition.

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Remark � 1. Clean or replace the air cleaner element more often when the ATV in operated on

dusty roads or in the heavily-polluted environment. 2. Maintenance should be performed more often when the ATV is operated in high

speed and after the ATV has accumulated a higher mileage. 3. Preventive maintenance

a. Ignition system -- perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occurs.

b. carbon deposit cleaning -- clean carbon deposits in cylinder head, piston head, exhaust system when power is obvious lower.

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PRE OPERATING INSPECTION

Inspect your vehicle before you ride it.

It only takes a few minutes to check and may save your life.

Check the tires condition and pressure.

Check the nuts, bolts and other fasteners.

Check the drive chain condition and slack.

Check the engine stop switch for good function.

Check the throttle for smooth opening and closing.

Check the fuel level in fuel tank

Check oil level in crankcase.

Check the coolant level in coolant reservoir.

Check brake fluid to make sure it’s sufficient and not contaminated.

Check the brake operation to see if there is any abnormal.

Check the ease of turning to the left and right of steering handle.

Check brake lever for effective braking. Try braking soon as you are driving off.

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Check and Refueling Insert the key and turn to “OPEN” position for opening the fuel cap.

After refueling, close the cap with key-on then turn the key to “LOCK” position. The key can be removed in “LOCK” position.

Pull out the key and check fuel cap to make sure it’s locked.

CAUTIONS�

� Stop the engine for refueling.

� Do not forces to close the cap without insert the key; it will damage the tank.

� Use unleaded gasoline with octane level 90 or higher.

� Avoid overfilling the gasoline, when refueling; it could cause a fire when the engine is hot.

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Tire pressure CAUTIONS�

Do not over inflate the tire pressure as indicated on the tire.

Check if there is any gravel in the tread grooves or any nail puncture. If so clean it.

Check for any crack or heavy worn-out. If worn-out exceeds the limit, replace it with new one.

Please check the marking on tires for detail specification.

Front and Rear Shock Absorbers

Apply pressure on both front steering handle and seat to check the function of front and

rear shock absorbers.

Recommended tire pressure: 5 psi (35 kPa)

Max. pressure� 3.8~10 psi (0.27~0.7 kgf/cm2)

Min. pressure� 3.8~10 psi (0.25~0.7 kgf/cm2)

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OPERATION

Main Switch

OFF

To turn off the engine. The key can be extracted.

ON

To start the engine. To operate the vehicle and general

electric compoment. The key cannot be taken out

HEAD LIGHT To turn on the head lights. To operate the vehicle and general

electric compoment. The key cannot be taken out

STEERING LOCK

Press the key in OFF position and turn the key to left in order to lock the steering handle.

To operate this function, the handle needs to turn to the left end.

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OPERATION

Electrical starter button

Electrical starter button for engine

starting

With the main switch “on”, press this

button while holding the front or rear

brake lever will start the engine.

CAUTIONS�

Headlight Switch

Low beam

-- For normal condition.

High beam -- For farther lighting.

Hazard Warning Switch

HAZARD

Push switch and all indicator lights will

start blinking together.

� STOP

H/L Beam Switch

Hazard Switch

Electrical starter button

When cranks the engine:

� Do not push down the starter button again as the engine is running.

� Do not press the starter button more than 10 seconds when start up.

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OPERATION

Signal light switch

� Pull switch to right, right signal light

flashing indicates turning to the right.

Pull switch to left, left signal light

flashing indicates turning to the left.

Push switch to turn off lights. CAUTIONS:

Horn Button Turn on main switch and press down the horn button, the horn will sound.

Choke lever (Carburetor only)

� If the engine is cold, choke lever transfers completely dials to ON (left) position.

� In the festival throttle value closed situation, presses the start button.

� As soon as engine warm-up, pull back choke lever to OFF (right) position.

Always turn on signal lights before turning.

Signal Light

Switch

Horn button Choke lever *Carburetor only

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OPERATION

Instrument Panel

Screen Info.

OPC

SET MODEGear position

Speed

Temp. Warning

Engine Temp.

Oil Check / Service

Fuel meter

Disp. Selection Info. Display

Over RPM Warning

2WD/4WD /LOCK Indication

see pag.21

see pag.31

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OPERATION

Instrument Panel

Lamp Information

Lamp Indicates Condition

Turn Signal

The left/right turn signal indicator flashes when the left/right signal is active.

Both left and right signal indicator flashes when the hazard warning signal is

active. If one or more turn lamp bulb has fused that will be fast blinking.

High Beam Indicates head lamp high beam is ON

OPC Warning

(if equipped)

If the system does not detect operator presence under certain conditions, an

alert will sound and illuminates the indicator. See page 39.

EPS Warning

(if equipped)

When the key is turned to the ON position, this indicator illuminates a while

and goes off. If the light constant on, please see your authorized ADLY dealer

for service. See pag.33.

Low Oil

Pressure

Indicates engine oil pressure is low. If the light constant on after start engine,

be check oil level and top-up or contact your authorized ADLY dealer for

service.

OPC

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OPERATION

Instrument Panel

Lamp Information

Lamp Indicates Condition

Low Fuel

Warning

Lamp Continuously ON and 1 Bar displayed in fuel meter. (The fuel level in

the tank is reserve.) Re-fuel immediately to a avoid vehicle immobilization.

If the lamp is continuous ON and fuel level is full than contact ADLY dealer.

Check Engine

Lamp ON before engine start than goes off when engine start. If lamp

constant illuminates there is a potential malfunction related to emission

control system (see page. 60~63), contact an ADLY dealer immediately.

CAUTIONS�

High water pressure may damage ATV components. Wash the ATV by hand or with

a garden hose using mild soap. Do not use alcohol to clean the instrument cluster.

Immediately clean off any gasoline that splashes on the instrument cluster.

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OPERATION

Instrument Panel � Use MODE button to select the desired

mode of the information display. � Use SET button to return previous

display.

The display contains the following

information:

Trip 1, Trip 2, Odometer, Clock, Engine RPM,

Engine TEMP., Average speed, Engine

operation time (HRT), Battery power,

Maintain reminder, MAX Speed, MAX Engine

RPM, MAX TEMP.

� For the information can be reset to ZERO is to press the SET button for 2 seconds.

Transmission Indication

� Press both MODE and SET button for 2

second in order to enter the setup

mode.

The setup is to set as following cycle:

Time >>> Wheel Circumference >>>

Service reminder

The wheel circumference setup information

is as following.

When service or warning light flash, it can be cleared by select to “ODO” position and hold the SET button for 2 seconds.

Tire Size Circumference

24 inch 1915 mm

25 inch 1995 mm

26 inch 2075 mm

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OPERATION

2WD/4WD Select Switch � The 2WD/4WD select switch is located

above the throttle lever. 2WD is for normal driving condition. Press the 2WD/4WD select switch to use 4WD mode.

� The vehicle is equipped front differential. Slide the switch to “LOCK” position will lock the front differential.

NOTE�

� The differential lock (LOCK) function will activate with 4WD regardless of the 2WD/4WD selection.

� When the power could not be transferred to the rear wheels efficiently, switch to the 4WD mode.

� Make sure the vehicle is completely stopped before switching 2WD mode to 4WD mode, or reversed.

� To use the differential lock function will make the steering handle difficult to operate. Be-ware to use this function with normal driving condition.

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OPERATION

Steering Handle Lock

The steering handle lock is located on the main switch.

� Turn the steering fully to the left.

� Insert the key into the main switch.

� Push the key then turn counter -clockwise to lock the steering.

� Remove the ignition switch key.

� When unlocking, simply turn the key clockwise.

NOTE�

� For preventing the vehicle to be stolen, lock the handle can be secured. � After locked, steering the handle bar left and right to secure the lock position.

� When leaving the vehicle, remember to remove the key.

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OPERATION

Gearshift Lever

Low (L) Use the position to get more power when climbing, dragging extra load, and for better acceleration.

HI (H)

Use this position for normal riding.

Neutral (N) Use neutral when you start the engine. Or if it is necessary to stop briefly with the engine idling.

Reverse (R) Use this position to ride in reverse. If you need to ride in reverse, make sure the area behind you is clear and only operate the ATV at low speed. Hold the brake lever when shifting

to reverse, or the engine will stop.

Parking (P) Use to hold the vehicle in place when parked or while starting the engine.

Whenever parking the ATV, apply the parking brake first and shift the selector lever to the “P” position.

L

H

N

R

P

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WARNING

� Improperly reverse operation could cause you to hit an obstacle or person behind you,

resulting in serious injury. � Make sure there are no obstacles or people behind you before selecting reverse gear. � When it is safe to proceed, go slowly.

� Be sure the vehicle is fully stopped before attempting to shift the transmission into any gear.

OPERATION

1. Bring the vehicle to a complete stop. Then make sure the transmission is in Neutral.

2. Depress and hold down the brake lever.

3. Be sure there are no obstacles or people on the way.

4. Correctly to catch the rod to disperse into to the R gear.

5. Release the rear brake lever.

6. Open the throttle gradually and ride slowly. Do not open the throttle suddenly or make

abrupt turn.

CAUTION�

� If the gearshift lever is moved while the vehicle is moving, the sub transmission may

be damaged. � Please always keep the gearshift lever in “N” position when ATV is not moving.

26

OPERATION

Power supply

There are 2 power supply sockets on the vehicle. One is attached to the right side of the body. Second socket is located inside of the storage box. You can use the accessory socket to power a warning light, spotlight, radio, or cell phone chargerM etc.

CAUTIONS�

To use accessory socket, turn on the ignition switch and start engine. Then turn off the headlights and open the accessory socket cap to insert the plug.

CAUTIONS�

� Max power consumption� 12V/2A

� Do not plug in any hand-generating accessory such as on automobile cigarette lighter because it can damage the socket.

� Do not use the socket in raining day. � Do not splash water or other liquid on socket when using the socket.

27

OPERATION

Front / Rear Brake � Use front (right hand) and rear (left hand)

wheel brakes simultaneously or foot brake when braking.

� Avoid unnecessary sudden braking as this

may load to the wheels locking the ATV going out of control.

� Avoid applying the brakes continuously for

a long period of time because that may overheat the brakes and reduce its braking efficiency.

� Slow down and brake early when riding in

rainy days or on slippery roads. Never apply the brakes suddenly to prevent the wheels locking and sliding.

28

OPERATION

Parking and Parking Brake

Look for lever parking area. Make sure the ground surface is firm. After bringing your ATV to a stop, hold the brakes while you shift into PARK.

Turn the ignition switch OFF.

� The parking brake lever is located on the steering right hand. Pull the lever to right in order to perform parking brake.

� The Lock-clip on the front brake lever

allows it to be used as an assistant parking brake. To operate, first squeeze the front brake lever and lock it with lock lever. Squeeze the front brake lever and the lock lever will be released.

� Before using parking brake, please

make sure your ATV is parking on a flat surface.

RELEASE ENGAGE

Lock-clip

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OPERATION

Engine Start-up & Cautions

Check oil and fuel prior to start-up.

1. Set the gear to parking and throttle lever at the “close” state.

2. Use key to turn “Main Switch” on.

3. Pull break lever and push electric starter button.

CAUTIONS�

4. In case the engine will not start after the starter running 3 ~ 4 seconds, push the throttle

lever slightly then try again and engine should start.

5. Use choke function on bottom of left switch if the temperature is low and difficult to start.

� Release the starter button immediately after engine start-up.

� Do not pressing the button again as engine is running, otherwise

engine may be damaged.

� Start-up the engine at an open area to avoided emission hazards.

30

OPERATION

Fuel Meter

The fuel meter is located on the right side of the instrument panel.

When the tank is full, the level light bars are shows at top. During the fuel consuming, light bars decrease from top then down to bottom.

It is recommend to added fuel when fuel meter symbol start to flash.

There’s about 4.0L fuel remains in the

tank when fuel symbol start to flashing.

ON

Fuel Level Light Bar

Fuel Meter Symbol

31

OPERATION

Display Selection

� Basic settings

Both press MODE+SET two second with no speed

signal (parking state) to enter setting screen. The

option on information display include 12H� 24H

change, time set up (HH:MM), wheel girth modify,

Km/H � MPH change, maintenance mileage

modify, temperature unit change C � F.

Press MODE to select option and press SET to modify the settings. Press MODE two

second to leave setting screen or do nothing, the mode will leave setting after 75 second.

� Information display in parking status

Information display include water temperature, average speed, time, battery voltage,

maintenance mileage tip, MAX speed, MAX RPM, MAX temperature, trip 1, trip 2, ODO.

Press SET to select information display and press SET two second to erase data.

Note: Water temperature, battery voltage and ODO are regulate can’t erase.

� Information display in driving status

The screen display three information include speed, time, RPM.

Press SET to select information display.

32

OPERATION

Electrical Power Steering (EPS)(Optional)

When ignition key turn to “ON” position, the warning lamp illuminated for about 2 seconds and

then extinguishes off.

The warning lamp also illuminated when the EPS fault. If the warning lamp is constant on or

illuminate while driving, please contact your authorized ADLY dealer for service.

CAUTIONS�

� The turning torque will reduce while EPS is action. Please hold the handle bar

absorbed no matter accelerates or decelerates.

� Never turn sharply at excessive speeds that can lead to vehicle rollover.

33

OPERATION

Tow Equipment

� Front Towing

1. Stop the engine and remove the key to

prevent loss during transporting.

2. Tie the tow ring with suitable straps or

rope.

3. Shift the transmission into neutral for

better mobility and to avoid damage to

the CVT transmission.

4. Release the brake for towing.

CAUTIONS�

� DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tip over may result

causing severe injury or death. Tow only from tow ring.

� Non-related personnel always stay clear of the area between the vehicle and the

towed object when towing.

� Keep the parallel with vehicle center while towing as far as possible. Follow the

rating of towing capacity. See page 7.

Tow Ring

34

OPERATION

Tow Equipment

� Rear Coupler

Coupler Connect/Disconnect

1. Pull the Posi-lock lever � and pull up the latch �

2. Put the coupler connect/disconnect to the hitch ball .

3. Push down the coupler latch and make sure the Posi-lock locked.

CAUTIONS�

� About the rating of towing capacity, please see page 7.

� Used security pin to avoid couple unexpected off.

� Always check coupler status before towing.

Safety pin hole

35

OPERATION

Tow Equipment

� Winch

1. Secure the hook in a firm place and make

sure that the safety latch on the winch

cable hook is fully seated when the load

is attached.

No hooked yet, No operate

2. Always operate the winch by winch

switch of remote control or the switch

mounted on the vehicle. “OUT” side is to

extend the cable and “IN” side is to

retract the cable.

36

OPERATION

Tow Equipment

� Winch

CAUTIONS�

� Always wear eye protection and heavy gloves when operating the winch.

� Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook

when operating winch.

� Never attempt to tow a load attached to the winch with a moving vehicle.

� Always keep the area clear around the winch cable and load of people (especially children)

and be concentrate while operating the winch.

� Always align the vehicle and winch with the load directly in front of the vehicle as much as

possible. Avoid winching with the winch cable at an angle to the winching vehicle’s

centerline whenever possible.

� Never attempt to winch loads that weigh more than the winch’s rated capacity. See page 7.

� Never touch, push, pull or straddle the winch cable while winching a load.

� Never let the winch cable run through your hands, even if wearing heavy gloves.

� Never use the winch for lifting people and hoist or suspend a vertical load.

� Never winch the hook fully into the winch. This can cause damage to winch components.

� Never grease or oil the winch cable. This will cause the winch cable to collect debris that

will shorten the life of the cable.

37

OPERATION

Operator Presence Detection

(ATV-700 EFI T3 only)

This vehicle is equipped with a feature that

detects operator presence on the vehicle.

If the system does not detect operator

presence under certain conditions, an alert

will sound and illuminates the indicator.

The alert and message will occur under

either of the following two conditions:

1. The parking lever is NOT in applied and

driver is not sit ON the saddle.

2. The parking lever is NOT in applied and

the saddle switch is not connection.

CAUTION�

This saddle switch is located underneath the saddle. Before remove saddle be sure the saddle switch is disconnection. Otherwise it may tear the switch or wire.

38

INSPECTION AND MAINTENANCE

Engine oil inspection and change

Inspection

1. Uses main parking brake to stand the ATV on the level ground, then run the engine for the 3~5 minutes and stop.

2. Remove the dipstick and wipes the oil to count then inserts it to the engine again. (Do not rotate it.)

3. Remove the dipstick and check whether oil level is in between the upper and lower marks.

39


OIL CHANGE

� Change engine oil after the first 300km or first month, and change the engine oil every 1,000km or 3 months which comes first, change oil filter after the first 300km or first month then change for each oil replacement.

� In order to maintain the engine’s maximum performance, check whether the engine oil is enough every month, add oil to upper limit if the engine oil has been found to be inadequate.

� Engine oil� Use API SH, JASO MA, or about and SAE 10W-30 grade or better engine oil.

Otherwise, damage will not be covered by warranty.

� Oil capacity� 3.0 Liter (2.4 liters for routine oil change or 2.7 liters with filter replace)

40


Transmission Oil Inspection and Change

Inspection�

� When ATV is stopped in the level ground, stop the engine and wait 3~5minutes. Check the transmission gear oil quantity by release the bolt and check from the hole.

Oil Replacement �

� Stop the engine on a level ground. Remove the infusion bolt and drain bolt, drain out the oil. � Install the drain bolt and tighten it. Fill new differential gear oil (150 c.c.), final gear oil (250

c.c.), and install the infusion bolt and tighten it. (Make sure the bolts are tightened and check that there’s no leakage.)

Front Diff. check bolt Rear gear oil check bolt

41


� The front differential oil drain bolt is located underneath the gear box. The rear gear box drain hole is located on the left side of the gear box.

Differential gear oil� 150 c.c. Genuine ADLY gear oil (SAE 80W or 85W-140)

Final gear oil� 250 c.c. Genuine ADLY gear oil (SAE 80W or 85W-140)

NOTICE�

After the oil has completely drained, replace a new drain plug washer, reinstall the drain plug.

Differential gear oil drain bolt Rear gear oil drain bolt

Final gear oil infusion Differential gear oil infusion

42


Oil Filter

� Remove the oil filter cartridge with an oil filter wrench. � Apply a thin coat of engine oil to the o-ring of the new oil filter cartridge. � Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified

torque with a torque wrench.

WARNING

� Oil level will not be correct when checking the oil level with the vehicle parked on an unleveled ground or immediately after the engine stopped.

� Engine and exhaust pipe are hot right after engine stopped. Pay special attention not to get burned when checking or replacing engine oil.

Oil filter

43


Checking the Spark Plug

� Remove the cap of spark plug. (Using the spark plug wrench in the tool kit.)

� Check the electrode if it is dirty or fouled by carbon deposits. Remove the carbon deposits on the electrode with steel wire, and clean the spark plug with gasoline, then, wipe dry with a rag.

� Check the electrode, and adjust its gap to 0.8 mm. (check it with a feeler gauge)

� Hand tight the spark plug as far as it can go and then tighten it another 1/2~3/4 turns with a wrench.

CAUTION �

� The engine is extremely hot after running. Allow ATV to cool down completely

before removing the spark plug to avoid being burned or the other possible injury.

� Use only spark plugs suitable for the engine specifications of this motorcycle

recommended by the manufacturer.(refer to specifications)

44


Inspection of fuel level � Uses main parking places stand ATV in

the level ground and turn the main switch to “ON” position, check the speedometer fuel level.

� Fuel gauge may be defective or electric circuit disconnected. If the fuel meter does not move, please ride slowly to an authorized service station to have your ATV checked.

NOTICE � � Do not check the fuel level or refuel while the engine is running. It is not necessary to

start engine to check the fuel level. � Make sure fuel cap on tank is closed tightly before riding ATV. � Do not run engine in an enclosed space. Ensure proper ventilation as exhaust fumes

may be dangerous and over exposure may result illness, injury or death. � There is a danger of fire and explosion when handling fuel. Never refuel in an enclosed

working area. � Do not over fill the fuel tank.

� Do not spill fuel onto hot engine or related parts.

45


Battery

This battery is located underneath the seat.

Remove and Check

1. Make sure the ignition switch OFF.

2. Remove the seat.

3. Remove the fix plate on the battery.

4. Disconnect the negative (-) terminal lead from the battery first then disconnect the positive

(+) terminal lead.

5. Remove the battery.

6. Only if you have regularly ridden the vehicle otherwise charges the battery as necessary.

7. Store your battery in an easy to obtain location off the floor, in an area protected from

freezing temperature or direct sunlight.

8. Slow charge the battery once every 30 day while not using.

46


Installation 1. Install the battery in reverse order of removal. 2. Check all bolts and other fasteners are secured.

NOTICE�

� This ATV uses a sealed MF battery; don’t remove the electrolytic solution caps. � In order to prevent electrical leakage and self-discharge when the battery sits idle for long

periods of time, remove the battery from ATV and store it in a well-ventilated and dimly lighted area. Store battery out of reach of children. If the battery is to be kept on the ATV, disconnect the battery’s negative cable.

� When replace the cables apply a thin coat of grease to the battery terminals when reconnecting.

� Please key off ignition switch before remove or install cable to avoid injure the EFI system.

NOTICE�

� Keep the ATV battery clean. If the battery’s posts are corroded and/or are covered with white powder, clean them with water.

� If there is obvious corrosion on the battery terminals, disconnect the battery cables and remove the corrosion with steel brush.

� If battery needs to be replace, install a same sealed-type battery. (MF, maintenance-free)

47


Coolant Maintaining the coolant will allow the cooling system to work properly and prevent freezing, overheating, and corrosion.

Coolant system inspection

1. Stops ATV in the level place.

2. Check reserved tank from viewing window to see if coolant lever is between the upper limit and lower limit mark.

3. Add coolant up to upper mark if coolant is lower.

Check the cooling system for leakage � Check radiator and piping for leakage.

Lower

Upper

Reserved tank

Radiator Cap

48

� Check the ground where the vehicle is from the parked for water dripped from the vehicle.

49


Replenishment of coolant Always keep radiator cap tightly closed. 1. Support vehicle on a level ground. 2. Remove the maintenance cover.

� Open reserved tank cap, refill coolant until reaches the limits. � If coolant level becomes too low and occurs too often, it may indicate there is something

wrong with the coolant system. � To avoid radiator getting rusty, do not use coolant other than those recommended.

Coolant recommended� ASTM or SAE approved coolant, ADLY radiator agent.

Concentration� 50%

Radiator capacity� Main radiator� 1,750 c.c. Reserved tank� 500 c.c.

NOTICE�

� Use soft water when mixing coolant. � Please pay special attention that using poor quality coolant may shorten the service

life of the radiator. � Coolant should be change once a year normally or 10000km which comes first.

NOTICE�

� Please refer to a table showing what percentage of anti-freeze should be used under different temperatures if the vehicle is to be operated in the low temperature areas.( below 0 oC )

50


A reference table for anti-freeze concentration percentages under different temperatures

1. Radiator anti-freezer shall use ASTM or SAE approved type. (ADLY radiator agent)

2. Proper anti-freeze percentages for different frozen temperatures are as follows.

anti-freeze percentages Frozen temperature Remark

20% -8 oC 50% concentration is used for all ATV before delivery to ensure the effectiveness of anti-freeze

30% -15 oC

40% -24 oC

50% -36 oC

3. If the specified anti-freeze is unavailable, use an equivalent with the same high quality.

4. Increase radiator maintenance intervals when the weather is extremely cold.

Warning � Remove the radiator cap while the engine is hot can cause the coolant to spray out,

seriously scalding you.

� Always let the engine and radiator cool down before removing the radiator cap.

51


Seat Removal � Pull the seat release knob located

underneath the left hand side of rear cover.

� Then lift the seat and pull to rear.

Idle Speed Adjustment (carburetor only) The screw to adjust engine idle speed is under the seat in front of the air cleaner box. � Park your ATV on a firm, level surface. � Open the seat. � Select the RPM mode of the tachometer. � Shift into PARK or Neutral. � Start the engine. � Adjust idle speed by turning the throttle

adjusting screw.

Idle speed (in neutral � � 1500 ± 100 RPM

If the engine is cold, start it and warm it up with 10 minutes of stop-and-go riding. Stop the engine and adjust the idle speed.

Adjust screw

CAUTION:

If vehicle equipped the OPC function, attend the

saddle switch before seat remove.

52


Air Cleaner Element

Removal�

1. Remove the seat, turn right to open filter box cap and then remove filter element. 2. Take the filter element out and clean or replace it. (Refer to maintenance schedule.) Install�

1. Install the filter element in reverse order of removal. 2. Used specified filter oil, if necessary, on the element to keep the ability of filtering.

NOTICE� � Dust deposit is the major cause of reduce horsepower and increase fuel consumption. � Change the air cleaner element more frequently to prolong the engine’s service life if

the ATV is drive in dusty area very often. � If air cleaner is installed improperly, dust will be absorbed into cylinders, which may

cause a premature wear and reducing output power and engine life. � Be careful not to soak the air cleaner when washing the ATV. Otherwise, it will cause

engine hard to start.

Filter box cap

Filter element

53


Parking Brake Adjustment

Look for lever parking area.

Turn the ignition switch OFF.

If the parking brake does not functioning will, adjust the nuts in 2 locations.

Adjust nut on the parking lever base.

Adjust nut on the parking brake caliper.

If it is necessary to start the engine when your ATV is stopped on a grade in gear, rock the vehicle back and forth to allow shifting the transmission into Neutral.

Release the parking brake and check the vehicle can move freely without parking function activate.

54


Brake Fluid Check Stop the ATV in the level ground then check the brake fluid level. The brake fluid reservoir is location on L/R brake master cylinder assembly and foot brake.

(Replenishment of brake fluid)

1. Loosen the screws and remove the master cylinder cover. 2. Wipe clean foreign materials, dirt around the reservoir, being careful not to let foreign

materials fall into reservoir. 3. Remove the diaphragm plate and the diaphragm. 4. Add brake fluid to upper lever.

5. Install the diaphragm and diaphragm plate then install the master cylinder cover. 6. Please note the diaphragm direction, and not let foreign materials fall into the reservoir.

Then tighten the master cylinder cover securely.

NOTICE� Used DOT 3 or DOT 4 brake fluid when replenish.

MIN

55


Fuse Fuse box is under the seat. Remove the seat and you can see the fuse box is on the right side. Turn off ignition switch, and check fuses if they are intact. Replace the blown fuse with a new one having the same specified amperage rating (30A or 15A or 10A). Using a fuse which the ampere is larger than specification, a brass or iron wire to replace a blown fuse is strictly prohibited to avoid damaging the electrical system and the circuit. � Open the fuse box cover, and pull out the fuse. Check it for damage or broken. � Fuses must be filmy secured with wire connectors when replacing. Loose connections will

result in overhead and damage. � Use only parts having the specified specification to replace electrical components such as

light bulbs. Using parts not having the specified specification for replacement may cause the fuse to blow and over-discharge the battery.

� Avoid spraying water directly on or around fuse box when washing the ATV. � Take your ATV to your dealer for an inspection if a fuse is blown by unknown causes.

56


Tool kit This tool bag is in the front storage box. The tools in the kit set are sufficient to perform routine maintenance and simple repairs. The tools kit includes the following items.

� Standard / Phillips screwdriver

� 14 x 17mm open end wrench

Tire pressure gauge

� Spark plug wrench

� Tool bag

57

CORRECT WAY OF DRIVING

Start of Driving

Turn on the key switch and start-up the engine.

Release the parking brake.

Hold the brake while change the gear into the desired position.

Press the throttle lever slowly to control your speed.

Acceleration is to increase the speed. Slowly press the throttle lever while driving on a slope. It will activate the engine power.

Deceleration is to decrease the speed. Release the lever will do.

This vehicle do not equipped with rear differential gear box. The rider must learn to move his weight and control the throttle not to thumb over.

Throttle lever

58

CORRECT WAY OF DRIVING

Stop of the Vehicle

Approaching to the parking point:

Release the throttle lever and apply both front and rear wheel brakes while the vehicle is

stopped.

Complete stop:

Stop the engine by turn off the main switch.

Do not park on uneven ground to avoid tipping over.

CAUTIONS�

BRAKE-IN PROCESS

During the first 500KM of riding, do not run the vehicle more then 60km/hr or approach

maximum RPM of the engine.

The brake-in process will greatly increase the lifetime and long term power of the

engine.

Do not turn the main switch or engine stop switch to “OFF” during operation.

59

ABNORMALITIES AND TROUBLE SHOOTING

If the engine fails to start or engine fails to keep running.

Check the gas tank is fuel are available and sufficient.

Whether the procedure for engine start up is correct.

Try to diagnose these malfunctions yourself first.

Contact the local dealer as soon as possible for checking on any abnormality of

your vehicle.

Diagnostic Display (EFI only)

When EFI system or component failure at engine running, the check engine

light will illuminate to remind driver make a promptly check and repair.

Use DELPHI diagnostic apparatus connect to Diagnosis port or use the special operation to

calling diagnostic codes to find the failure of EFI system or component. Refer to next page

for diagnostic codes calling and description.

This Diagnosis port is located underneath the seat.

The EFI diagnostic display is for preliminary trouble judge.

Please see your ADLY dealer for all major repairs.

60

ABNORMALITIES AND TROUBLE SHOOTING

Diagnostic Display (EFI only)

� EFI system will save last record of the errors within engine operation on the ECM.

� This record won’t erase until the fault solved and use the proper apparatus to erase codes.

� Diagnostic codes interpretation�

1. Turn ON the ignition switch and OFF, ON, OFF, ON within 2 second.

2. ECM will display diagnostic codes by flashing check engine light on speedometer.

3. Each diagnostic code composed by 4 bits. The flash pause is 3.2 second between code and

code. The flashing frequency of number is flash on 0.4 second and flash off 0.4 second.

Stay 1.2 second between bit and bit. The number of zero flash 10 times other numbers flashes

homologous times.

4. Diagnostic codes show on DELPHI diagnostic apparatus (HEX) and check engine light (DEC)

are description of fault show in following table.

Note:

After trouble shooting, use the DELPHI diagnostic apparatus to erase the diagnostic code.

61

Diagnostic Display

Diagnostic Codes

System / Component DTC Description HEX DEC

Manifold Absolute Pressure Sensor (MAP)

MAP Circuit Low Voltage or Open 107 263

MAP Circuit High Voltage 108 264

Intake Air Temperature Sensor (IAT)

IAT Circuit Low Voltage 112 274

IAT Circuit High Voltage or Open 113 275

Coolant/Oil Sensor

Coolant/Oil Temperature Sensor Circuit Low Voltage 117 279

Coolant/Oil Temperature Sensor Circuit High Voltage or Open

118 280

Throttle Position Sensor (TPS)

TPS Circuit Low Voltage or Open 122 290

TPS Circuit High Voltage 123 291

Oxygen Sensor O2S 1 Circuit Low Voltage 131 305

O2S 1 Circuit High Voltage 132 306

Oxygen Sensor Heater O2S Heater Circuit High Voltage 32 50

O2S Heater Circuit Low Voltage 31 49

Fuel Injector Injector 1 Circuit Malfunction 201 513

Injector 2 Circuit Malfunction 202 514

Fuel Pump Relay (FPR) FPR Coil Circuit Low Voltage or Open 230 560

FPR Coil Circuit High Voltage 232 562

Crankshaft Position Sensor (CKP)

CKP Sensor Noisy Signal 336 822

CKP Sensor No Signal 337 823

Ignition Coil Cylinder 1 Ignition Coil Malfunction 351 849

Cylinder 2 Ignition Coil Malfunction 352 850

Idle Control System Idle Speed Control Error 505 1285

62

Diagnostic Display (cont.) Diagnostic Codes

System / Component DTC Description HEX DEC

System Voltage System Voltage Low 562 1378

System Voltage High 563 1379

Tachometer Tachometer Circuit Low Voltage 1693 5779

Tachometer Circuit High Voltage 1694 5780

Oxygen Sensor 2 O2S 2 Circuit Low Voltage 137 311

O2S 2 Circuit High Voltage 138 312

Oxygen Sensor Heater 2 or AC clutch

O2S Heater 2 Circuit High Voltage 38 56

O2S Heater 2 Circuit Low Voltage 37 55

Vehicle Speed Sensor VSS No Signal 500 1280

Park Neutral Switch Diag. Park Neutral Switch Error 850 2128

CCP CCP short to high 445 1093

CCP short to low/open 444 1092

BLM Max Adapt BLM Max Adapt(Kohler Special) 171 369

BLM Min Adapt BLM Min Adapt(Kohler Special) 172 370

PE system Lean PE sys. Lean(Kohler Special) 174 372

Evaporator temperature sensor

A/C Evaporator Temperature Sensor Circuit Low 537 1335

A/C Evaporator Temperature Sensor Circuit high or open 538 1336

AC Clutch Relay A/C clutch Relay Control Circuit High 647 1607

A/C clutch Relay Control Circuit Low 646 1606

ECU diagnostic Calibration and software Check Sum fail 601 1537

63

VIN NUMBER AND IDENTICIFICATION

Please record the VIN and engine number for further reference.

The frame number (VIN) is stamped on the front

right side of frame.

FRAME NO. RFL

FRAME NUMBER

The engine number is engraved on middle top of

right crankcase.

ENGINE NO.

ENGINE NUMBER

64

P.D.I. (Pre-Delivery Inspection)

� 1. Record the frame and engine number into the owner’s manual.

� 2. Check that all tires have correct pressure specified in the owner’s manual.

� 3. Engine oil (4 stroke, SAE10W/30 or 10W/40 ) is enough.

� 4. Battery is installed properly.

� 5. All brakes are functional properly.

� 6. Fuel tank has enough gasoline to operate.

� 7. Check the suspension for proper setup.

� 8. Check that all electrical components and lights are working properly.

� 9. Make sure that the owner’s manual and tool bag are installed in the tool box.

� 10. Make sure that the bolts and nuts are fastened properly according to the manual.

65

MAINTENANCE AND SERVICE RECORD 300 KM 500 KM 1,000 KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

2,000 KM 3,000 KM 4,000 KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

66

MAINTENANCE AND SERVICE RECORD 5,000 KM 6,000 KM 7,000 KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

8,000 KM 9,000 KM 10,000 KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

67

MAINTENANCE AND SERVICE RECORD 11,000 KM 12,000 KM 13,000 KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

14,000 KM 15,000 KM 16,000 KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

68

ABNORMALITIES SERVICE RECORD ODOMETER : KM ODOMETER : KM ODOMETER : KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

ODOMETER : KM ODOMETER : KM ODOMETER : KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

69

ABNORMALITIES SERVICE RECORD ODOMETER : KM ODOMETER : KM ODOMETER : KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

ODOMETER : KM ODOMETER : KM ODOMETER : KM

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES� ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

NOTES : ________________

_______________________

_______________________

_______________________

_________________________

DEALER�

_________________________

DATE�

70

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ATV700 700EFI T3 Owner's Manual