Bnmn8tf8tf8f585x85fitc8tc75f74f75f8tx8tc8tx85
- 1. 1 Our ATV is manufactured under strict quality control systems. The warranty document sent to dealers guarantees all written items. Given that you follow the maintenance procedure by using original parts and riding normally, we readily assent to repair or change them. This warranty excludes: 1.Using unspecified Engine Oil. 2.Improper maintenance or repairs. 3.Using non-original or modified accessories and parts. 4.Operating inaptly, lack of conformity to manual. 5.Normal wear and tear Seat, Spark Plug, Bulbs, Wire, Filters, Battery, Brakes, Belt, Chain, Sprockets, Tyres etc. This manual is a simple introduction of operation and basic maintenance checking. In case of further questions, contact your dealer for assistance. Official Distributor: ASP Group s.r.o. Adresa: Staroplzenecka 290, 326 00, Letkov Czech Republic Tel.: +420 378 21 21 21 E-mail: info@aspgroup.cz Web: www.aspgroup.eu User Manual BLADE 550 IRS
- 2. BATTERY Caution BRAKE SHOE Caution BRAKE FLUID Caution Battery emits explosive gases; flame is strictly prohibited. Keeps the place well ventilated when charging the battery. Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it out immediately with water and then go to hospital to see an ophthalmologist. If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor. Keep electrolyte beyond reach of children. Do not use an air hose or a dry brush to clean components of the brake system; use a vacuum cleaner or the equivalent to avoid dust flying. Inhaling brake shoe or pad dust may cause disorders and cancer of the breathing system. Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children. 2 5 3 CARBON MONOXIDE Caution GASOLINE USED ENGINE OIL Caution HOT COMPONENTS Caution Caution When running your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor. Exhaust contains toxic gas which may cause one to lose consciousness and even result in death. Gasoline is a low ignition point and explosive material. Work in a well- ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored. Gasoline is highly flammable, and may explode under some conditions, keep it away from children. Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children. Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.
- 3. NAME: PURCHASING DATE: TYPE: FRAME NO.: KEY NO.: SPECIAL NOTE: Fuel: Brakes: Tyres: Lighting System: Mirrors: Engine Oil: Before you set-off on a journey: Check you have sufficient petrol for your journey. Check the brakes are working properly. Check tyres are adequately inflated. Check tyres for physical damage. Check lights and signalling devices are working. Check mirrors are clean and correctly adjusted. Check oil level. Your key's identification number is engraved on the steel plate beside your key as shown in the above illustration. Record this number and store carefully to provide for reference if you need a new key. Specifications........................................................................5 Important Identification Numbers.........................................15 General Illustration..............................................................17 Operation Indications..............................................................17 Periodical Maintenance Schedule...........................................33 Basic safety rules....................................................................38 4 5 5 5 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH This list is only for reference; the parts are according to real vehicle. Any modification may be done without prior notice. Above 92 km/hr 205 kg 300 kg 505 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2155 mm 930 mm 1205 mm 1190 mm 940 mm 162 kg 168 kg 330 kg 1300 mm Double A-Arm Unit Swing Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm) Disk ( 220mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore 86 mm Stroke 69.4 mm Number/ Arrangement Single Cylinder Displacement 403.1 cc Exhaust Concentration Compression Ratio 9.2:1 Cylinder Max. Torque 25.5Nm / 4000rpm Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC 14.9kw / 6500rpm Fuel Capacity Air Filtration ITEM 400C.C. FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 25x8-12 25x10-12 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity 3.5L BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 350 c.c.
- 4. 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH This list is only for reference; the parts are according to real vehicle. Any modification may be done without prior notice. Above 92 km/hr 220 kg 319 kg 539 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2155 mm 990 mm 1235 mm 1235 mm 960 mm 180 kg 184 kg 364 kg 1280 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm)x2 Disk ( 180mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore 86 mm Stroke 69.4 mm Number/ Arrangement Single Cylinder Displacement 403.1 cc Exhaust Concentration Compression Ratio 9.2:1 Cylinder Max. Torque 25.5Nm / 4000rpm Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC 14.9kw / 6500rpm Fuel Capacity Air Filtration ITEM 400C.C.(IRS) FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 25x8-12 25x10-12 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity 3.5L BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 450 c.c. Double A-Arm 5 5 6 5 5 7 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH Above 92 km/hr 257 kg 358 kg 615 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2155 mm 990 mm 1235 mm 1235 mm 960 mm 199 kg 166 kg 365 kg 1280 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm)x2 Disk ( 220mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore 92 mm Stroke 69.4 mm Number/ Arrangement Single Cylinder Displacement 461.3 cc Exhaust Concentration Compression Ratio 10.1:1 Cylinder Max. Torque 27.5Nm / 3500rpm Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC 14.7kw / 6000rpm Fuel Capacity Air Filtration ITEM FBF 460C.C. FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 AT 25x8-12 AT 25x10-12 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity 3.86L BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 350 c.c. Unit Swing
- 5. 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH Above 92 km/hr 265 kg 372 kg 637 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2155 mm 990 mm 1235 mm 1235 mm 960 mm 206 kg 181 kg 387 kg 1280 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm)x2 Disk ( 180mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore 92 mm Stroke 69.4 mm Number/ Arrangement Single Cylinder Displacement 461.3 cc Exhaust Concentration Compression Ratio 10.1:1 Cylinder Max. Torque 27.5Nm / 3500rpm Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC 14.7kw / 6000rpm Fuel Capacity Air Filtration ITEM FBF-D(IRS) 460C.C. FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 AT 25x8-12 AT 25x10-12 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity 3.86L BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 450 c.c. Double A-Arm 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH Above 92 km/hr 310 kg 348 kg 658 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2360 mm 990 mm 1250 mm 1235 mm 960 mm 224 kg 184 kg 408 kg 1450 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm)x2 Disk ( 180mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore 92 mm Stroke 69.4 mm Number/ Arrangement Single Cylinder Displacement 461.3 cc Exhaust Concentration Compression Ratio 10.1:1 Cylinder Max. Torque 27.5Nm / 3500rpm Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC 14.7kw / 6000rpm Fuel Capacity Air Filtration ITEM FBF-DL(IRSLT) 460C.C. FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 AT 25x8-12 AT 25x10-12 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity 3.86L BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 450 c.c. Double A-Arm 5 5 8 5 5 9
- 6. 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH This list is only for reference; the parts are according to real vehicle. Any modification may be done without prior notice. Above 92 km/hr 205 kg 300 kg 505 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2155 mm 930 mm 1205 mm 1190 mm 940 mm 162 kg 168 kg 330 kg 1300 mm Double A-Arm Unit Swing Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm) Disk ( 220mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore Stroke Number/ Arrangement Single Cylinder Displacement Exhaust Concentration Compression Ratio Cylinder Max. Torque Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC Fuel Capacity Air Filtration ITEM 500C.C. FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 25x8-12 25x10-12 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 350 c.c. Ø92 mm 75.6 mm 502.56 cc 9.9:1 14.8kw / 7000rpm 33.3Nm / 5000rpm 3.5L 5 5 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH This list is only for reference; the parts are according to real vehicle. Any modification may be done without prior notice. Above 92 km/hr 220 kg 319 kg 539 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2155 mm 930 mm 1250 mm 1235 mm 940 mm 180 kg 184 kg 364 kg 1280 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm) Disk ( 180mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore Stroke Number/ Arrangement Single Cylinder Displacement Exhaust Concentration Compression Ratio Cylinder Max. Torque Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC Fuel Capacity Air Filtration ITEM 500C.C.(IRS) FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 26x8-14 26x10-14 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 450 c.c. Ø92 mm 75.6 mm 502.56 cc 9.9:1 14.0kw / 7000rpm 33.3Nm / 5000rpm 3.86L Double A-Arm Double A-Arm 10 1 1
- 7. 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH This list is only for reference; the parts are according to real vehicle. Any modification may be done without prior notice. Above 70 km/hr 220 kg 319 kg 539 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2155 mm 930 mm 1250 mm 1235 mm 940 mm 180 kg 184 kg 364 kg 1280 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 200mm) Disk ( 180mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore Stroke Number/ Arrangement Single Cylinder Displacement Exhaust Concentration Compression Ratio Cylinder Max. Torque Ignition Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC Fuel Capacity Air Filtration ITEM FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 26x8-14 26x10-14 Shaft drive L, H, N, R Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 450 c.c. Ø92 mm 75.6 mm 502.56 cc 9.9:1 14.4kw / 5500rpm 31.2Nm / 3600rpm 3.86L Double A-Arm Double A-Arm 500 C.C. (IRS/ EFI) Transistorized Ignition 13 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH This list is only for reference; the parts are according to real vehicle. Any modification may be done without prior notice. Above 92 km/hr 220 kg 319 kg 539 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2360 mm 930 mm 1250 mm 1235 mm 940 mm 180 kg 184 kg 364 kg 1450 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 230mm) Disk ( 180mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore Stroke Number/ Arrangement Single Cylinder Displacement Exhaust Concentration Compression Ratio Cylinder Max. Torque Ignition C.D.I. Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC Fuel Capacity Air Filtration ITEM 500C.C.(IRSLT) FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 26x8-14 26x10-14 Shaft drive L, H, N, R, P Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 450 c.c. Ø92 mm 75.6 mm 502.56 cc 9.9:1 14.8kw / 7000rpm 33.3Nm / 5000rpm 3.86L Double A-Arm 12
- 8. 14 0 ~ 300 km/hr 93 ~ 112dB/A Below 7.0g/ km Below 0.4g/ Km Below 1.5g/ km 18 0.3L NGK CR7E 12V 18AH This list is only for reference; the parts are according to real vehicle. Any modification may be done without prior notice. Above 70 km/hr 220 kg 319 kg 539 kg Overall Length Weight Dimension Engine LAMPS Wheel Tread Curb Weight Overall Height Overall Width Wheel Base 2360 mm 930 mm 1250 mm 1235 mm 940 mm 180 kg 184 kg 364 kg 1450 mm Double A-Arm Type Fuel Used Petrol Cycle/cooling 4-Stroke/Water Cooled Front Rear Front Front Rear Total Rear Total Disk ( 230mm) Disk ( 180mm) Transmission devices Suspension System Tire Specifications Brake System Performance Passengers/ Weight Two / 150 kg Total Weight S.O.H.C. Speedometer Horn Bore Stroke Number/ Arrangement Single Cylinder Displacement Exhaust Concentration Compression Ratio Cylinder Max. Torque Ignition Starting System Electrical / Recoil starter Spark Plug Sponge Battery Max. HP Front Front Front Rear Rear Rear Max. Speed Transfer Solid Particulate CO Nox HC Fuel Capacity Air Filtration ITEM FRONT LAMPS (HI / LO) REAR LAMPS 12V 55WX2 55WX2 12V 5WX1 26x8-14 26x10-14 Shaft drive L, H, N, R, P Manual lever Shift lever Shift Clutch type Transmission Wet multi-plate Continuously variable Centrifugal type Lubrication System Engine lubrication system Pump forced circulation SAE 10W/40 SG/CC Engine oil capacity BRAKE LAMPS 12V 21WX1 TURN LAMPS 12V 10WX4 Gear lubrication Differential / Final Reduction device Spec. Capacity 450 c.c. Ø92 mm 75.6 mm 502.56 cc 9.9:1 14.4kw / 5500rpm 31.2Nm / 3600rpm 3.86L Double A-Arm 1. Chassis Number: Record chassis and engine number for future reference. Number is located front right hand side of chassis as shown in (1). 2. Engine number is located front of the engine as shown in (2). 3. Manufacturer's DATA PLATE The manufacturer's data plate is located front right hand side of chassis as shown in (3) 1 3 2 15 500 C.C. (IRSLT / EFI) Transistorized Ignition
- 9. Before riding thoroughly read these labels of essential safety operation instructions. Do not tear off stickers. In case of wear or damage contact your dealer for replacements. 16 Position Lamp ON All electrical systems operational OFF While parking 1. Ignition Switch Function / Position 2. Signs and Functions Position Position Function Name Starter Switch Dimmer Switch Hazard Warning Turn Signal Switch Horn Choke Lever Start engine Hi-Beam/Lo-Beam Switch Continues flash Right/Left-hand direction Sounded by pushing Use in low temperature Function NO NO YES Key Out ※ This vehicle is equipped with a safety protection system，to start the engine must be brake applied. 1 7 1. Hazard Lights 2. High/Low Beam Switch 3. Starter Switch 4. Rear Brake Lever 5. Winker Switch 6. Horn 7. Choke Lever 8. Over-ride 9. Speedometer & Display 10. Ignition Switch 11. Front Brake Lever 12. 2D/4D/LOCK Switch 13. Throttle 14. Parking Brake 15. Power Source 16. L/H/N/R/P Lever 17. Fuel Tank (for Carburetor model only)
- 10. Remove the function of over-ride 1. Set the shift gear at “R”, then press over-ride button (keep press the button) 2. As you move your finger away from over-ride button, the speed will be limited again when reverse. function of over-ride 3. BRAKE LEVER 12mm Rear Brake Lever Parking Brake Attention: Attention: Before each journey check whether the accustomed resistance exists with activity of the brake at the brake lever. Also check there is sufficient quantity of brake fluid in the reservoir. Before each trip check the brake actuating system. The gap of the brake lever end should be 12 mm approximately. Inform your local dealer of possible deviations. Front Brake Lever 12mm Brake Fluid Level 18 5. SHIFT LEVER Shift lever instructions: 1. Engine starts only in Neutral (N) position 2. Engage a brake and push the knob in and move the shift lever from N to H, L or R (L Shift is used for rough surfaces) Shifting H to L and any gear/direction the vehicle must be at a complete stand still 3. For reverse, with the brake on, push the knob in and move the shift lever from N to R ※ Attention:Irregularities of brakes such as leaks and poor performance should only be dealt with by an authorised dealer. The brake fluid level must be above the MIN mark. If the level keeps going down have an authorised dealer check it. Always use DOT #4 brake fluid. 4. REAR BRAKE PEDAL NOTE: By squeezing the rear brake lever may also activate the rear brake pedal. 19 By pressing the pedal brake will activate the front and rear brakes. L: High torque use (advance gear) H: Normal use (driving gear) N: Parking use (Neutral) R: Reverse use P: Parking use (for long chassis model) Parking shift lever instructions: 1. Engage a brake and push the knob in then move the shift lever to ”P” position. Check the “P” indicator is bright on the dashboard. 2. Switching the parking break lever on the “Parking” position, make sure the parking procedure is completely. 3. At “P” position, the engine RPM was limited, open throttle will damage the engine. For RPM checking or adjusting, please shift the lever to “N” position.
- 11. Notice:Operating the shift lever when vehicle is moving can be hazardous. This is strictly prohibited. Always wait till the vehicle stops completely, do not operate the ATV at high speed in reverse under any ciscumstances 6. 2WD/4WD SELECT LEVER The 2WD/4WD SELECT LEVER is for the use of changing the engine power supplied to the wheels. You can select 2WD or 4WD for your preference according to different surface conditions. 4. Disable the parking “P” procedure: engage a brake and shift the lever to “N”, Release the parking brake and shift the lever to the H or L or R. Release the brake and open throttle for acceleration operation. 6. 2WD/4WD/LOCK SELECT BUTTON The 2WD/4WD/LOCK SELECT BUTTON is for the use of changing the engine power engages on the wheels. You can select 2WD, 4WD or LOCK for different road conditions. Picture 1 Picture 2 2WD：Engage the engine power on the rear wheels only. This is mainly use for normal riding. 4WD：Engage the engine power on both front and rear wheels with differential function. There is a slip limited gear assy. inside the front differential can engage the right and left front wheels at different speeds. This provides much more traction than 2WD and should be used when riding on wet and slippery surfaces. LOCK：Engage the engine power on both front and rear wheels without differential function. This provides all traction to four wheels and should be used when two or more wheels skid. Shifting the 2WD/4WD/LOCK button： 1. Stop the vehicle completely. 2. Without Lock system: Shift the transfer lever to the preferred position (refer to picture 1). 3. With Lock system: (refer to picture 2) 3-1. 4WD Mode: Press the button to change mode from 2WD to 4WD and the indicator lamp will ON at dashboard in 4WD mode. 3-2. Lock Mode: Always follow the sequence 2WD→4WD→Lock to operate the button. When engage the lock functions, it should press the button to 4WD mode then shift the lock lever to the “LOCK” position. Note: During 2WD mode, lock button without function. 3-3. Release lock function: To unengaged the lock function, always backward the sequence of 3-2 from LOCK→4WD→2WD. Press the button when ATV is moving can be extremely dangerous can lose control while riding with a hand removed from the handlebar. The gear box mechanism can be damaged if pressing the shifting button when the ATV is in motion. Always stop the ATV completely before shifting between 2WD, 4WD and LOCK. WARNING ● 20 21
- 12. 7. RECOIL STARTER In case the vehicle does not start with the electric starter, the emergency recoil starter can be used to start the engine. To use the recoil starter, shift to neutral (N) and grip the starter rope-handle, which is on the engine magneto cover. Pull the rope until you feel the starter engage. Pull the rope forcefully to start the engine. At the moment the engine starts,be sure to return the starter rope to its prior normal position. NOTE: Switch off the headlights when starting the engine with the recoil starter. 8. TIRE Attention: Attention: ※Tire pressure: 5 psi (off road) / 10 psi (on road) The vehicle is equipped with tubeless tyres. Tubeless tyres should never be repaired. Damaged tyres have to be renewed immediately. Your authorised dealer should only renew tubeless tyres. Since the tyre pressure influences the driving ability, the mandatory tyre pressure should always be maintained. You should determine outer damages of tires. The suggested minimum profile depth is 3mm; change the tyre immediately if below 3mm. 9. CHECK COOLANT RESERVE TANK Add coolant to proper level if too low. Check the coolant level in the front left side mudguard. Reserve Tank Remove the front reserve tank cover, and then remove reserve tank filler cap. Reinstall the reserve tank filler cap. 10. STEERING LOCK Caution The reserve coolant tank level should not be over filled to avoid expansion when hot. The steering lock in principle should be used for theft protection. The handle bar is to be turned to the left and the key in the steering lock pressed and turned simultaneously (see illustration). 22 23 ※Tire Pressure ( for 550 IRS LT): Front : 5.7 psi; Rear : 5.0 psi ( For Carburetor Model only )
- 13. FUNCTIONS BAR RPM: Bar Graphic Tachometer RPM: Digital Tachometer Shift Warning RPM MAX RPM: Maximum Tachometer SPD: Speed Meter MAX: Maximum Speed Meter AVG: Average Speed Meter 1. The bar graphic tachometer reading is always displayed at the bar graph. 2. Tachometer bar graphic displays up to 11,000 RPM. 1. RPM is displayed in 2nd row. 2. Digital tachometer displays up to 19,900 RPM. 3. Tachometer signal picked up from either CDI or Ignition coil. 1. Function enables you to set up an RPM shift warning. 2. Bar-graphic tachometer flashes when RPM reaches pre-set value, and stops flashing after you shift gear. 1. MAX RPM is displayed on 2nd row. 2. Displays highest tachometer reading achieved after last RESET operation. 1. Speed meter display is on 1st row of the screen. 2. Displays speedometer reading up to 300.0 Km/H or 187.5 mph. 1. MAX is displayed on 1st row. 2. Displays highest speed achieved after last RESET operation. 1. AVG is displayed on 2nd row. 2. Calculates average speed from last RESET. 11. SPEEDOMETER AND DISPLAY DIGITAL TYPE 1. Tachometer Scale 2. Bar Tachometer 3. 1st row display: Speedometer and MAX speedometer. 4. 2nd row display: Other functions 5. RESET Button 6. MODE Button 7. Fuel Meter Bar (Optional) 8. LED Indicator symbols Left-Direction Indicator/Green Right-Direction Indicator/Green Main-Beam Headlamp/Blue Drive Gear/Green Neutral Gear/Green Engine Coolant Temperature/Red Reverse Gear/Red L/H N R PANEL DESCRIPTIONS Engine oil indicator Battery charge indicator 1. Engine oil indicator (Red): if this light turns on, please check if is enough engine oil, otherwise, please contact with your local dealer for inspection. 2. Temperature indicator (Red): if lights turn on with engine running, implies cooling system problem. Please contact with your local dealer for inspection 3. Battery charge warning light: if the light turns on while engine running, implies malfunction of battery system. Please contact with your local dealer for inspection ※When turn on ignition switch, engine oil indicator/ temperature indicator/ battery indicator will self-diagnostic, if this process is not found, could be some malfunction. Please contact with your local dealer for inspection 4. Turn signal light (green): on use of turn signal, lights will flash and audible warning Hazard warning: left/right light will flash and audible warning Warning: 1. Engine oil warning light will light up when low on oil. Please proceed to fill with TGB special oil, after filling up, warning light will turn-off. Please always ride the vehicle with the engine oil warning light off, otherwise, it will cause damage to the engine. 2. If will cause severe damage to the engine if engine keep running under overheating circumstances 1. TRIP function registers cumulative trip distance from last RESET while bike is being ridden. 2. Display is on 2nd row of screen. 1. ODO registers cumulative distance traveled during motorbike operation. 2. ODO data is stored in memory, even when power is off. 1. Calculates total operation time from last RESET. 2. Count automatically begins with vehicle movement. 1. Calculates total operation time from the beginning of bike use. 2. Count automatically begins with vehicle movement. 3. TT data is stored in memory, even when power is off. It displays 12- or 24-hour current time. 1. Has 7 bargraphic indicator of fuel status. 2.Last bar flashes to indicate low fuel level. TRIP 1 & 2: Trip Meter 1& 2 ODO: Odometer RT: Riding Timer TT: Total Riding Timer 12/24 hour Clock Fuel Meter (Only for models with the function) 24 25
- 14. BUTTON OPERATIONS 2.Press the MODE button to move partial functions in loop from one function screen to another when speed sensor detects signal input. MODE BUTTON 1. Press the MODE button to move all functions in loop sequence from one function screen to another when the speed sensor does not detect any signal input. RESET BUTTON 1. Press MODE button to the desired screen then press RESET button for 2 seconds to reset TRIP 2, MAX, and MAX RPM data from stored values to zero individually. 2. The data of Trip 1, AVG & RT is reset at the same time when one of the 3 data functions is being reset. 3. ODO, clock and TT data cannot be reset. SHIFT RPM WARNING OPERATION 1. Press MODE button to the RPM screen; pull on the throttle until the desired shift RPM warning displayed. 2. Press RESET button to confirm and set up the shift warning RPM. 3. Bar-graphic tachometer will flash to warning you shift gear. 4. Operate items 1 & 2 to readjust the shift warning RPM. UNIT & WHEEL CIRCUMFERENCE SETTING UNIT & WHEEL CIRCUMFERENCE SETTING 1. Setup operations include 12/24hour clock, shift warning RPM, numbers of engine rotation per signal, wheel circumference and units. These must be set up step by step. The computer will automatically revert to main screen if no button operation for 75 seconds at any setting screen. 2. Press both MODE & RESET buttons to go into setting screen. In setting screens, press RESET button to add the flashing digit by 1 or convert units, press MODE button to confirm the digit setting and jump to next digit or next setting screen to be set. Press MODE button for 2 seconds at any setting screen to finish the setting and go to main screen. 3. It displays "12 or 24H and XX:XX-XX" symbols and AM/PM in case you select 12H. 4. Press RESET button converts 12/24H, press MODE button to complete the setting and jump to clock digit setting. 5. Press RESET button to increase flashing digit by one; press MODE button to confirm digit setting and jump to next digit. 6. Press MODE button to go to shift warning RPM setting screen after set clock. 7. It displays " RPM rXXX00 ". Press RESET button to increase flashing digit by one; press MODE button to confirm digit setting and jump to next digit. 8. Press MODE button to go to numbers of engine rotation per signal setting screen after completed shift warning RPM setting. 9. It displays "SPC-X.X RPM", the default value is 1.0; there are 4 options: 1.0, 2.0, 3.0 and 0.5. It means the numbers of engine rotation per signal. For example the value 2.0 means the engine rotate 2 turns to output a signal. 10. Press RESET button to move in loop sequence from one to another value of the 4 values. Press MODE button to confirm the setting and go to wheel circumference setting screen. 11. In "cXXXX" display, "c" means "Circumference", following 4 default digits; flashing digit is digit to be set. 12. Press RESET button to increase flashing digit by one; press MODE button for 2 seconds to confirm digit setting and jump to main screen. 26 27
- 15. SPEEDOMETER AND DISPLAY MECHANICAL TYPE 1. Speedometer 2. Fuel meter 3. Odometer 4. Hi-beam signal light (Blue): will turn on when use Hi-beam light 5. Engine oil indicator (Red): if this light turns on, please check if is enough engine oil, otherwise, please contact with your local dealer for inspection. 6. Temperature indicator (Red): if lights turn on with engine running, implies cooling system problem. Please contact with your local dealer for inspection 7. Battery charge warning light: if the light turns on while engine running, implies malfunction of battery system. Please contact with your local dealer for inspection ※When turn on ignition switch, engine oil indicator/ temperature indicator/ battery indicator will self-diagnostic, if this process is not found, could be of some malfunction. Please contact with your local dealer for inspection 8. Turn signal light (green): on use of turn signal, lights will turn on and audible warning Hazard warning: left/right light will flash and audible warning 9. Shifting instruction light 1. Engine oil warning light will light up when low on oil. Please proceed to fill with TGB special oil, after filling up, warning light will turn-off. Please ride the vehicle with the engine oil warning light off, otherwise, it will cause damage to the engine. 2. If will cause severe damage to the engine if engine keep running under overheating circumstances WARNING： 5 6 7 4 9 8 1 2 3 F N R 28 SPEEDOMETER WITH PARKING INDICATOR AND EFI MODEL TYPE I TYPE II L/H N R P PANEL DESCRIPTIONS 1. Tachometer Scale 2. Bar Tachometer st 3. 1 row display: Speedometer and MAX speedometer. nd 4. 2 row display: Other functions. 5. MODE Button 6. SET Button. 7. Fuel Meter bar (Optional). 8. LED Indicator symbols Main-Bean Headlamp/Blue Engine oil indicator/Red Battery charge indicator Engine coolant Temperature/ Red Engine check / Yellow (EFI model) Turn single indicator/ Green Drive Gear/ Green Neutral Gear/ Green Reverse Gear/ Green Parking Gear/ Green 29 1. Engine oil indicator (Red): if this light turns on, please check if it is enough engine oil, otherwise, please contact with your local dealer for inspection. 2. Temperature indicator (Red): if light turn on with engine running, implies cooling system problem. Please contact with your local dealer for inspection. 3. Battery charge warning light: if the light turns on while engine running, implies malfunction of battery system. Please contact with your local dealer for inspection. ※When turn on ignition switch, engine oil indicator/temperature indicator/battery indicator will self- diagnostic, if this process is not found, could be some malfunction. Please contact with your local dealer for inspection. 4. Turn signal light (Green): on use of turn signal, lights will flash and audible warning. Hazard warning: left/right light will flash and audible warning. 5. Engine check light (Yellow): if this light turns on, please contact with your local dealer for inspection. Warning: 1. Engine oil warning light will light up when low on oil. Please proceed to fill with TGB special oil, after filling up, warning light will turn-off. Please always ride the vehicle with the engine oil warning light off, otherwise, it will cause damage to the engine. 2. If will cause severe damage to the engine if engine keep running under overheating circumstances.
- 16. 30 31 FONCTIONS BOUTONS OPÉRATIONS TYPE I TYPE II BAR RPM: Bar Graphic Tachometer (for TYPE I only) RPM: Digital Tachometer (for TYPE II only) MAX RPM: Maximum Tachometer SPEED: Speed Meter MAX SPEED: Maximum Speed Meter SPEED AVG: Average Speed Meter TRIP A & TRIP B: Trip Meter A & B ODO: Odometer RT: Riding Timer TT: Total Riding Timer Fuel Meter (Only for models with the function) 1. The bar graphic tachometer reading is always displayed at the bar graph. 2. Tachometer bar graphic displays up to 11,000 RPM. 1. RPM is displayed in 2nd row. 2. Digital tachometer displays up to 19,900 RPM. 3. Tachometer signal picked up from either or Ignition coil. 1. MAX RPM is displayed on 2nd row. 2. Displays highest tachometer reading achieved after last RESET operation. 1. Speed meter display is on 1st row of the screen. 2. Displays speedometer reading up to 300.0 Km/H or 187.5 MPH. 1. MAX is displayed on 1st row. 2. Displays highest speed achieved after last RESET operation. 1. AVG is displayed on 2nd row. 2. Calculates average speed from last RESET. 1. TRIP function registers cumulative trip distance from last RESET while bike is being ridden. 2. Display is on 2nd row of screen. 1. ODO registers cumulative distance traveled during motorbike operation. 2. ODO data is stored in memory even when power is off. 1. Calculates total operation time from last RESET. 2. Count automatically begins with vehicle movement. 1. Calculates total operation time from the beginning of bike use. 2. Count automatically begins with vehicle movement. 3. TT data is stored in memory even when power is off. 1. Have 7 bar graphic indicator of fuel status. 2. Last bar flashes to indicate low fuel level. CDI (ECU) MODE BUTTON ODO → RPM → TRIP A → TRIP B → MAX SPEED → SPEED AVG → RT → TT → MAX RPM ODO RESET FUNCTION TIME FUNCTION 1.Press the MODE button to move all functions in loop sequence from one function screen to another. → TIME → 2. Press MODE for 10 seconds to change the display for KMH or MPH. 1. Press MODE to the desired screen then press MODE and SET button simultaneously for 6 seconds to reset the data from stored values to zero. Each reset are individually, including TRIP A, TRIP B, RT, AVG SPEED, MAX SPEED and MAX RPM. 2. ODO, Clock and TT data cannot be reset. 1. Press MODE to the (ODO screen for TYPE I or TIME screen for TYPE II) then presses MODE and SET button simultaneously for 3 seconds to set up the time. 2. When the digit is blinking, press SET button to desire digit then press MODE button to set up and jump to next digit. 3. After the time setting, press MODE and SET button simultaneously for save and back to ODO screen. 4. During setting, if the digit did not change over10 seconds, the setting will auto save and back to time screen. 5. When speed over 10km/hr, the setting will save automatically.
- 17. PERIODICAL MAINTENANCE SCHEDULE 12. MAINTENANCE SCHEDULE ◎The below maintenance schedule is established by months, Kilometers and Miles and are dependent on which ever comes first. ◎Have your vehicle checked, adjusted, and recorded maintenance data by TGB dealer to maintain the ATV at the optimum condition. ◎Use the chart below for necessary service work to keep the vehicle operating at peak performance and economy. L: Lubricate C:Clean R: Replace T: Tighten I: Inspection, cleaning and adjustment Have your ATV serviced and checked by an Authorised TGB Dealer. Ensure the service book is stamped and signed. Failure to do so could invalidate your warranty. The maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first. 1.Clean or replace the air cleaner element more often when the ATV is operated in dusty conditions or in a heavily polluted environment. 2.Maintenance should be performed more often if the ATV is frequently 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 misfire, after- burn, and overheating occurs. b.Carbon deposit removal－ remove carbon deposits in cylinder head, piston and exhaust system when power is obviously lower than normal. REMARKS: ITEM INTERVAL MONTHS 1 3 6 12 Kms INITIAL 200 EVERY 1000 EVERY 2000 EVERY 4000 MILES INITIAL 120 EVERY 600 EVERY 1200 EVERY 2400 Muffler Bolts and Exhaust Pipe Nuts Valve Clearance I - I I Air Cleaner - C C R Engine Idle RPM I I I I Spark Plus - - I I Replace Every 6000KM (4000 MILES) T T T T Engine Oi R - R R Oil Filter R - R R Front Differential Set Oil - Final Gear Oil - C.V.T Belt - - I I Fuel Tube - I I I Replace Every 4 Years Throttle Cable Play I I I I Brakes I I I I Brake Hose - - I I Replace Every 4 Years Brake Fluid - I I Replace Every 2 Years Tires - I I I Suspensions - - I I Steering System I I I I Chassis Bolts and Nuts T T T T General Lubrications - L L L I Replace Every 6000KM (4000 MILES) or 6 Months Replace Every 6000KM (4000 MILES) or 6 Months R R R R R R Grease nipple(Universal Joint Assy) - L L - 33 * Fuel Filter (EFI Model) Replace Every 2 Years 32 WHEEL CIRCUMFERENCE 1. Key OFF. 2. Press MODE button and permanently. 3. Key ON and press SET button to wheel circumference screen. 4. In “cXXXX” display, “c” means “Circumference”, following 4 default digits; flashing digit is digit to be set 5. When the digit is blinking, press SET button to desire digit then press MODE button to set up and jump to next digit. 6. Press MODE for 3 seconds for saving the set up. 7. During setting, if the digit did not change over10 seconds, the setting will auto save and back to ODO screen.
- 18. 13. SPARK PLUG Recommended spark plug: CR7E. Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap. Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug washer and install the spark plug by screwing it. Tighten the plug by turning 1/2 turn more with plug socket after installed. Spark plug gap:0.7~0.8 mm 14. AIR CLEANER Remove seat. Loosen 4 hooks from the air cleaner cover and then remove the cover. Loosen the clamp strip and 1 screw of air cleaner element, and then remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze it completely dry. 15. CARBURETTOR IDLE SPEED ADJUSTMENT Set the parking brake. Shift the transmission to neutral. Warm up engine. Connect tachometer (the wire clamp of tachometer is connected to the high tension cable). Turn the throttle valve stopper screw to specified idle speed. Specified idle speed: ATV400:1700±100 rpm/ATV500:1500±100rpm 16. ENGINE OIL OIL CHANGE ENGINE OIL FILTER CHANGE Turn off engine, and park the ATV in flat surface with parking brake. Check oil level with oil dipstick. Do not screw the dipstick into engine when checking. If oil level is low level, fill with recommended oil toupper level. Place an oil pan under the ATV and remove oil drain plug. After drained, make sure washer can be re-used. Install oil drain plug to a satisfactory torque. Drain engine oil out. Install oil Filter to a satisfactory torque. Add oil to crankcase (oil viscosity SAE 10W-40) Install dipstick, start the engine for several minutes. Turn off engine and check oil level again. Check for any engine oil leaks. Engine oil capacity: 3500/3860c.c. when replacing 34 35 (For Carburetor model only) ※ For EFI Model, Please contact your local dealer for idle adjustment.
- 19. Attention:Only install the correct fuse for replacement.If the fuse should burn out several times, you should immediately consult your authorised dealer. Attention: The maximum power consumption for power source must not exceed 5a. Before using power source, it should start the engine and turn off the head lamps. 36 37
- 20. 38 39
- 21. 40 41
- 22. 42