1987 Quadzilla Manual

The 1987 Quadzilla is a high-performance all-terrain vehicle featuring a powerful 500cc liquid-cooled engine, full suspension system, automatic transmission with reverse, front and rear hydraulic disc brakes, electric start, full instrumentation, front and rear racks, and tow hitch. Below are key sections for safety, features, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Pre-Ride Inspection 3. Controls and Operation 4. Specifications 5. Maintenance Schedule 6. Basic Maintenance Procedures 7. Storage Guidelines 8. Safety Information 9. Warranty Information 10. Troubleshooting

Features at a Glance

Key components: 500cc liquid-cooled engine, Automatic CVT transmission, Full suspension system, Hydraulic disc brakes, Electric start system.

Feature	Description
Engine	500cc liquid-cooled 4-stroke single cylinder
Transmission	Automatic CVT with reverse gear
Suspension	Independent front, swingarm rear with adjustable shocks
Brakes	Hydraulic disc front and rear
Starting System	Electric start with backup recoil
Fuel Capacity	4.5 gallons
Towing Capacity	850 lbs with optional hitch
Instrumentation	Speedometer, odometer, fuel gauge, warning lights
Lighting	Headlight, taillight, brake light
Storage	Front and rear cargo racks

Pre-Ride Inspection

Always perform pre-ride inspection before operating.

Check fuel level: Ensure adequate fuel for planned ride.
Inspect tires: Check pressure and condition for damage.
Test brakes: Verify proper brake operation front and rear.
Check lights: Ensure all lights are functioning properly.
Inspect controls: Verify throttle, brake levers operate smoothly.

WARNING! Never operate without proper pre-ride inspection. Failure to inspect may result in accident or injury.

Controls and Operation

Main controls: Throttle lever, brake levers, gear selector, ignition switch.

Starting Procedure: Turn ignition key to ON, ensure transmission in PARK, pull brake lever, press start button.

Transmission: PARK for parking, DRIVE for forward, REVERSE for backing up. Throttle: Squeeze lever to accelerate, release to decelerate. Brakes: Front and rear brake levers on handlebars. Instrument Panel: Speedometer, fuel gauge, neutral light, high beam indicator.

Specifications

Engine: 500cc 4-stroke single cylinder, liquid-cooled
Bore x Stroke: 92.0mm x 75.0mm
Compression Ratio: 9.2:1
Fuel System: 34mm carburetor
Transmission: Automatic CVT with reverse
Final Drive: Shaft drive
Suspension Front: Independent double wishbone
Suspension Rear: Swingarm with adjustable shocks
Brakes Front/Rear: Hydraulic disc
Tires Front/Rear: 25x8-12 / 25x10-12
Dimensions (LxWxH): 83" x 46" x 47"
Dry Weight: 602 lbs

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Service	Every 100 hrs	Every 300 hrs	Every 600 hrs
Oil change	✓	✓	✓
Oil filter		✓	✓
Air filter	✓	✓	✓
Spark plug		✓	✓
Brake fluid			✓
CVT service		✓	✓
Valve clearance			✓

Basic Maintenance Procedures

Engine Oil Change: Run engine to warm oil, drain via drain plug, replace with 10W-40 4-stroke oil.

Air Filter: Remove cover, clean foam filter with solvent, re-oil with filter oil.
Spark Plug: Remove with spark plug wrench, gap to 0.028-0.031 inches.
Brake Pads: Inspect for wear, replace if thickness below 1/8 inch.
Tire Pressure: Maintain 5 psi for soft terrain, 8 psi for hard surfaces.
Chain Adjustment: Check slack, adjust to 1-1.5 inches of free play.

CAUTION! Always use genuine replacement parts. Improper maintenance may void warranty.

Storage Guidelines

For long-term storage, prepare vehicle properly to prevent damage.

Fuel System: Add fuel stabilizer, run engine for 5 minutes.
Battery: Disconnect negative terminal, store in cool dry place.
Tires: Inflate to maximum pressure, elevate off ground if possible.
Cleaning: Wash thoroughly, apply protectant to plastic and rubber.
Cover: Use breathable cover to protect from dust and moisture.

Tip: Store in cool, dry location away from direct sunlight.

Safety Information

Always wear approved helmet, eye protection, gloves, long sleeves, long pants, and over-the-ankle boots.

WARNING! Never operate on public roads. Avoid paved surfaces - tires not designed for pavement. Never carry passengers unless equipped with passenger seat and footpegs. Never operate under influence of alcohol or drugs.

Warranty Information

Limited warranty: 12 months from date of purchase. Coverage includes defects in materials and workmanship. Normal wear items, improper maintenance, accidents, and modifications not covered. Keep purchase receipt for warranty claims. Contact authorized dealer for service.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, battery	Check fuel level, spark plug, battery charge, kill switch position
Poor performance	Air filter, fuel system	Clean air filter, check fuel lines, inspect carburetor
Overheating	Coolant, radiator	Check coolant level, clean radiator fins, inspect water pump
Brakes dragging	Calipers, fluid	Inspect calipers for sticking, check brake fluid condition
Electrical issues	Battery, connections	Test battery voltage, check all electrical connections
Transmission slipping	Belt, clutch	Inspect CVT belt, check clutch operation

Service: Contact authorized dealer for complex repairs. Use genuine parts only.

Emergency: For roadside assistance, contact 1-800-QUAD-ZILLA