USER'S MANUAL IMPORTANT NOTICE This machine is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway. This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV.
USER'S MANUAL INTRODUCTION Congratulations on your purchase of the RD400. This manual will provide you with a good basic under standing of the features and operation of this ATV. This manual includes important safety information. It provides information about special techniques and skills necessary to ride your ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a dealer.
USER'S MANUAL IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow warning instructions could result in injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
USER'S MANUAL CONTENTS 1.Location of the warning and specification labels Safety information 3.Description and machine identification 1 5 11 Vehicle identification number 12 4.
USER'S MANUAL 6.Operation Starting a cold engine Starting a warm engine Warming up Drive select lever operation and reverse driving Engine break-in Parking Parking on a slope Accessories and loading 7.
USER'S MANUAL Rear brake shoe inspection Brake fluid level check Brake fluid replacement Front brake lever free play Rear brake pedal and lever adjustment Adjusting the rear brake light switch Cable inspection and lubrication Lubricating the brake levers and brake pedal Wheel installation Battery Battery maintenance Fuse replacement Replacing a headlight bulb Headlight beam adjustment Tail/brake light bulb replacement Troubleshooting Troubleshooting chart 9.Cleaning And Storage A. Cleaning B.
USER'S MANUAL LOCATION OF THE WARNING AND SPECIFICATION LABELS 1
USER'S MANUAL Read and understand all of the labels on your machine. They contain important information for safe and proper operation of your ATV. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, a replacement label is available from your dealer. 2 ! WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OFF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold • Recommended : FRONT : 25kPa, (0.
USER'S MANUAL ⑤ 3 ! ! WARNING WARNING Improper ATV use can result in SEVERE INJURY or DEATH, NEVER ride with passengers. Riding with passenges can cause a loss of control, resulting in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN ONE PASSENGER NEVER USE WITH DRUGS OR AL COHOL NEVER operate: • without proper training or instruction. • at speeds too fast for your skills or the conditions.
USER'S MANUAL 6 ⑨ 7 ⑥ ! WARNING DRIVE SELECT LEVER • Read owner’s manual carefully before operating. • ATV MUST be stopped before shifting select lever. • Shifting info or from reverse or park is impossible without applying rear brake. Operating this ATV if you are under the age of 16increases your chance of severe injury or death. NEVER operate this ATV if lyou are under age 16.
USER'S MANUAL SAFETY INFORMATION An ATV handles differently from other vehicles including motorcycles and cars. Acollision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described. Never operate anATV without proper training or instruction.
USER'S MANUAL Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility, operating conditions, and your experience.
USER'S MANUAL Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high speed. Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill.
USER'S MANUAL Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control. Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
USER'S MANUAL When transporting theATV in another vehicle, be sure it is kept upright and that the fuel cock is in the"OFF" position. Otherwise, fuel may leak out of the carburetor or fuel tank. POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN WHAT CAN HAPPEN Gasoline can catch fire and you could be burned. Gasoline is poisonous and can causeinjuries. HOW TO AVOID THE HAZARD Always turn off the engine when refueling.
USER'S MANUAL POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your ATV in an area with adequate ventilation.
USER'S MANUAL DESCRIPTION AND MACHIN IDENTIFICATION 1 Rear shock absorber assembly spring pre load adjusting ring 2 Spark arrester 3 Storage box and tool kit 4 Spa rk plug 5 Front shock absorber a s sembly spring pre load adjusting ring 6 Brake pedal 7 V-belt case 8 F uel cock 9 Ai rfilter case 10 Fuses 11 Tail/ brake ligh t 12 Front Shock absorber assembly Spring Preload adjusting Ring 13 V-belt cooling duct check hose 14 Oil Filter cartridge 15 Engine oil dipstick 16 Rear brake lever 17 Left handlebar
USER'S MANUAL Vehicle identification number The vehicle identification number is stamped into the frame. ① Vehicle identification number (front left side) NOTE: The vehicle identification number is used to identify your machine.
USER'S MANUAL CONTROL FUNCTIONS Indicates a potential hazard that could result in serious injury or death. Main switch Functions of the respective switch positions are as follows: ON: The engine can be started only at this position and the headlights and taillight come on whenthe light switch is on. ① Main switch OFF: All electrical circuits are switched off. The key can be removed in this position.
USER'S MANUAL Neutral indicator light “N” Indicator and warning lights This indicator light comes on when the drive select lever is in the “N” position. Reverse indicator light “R” This indicator light comes on when the drive select lever is in the “R” position.
USER'S MANUAL Four-wheel-drive indicator light This indicator light comes on when the 2WD/ 4WD switch is in the 4WD position. Oil temperature warning light ? When the oil temperature reaches a specified level, this light comes on to warn that the engine oil temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.
USER'S MANUAL Oil temperature warning light checking method Turn the main switch to "ON"and the engine stop switch to Oil temperature warning light does not come on. Oil temperature warning light comes on. Push shart switch with the transmission in neutral. Check engine oil temperature. Oil temperature warning light comes on momentarily. Oil temperature warning light does not come on. Oil temperature is low. Oil temperature is high. Allow to cool.
USER'S MANUAL Handlebar switches Do not use the headlights with the engine turned off for more than fifteen minutes. the battery may discharge to the point that the starter motor will not operate properly. If this should happen, remove the battery and recharge it. Engine stop switch “ / ” Make sure that the engine stop switch is set to“ ” before starting the engine. The engine stop switch controls ignition and can be used at all times to stop the engine, especially in an emergency.
USER'S MANUAL Start switch “ ” The starter motor cranks the engine when this switch is pushed. See starting instructions prior to starting the engine. (See page 43 for details). ① Four-wheel drive switch “2WD/4WD” On-command four-wheel drive switch “2WD /4WD” To change from two-wheel drive (2WD) to four-wheel drive (4WD), stop theATVand set the switch to the 4WD position. To change from four-wheel drive (4WD) to two-wheel drive (2WD), stop theATV and set the switch to the 2WD position.
USER'S MANUAL POTENTIAL HAZARD Changing from 2WD to 4WD or from 4WD to 2WD while the ATV is moving. WHAT CAN HAPPEN TheATV handles differently in 2WD than in 4WD in some circumstances. Changing from 2WD to 4WD or from the ATV to unexpectedly handle differe ntly. This could distract the operator and increase the risk of losing control and an accident. HOW TO AVOID THE HAZARD Always stop theATV before changing from 2WD to 4WD or vice-versa.
USER'S MANUAL Throttle lever Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns to the idle position as soon as the lever is released. Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the machine by varying the throttle position. Because the throttle is spring-loaded, the machine will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever.
USER'S MANUAL Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. POTENTIAL HAZARD Improper adjustment of the speed limit er and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an acci dent or be injured.
USER'S MANUAL Front brake lever The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. ① Brake pedal ① Front brake lever Brake pedal and rear brake lever. The brake pedal is located on the right side of theATV and the rear brake lever is located on the left handlebar. Push down on the pedal or pull the lever toward the handlebar to apply the rear brake.
USER'S MANUAL Parking brake Use the parking brake when you have to start the engine or park the machine, especially on a slope. Apply the rear brake lever and push down the lock plate to apply the parking brake. Squeeze the rear brake lever to release the parking brake. POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The AT V could s ta rt movi ng unexpe ct edl y i f the parking brake is not applied before starting the engine. This could cause loss of control or a collision.
USER'S MANUAL Drive select lever Recoil starter The drive select lever is used to shift your machine into the forward, neutral and reverse positions. (Refer to page 46 for the drive select lever operation.) Firmly grasp the handle and pull slightly until engagement can be felt. Then pull forcefully, being careful not to pull the rope all the way out.
USER'S MANUAL Fuel tank cap Remove the fuel tank cap by turning it counter clockwise. POTENTIAL HAZARD Starting the engine without shifting into the neutral position. WHAT CAN HAPPEN The ATV could start to move unexpect edly, which could cause an accident. HOW TO AVOID THE HAZARD Shift the drive select lever into the neutral position and apply the parking brake before starting the engine.
USER'S MANUAL Fuel cock The fuel cock supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions. RES: This indicates reserve. If you run out of fuel the carburetor. Normal riding is done with the lever in this position. ON: With the lever in this position, fuel flows to flow. Always turn the lever to this position when the engine is not running. OFF: With the lever in this position fuel will not while riding, turn the lever to this position.
USER'S MANUAL Starter (choke) “ ” Starting a cold engine requires a richer air-fuel mixture. Aseparate starter circuit supplies this mixture. Move in direction a to turn on the starter(choke). Move in direction a to turn off the starter(choke). Refer to tarting a cold engine for proper operation. (See page 43).
USER'S MANUAL Seat To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear. NOTE: Make sure that the seat is securely fitted.
USER'S MANUAL Storage box Maximum load limit: 2 kg (4.4 lb). NOTE: There is a check hose at the bottom of the storage box. If any water collects in this hose, remove the hose, empty it, and then install it. To protect from damage, do not put metal products, like tools or sharply edged products directly in the storage box. If they must be stored, wrap them in appropriate cushion material.
USER'S MANUAL Front carrier Maximum load limit: 40 kg (88 lb). Rear carrier Maximum load limit: 80 kg (176 lb). Front shock absorber adjustment. The spring preload can be adjusted to suit the rider’s weight and riding conditions. Adjust the spring preload as follows. To increase the spring preload, turn the adjusting ring in direction a . To decrease the spring preload, turn the adjusting ring in direction b .
USER'S MANUAL Rear shock absorber adjustment The spring preload can be adjusted to suit the rider weight and riding conditions. Adjust the spring preload as follows: To increase the spring preload, turn the adjusting ring in direction a . To decrease the spring preload, turn the adjusting ring in direction b . POTENTIAL HAZARD Improper shock absorber adjustment. WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability, which could lead to an accident.
USER'S MANUAL NOTE: A special wrench can be obtained at a dealer to make this adjustment. Indicates a potential hazard that could result in serious injury or death. Standard position: 2 1 - Minimum (soft). 5 - Maximum (hard). ① Special wrench.
USER'S MANUAL PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE Front brake Check operation, free play, fluid level and fluid leakage. Fill with DOT 4 brake fluid if necessary. Rear brake Check operation, free play, fluid level and fluid leakage. Fill with DOT 4 brake fluid if necessary. Fuel Engine oil Check fuel level. Fill with fuel if necessary. Check oil level. Fill with oil if necessary... Fina l gear oil/ differential gear oil Check for leakage.
USER'S MANUAL Front and rear brakes Brake levers and brake pedal Check for correct free play in the front brake lever. If the free play is incorrect, have a dealer adjust it. Check for correct free play in the rear brake lever and brake pedal. If the free play is incorrect,adjust it. (See pages 127--129.) Check operation of the levers and pedal.They should move smoothly and there should be a firm feeling when the brake is applied. If not, have a dealer in-spect them.
USER'S MANUAL Brake fluid leakage (All brake) Check to see if any brake fluid is leaking out of the hose, joint or brake fluid reservoir of the front brake. Apply the brake firmly for one minute. If the lever moves slowly inward, there may be a leak in the brake system. If there is any leakage, the brake system should be inspected by a dealer. POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident.
USER'S MANUAL Fuel Your ATV engine has been designed to use regular unleaded gasoline with a pump octane number ([R+M]/2) of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. Make sure there is sufficient gasoline in the tank. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total: 13.5 L (2.97 Imp gal, 3.
USER'S MANUAL Gasohol There are two types of gasohol; gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by ATV because it may cause fuel system damage or vehicle performance problems. POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury. Fuel expands when it heats up.
USER'S MANUAL Engine oil Final gear oil Make sure the engine oil is at the specified level. Add oil as necessary. (See pages 102--107). Make sure the final gear oil is at the specified level. Add oil as necessary. (See pages 107--109 for details). Recommended oil: SAE 80 API GL-4 Hypoid gear oil. In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
USER'S MANUAL Differential gear oil Make sure the differential gear oil is at the specified level. Add oil as necessary. (See pages 110--111 for details). Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a ATV dealer or refer to the Service Manual for correct tightening torque. Recommended oil:SAE 80 API GL-4 Hypoid gear oil. Lights Check the headlights and tail/brake light to make sure they are in working condition.
USER'S MANUAL Rear 25 kPa (0.25 kgf/cm2, 3.6 psi). Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides. 3. Tire pressure below the minimum dislodge specified could cause the tire to from the rim under severe riding conditions. The following are minimums: Front 22 kPa (0.22 kgf/cm2, 3.2 psi). Rear 22 kPa (0.22 kgf/cm2, 3.2 psi). 4. Use no more than the following pressures when seating the tire beads. Higher pressures may cause the tire to burst.
USER'S MANUAL How to measure tire pressure Use the low-pressure tire gauge. NOTE: The low-pressure tire gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect. Set pressure with tires cold. Set tire pressures to the following specifications: Recommended pressure Minimum Maximum 25kPa Front (0.25kgf/cm, 3.6psi) 22kPa (0.22kgf/cm, 3.2psi) 28kPa (0.28kgf/cm, 4.0psi) 25kPa (0.
USER'S MANUAL Tire wear limit When the tire groove decreases to 3 mm (0.12 in)due to wear, replace the tire. a Tire wear limit.
USER'S MANUAL Starting a cold engine OPERATION POTENTIAL HAZARD Freezing control cables in cold weather . WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or colli-sion. Indicates a potential hazard that could result in serious injury or death. POTENTIAL HAZARD OperatingATV without being familiar with all controls. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding. 1.
USER'S MANUAL NOTE: Position 3: Cold engine start ambient temperature above 25 ° C (80 ° F) and warm engine start position. When the drive select lever is in the neutral position, the neutral indicator light should come on. If it does not come on, ask a ATV dealer to inspect the electric circuit. The engine can be started in any gear if the brake pedal is applied. However, it is recommended to shift into neutral before starting the engine. 5.
USER'S MANUAL NOTE: If the engine fails to start, release the start switch, then push the start switch again. Pause a few seconds before the next attempt. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. If the battery is discharged, pull the recoil starter to start the engine. See the engine break-in?section prior to operating the engine for the first time.
USER'S MANUAL Drive select lever operation and reverse driving. Before shifting, stop the machine and return the throttle lever to its closed position. Otherwise, the transmission may be damaged. Shifting: forward 1. Bring the machine to a complete stop and return the throttle lever to the closedposition. 2. Shift the gear from neutral to forward and vice versa by moving the drive select lever along the shift guide. 3. Open the throttle lever gradually.
USER'S MANUAL Shifting: reverse 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Apply the brake pedal. 3. Shift the gear from neutral to reverse and vice versa by moving the drive select lever along the shift guide. 4. Check behind for people or obstacles, then release the brake pedal. 5. Open the throttle lever gradually and continue towatch to the rear while backing. ① Drive select lever. NOTE: When in reverse, the reverse indicator light should be on.
USER'S MANUAL POTENTIAL HAZARD Improper operation in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in serious injury. HOW TO AVOID THE HAZARD When you shift into reverse, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.
USER'S MANUAL Each ful l throttl e acceleration sequence should be followed with a substantial rest period for theengine by cruising at lower r/min so the engine can riditself of the temporary build up of heat If any abnormality is noticed during this period, consult a ATV dealer. Engine break-in There is never a more important period in the life of your machine than the period between zero and 20 hours. For this reason, we ask that you carefully read the following material.
USER'S MANUAL 10-20 hours: Avoid prolonged operation above 3/4 throttle. Parking When parking, stop the engine and shift into neutral. Turn the fuel cock to “OFF” and apply the parking brake. Rev the machine freely but do not use full throttle at any time. After break-in: Avoid prolonged full throttle operation.Vary speeds occasionally.
USER'S MANUAL Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake lever and pedal applied, apply the parking brake, and then lowly release the brake pedal. POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN TheATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
USER'S MANUAL Accessories Accessories should be rigidly and securely mounted. An accessory which can shift position or come off while you are riding could affect your ability to control the ATV. Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. Choose only accessories designed for your ATV. Do not mount an accessory where it could interfere w i t h yo ur a bil i t y t o c ontr ol t h e AT V.
USER'S MANUAL Loading Cargo or a trailer can change the stability and handling of anATV. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: Never exceed the weight limits shown.An over loaded ATV can be unstable. Do not exceed the maximum tongue weight. You can measure tongue weight with a bathroom scale. Put the tongue of the loaded trailer on the scale with the tongue at hitch height.
USER'S MANUAL Ride more slowly than you would without a load. The more weight you carry, the slower you should go. Allow more braking distance. A heavier vehicle takes longer to stop. Avoid making sharp turns unless at very slow speeds. Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the ATV. POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly.
USER'S MANUAL Indicates a potential hazard that could result in serious injury or death.
USER'S MANUAL 56
USER'S MANUAL 57
USER'S MANUAL Owner ’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages 5--10 . Please also read all caution and warning labels on your ATV. Indicates a potential hazard that could result in serious injury or death. GETTING TO KNOW YOUR ATV This ATV is for recreation and utility use. This section, R i d i n g y o u r AT V, p r o v i d e s g e n e r a l AT Vr i d i n g i nst ruc ti ons for recreational riding.
USER'S MANUAL RIDE WITH CARE AND GOOD JUDGEMENT HOW TO AVOID THE HAZARD Get training if you are inexperienced. Beginning and inexperienced operators should complete Beginners should get training from a certifiedinstructor. Become familiar with thisATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum perfor mance until the certified training course offered by ATV.
USER'S MANUAL Not recommended for children under 16 years of age. POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. HOW TO AVOID THE HAZARD A child under 16 should never operate an ATV with engine size greater than 90 cc.
USER'S MANUAL This ATV is designed to carry operator and cargo only passengers prohibited. POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
USER'S MANUAL Apparel Operating without protective clothing increases your chances of severe injury in the event of an accident. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Alwayswearanapprovedmotorcycle helmet that fits properly. You should also wear:eye protection(goggles or face shield)gloves boots long-sleeved shirt or jacket. Ope ra ti ng thi s AT V wi thout we ari ng a n a pprove d motorcycle helmet, eye protection and protective clothing.
USER'S MANUAL Do not operate after consuming alcohol ordrugs. Operator performance capability is reduced by the influence of alcohol or drugs. POTENTIAL HAZARD Operating this ATV after consuming alcoh ol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
USER'S MANUAL Pre-operation checks Always perform the pre -operation checks l isted on page 33 before riding for safety and proper care of the ATV. POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire pressure, may cause loss of control, increasing your risk of an accident. POTENTIAL HAZARD Failure to inspect the ATV before operating.
USER'S MANUAL Speed limiter For riders less experienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning the adjusting screw in limits the maximum engine power available and decreases the maximum speed of theATV. Turningthe adjustingscrew in decreases top speed and turning it out increases top speed.
USER'S MANUAL Loading and accessories Use extra caution when riding the ATV with additional loads, such as accessories or cargo. TheATV’s handling may be adversely affected. Reduce your speed when adding additional loads. POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo improperly. MAXIMUM LOADING LIMIT WHAT CAN HAPPEN Vehicle loading limit: 210 kg (463 lb). Could cause changes in vehicle handling which could lead to an accident.
USER'S MANUAL During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control theATV or could cause you to lose your balance and fall off of the ATV.
USER'S MANUAL Avoid wheelies and jumping. You may lose control of the ATV or overturn. POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
USER'S MANUAL Modifications POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
USER'S MANUAL Exhaust system The exhaust system on the ATV is very hot during and following operation. To prevent burns, avoid touching the exhaust syste m. Park t he ATV in a plac e where pedestrians or children are not likely to touch it. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it. POTENTIAL HAZARD Hot exhaust system.
USER'S MANUAL BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. Riding on paved surfaces can cause loss ofcontrol. POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATVs are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots andstreets.
USER'S MANUAL Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
USER'S MANUAL Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hiddenhazards which may cause the ATV to upset. POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes,without enough time to react. Could result in the ATV overturn ing or going out of control.
USER'S MANUAL POTENTIAL HAZARD Failure to use extra care when operatingon excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
USER'S MANUAL When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on theATV to make you more visible. Watch care fully for other vehicles. Do not ride in areas posted "no trespassing" Do not ride on private property without getting per-mission.
USER'S MANUAL Select a large, flat area off-road to become familiar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice control of the throttle, brakes, and turning techniques in this area before trying more difficult terrain. With the engine idling, return the starter (choke)to the closed position, shift the drive select lever into the forward positi on, a nd t hen rel ease the parking brake. Apply the throttle slowly and smoothly.
USER'S MANUAL TURNING YOUR ATV HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner Manual. To achieve maximum traction while riding off -road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the in side of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily.
USER'S MANUAL Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper ridi ng procedures such a s abrupt thrott le changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV be gi ns t o tip over t o the outside while negotiating a turn, lean more to the inside.
USER'S MANUAL HOW TO AVOID THE HAZARD Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting largehills. CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver yourATV well on flat ground before attempt ing any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill.
USER'S MANUAL An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
USER'S MANUAL If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. POTENTIAL HAZARD Improperly crossing hills or turning onhills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
USER'S MANUAL When crossing the side of a hill: Always follow proper procedures as described in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
USER'S MANUAL If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning.
USER'S MANUAL If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake. 4WD: Apply both front and rear brakes gradually. When fully stopped, lock the parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner’s Manual.
USER'S MANUAL RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Engine compression will do most of the braking for you. For maximum engine compression braking effect, change to 4WD before beginning to descend the hill. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces.
USER'S MANUAL POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner’s Manual. Note: a special technique is required when braking as you go down a hill. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
USER'S MANUAL CROSSING A SLOPE Traversing a sloping surface on your ATV re q uires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. POTENTIAL HAZARD Improperly crossing hills or turning onhills. WHAT CAN HAPPEN Could cause loss of control or cause the ATVto overturn.
USER'S MANUAL 88
USER'S MANUAL CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving,sha llow water of up to a maximum of 35 cm (14 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset theATV. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
USER'S MANUAL Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. After riding your ATV in water, be sure to drain the trapped water by removing the check hose at the bottom of the air filter case, the V-belt cooling duct check hose, the drive select lever box check hose and the storage box check hose. Also, remove the V-belt case drain plug to drain any water that may have accumulated.
USER'S MANUAL ① V-belt cooling duct check hose (left front side of ATV). ① Storage box check hose. ① Drive select lever box check hose. ① V-belt case drain plug.
USER'S MANUAL RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn.
USER'S MANUAL SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to anaccident. If the rear wheels of your ATV start to slide side ways, control can usually be regained (if there is room to do so) by steering in the direction of the slide. Applying the brakes or accelerating is not recommended until you have corrected the slide.
USER'S MANUAL With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
USER'S MANUAL WHAT TO DO IF This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 93--94). WHAT TO DO If your ATV does no turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again.
USER'S MANUAL If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of theATV to maintain proper balance. If the ATV starts to tip, steer down the hill ( if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 87 --88). Indicates a potential hazard that could result in serious injury or death.
USER'S MANUAL PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages. Owner’s manual and tool kit You are recommended to put this owner’s manual in the vinyl bag and always carry it on the bottom of the seat as shown.
USER'S MANUAL POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. ① Owner’s manual. ② Owner’s tool kit. ③ Low-pressure tire gauge. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories.
USER'S MANUAL PERIODIC MAINTENANCE/LUBRICATION NOTE: For ATVs not equipped with an odometer or an hour meter, follow the maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
USER'S MANUAL EVERY ITEM Engine oil Engine oil filter cartridge Engine oil strainer* Final gear oil Differential gear oil Front brake* Rear brake* Select lever safety system cable* V-belt* Wheel* Wheel bearing* Front and rear suspension* Steering system* Drive shaft universal joint* Axle boots* ROUTINE month whichever k m comes first (m i) hours Replace.(Warm engine before draining). Replace. Clean. Check for oil leakage. Replace every 12 months. Check operation/fuid leakage.(See NOTE page 8).
USER'S MANUAL ITEM Fittings and fasteners* Lights and switches* ROUTINE month whichever k m comes first (m i) hours EVERY 1 320 (200) 20 INITAL 3 6 6 12 1,200 1,200 2,400 4,800 (750) (1,500) (1,500) (3,000) 75 1 50 150 3 00 Correct if necessary. Check all chassis fittings and fasteners. Adjust headinght beams. Check operation. Since these items require special tools, data and technical skills, have a HSUNdealer pertorm the sevice. NOTE: Recommended brake fluid: DOT 4.
USER'S MANUAL Panel removal and installation The panel illustrated needs to be removed to perform some of the maintenance described in this chapter. Refer to this section each time the panel has to be removed or installed. Panel A To remove Remove the bolt, and then take the panel off. To install Place the panel in the original position and install the bolt. When installing the panel, be sure not to pinch the cables or wires.
USER'S MANUAL Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the ATV on a level surface. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Wait a few minutes until the oil settles. 4.
USER'S MANUAL 7. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 5. Insert the dipstick in the oil filler hole (without screwing it in), and then remove it again to check the oil level. NOTE: The engine oil should be between the minimum and maximum level marks. ① Maximum level mark ② Minimum level mark 6. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.
USER'S MANUAL NOTE: Skip steps 4-6 if the oil filter cartridge is not being replaced. To change the engine oil (with or without oil filter cartridge replacement). 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil, and then remove the engine oil filler cap. 3. Remove the engine oil drain bolt to drain the oil from the crankcase. 4. Remove the oil filter cartridge with an oil filter wrench.
USER'S MANUAL ① O-ring ① Oil filter wrench NOTE: An oil filter wrench is available at a nearby ATVdealer. 5. Apply a light coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure the O-ring is seated properly.
USER'S MANUAL 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 23 N·m (2.3 m·kgf, 16 ft·lbf) 8. Add the specified amount of recommended engine oil, and then install the engine oil filler cap and tighten it. Recommended engine oil: See page 151.
USER'S MANUAL In order to prevent clutch slipppage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. Final gear oil Final gear oil measurement 1. Place the machine on a level surface. 2.
USER'S MANUAL Final gear oil replacement 1. Remove the final gear case cover by removing the bolts. 3. If the oil is below the brim of the filler hole,add sufficient oil of the recommended type to raise it to the correct level. Be sure no foreign material enters the final gear case. 4. Install the oil filler bolt, and then tighten it tothe specified torque. Tightening torque: Final gear oil filler bolt: 23Nm(2.3m · kgf, 16ft · lbf) ① Final gear case cover ② Bolt ( 2) 2.
USER'S MANUAL 4. Remove the oil filler bolt and the drain bolt to drain the oil. Recommended oil: SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.23 L (0.20 Imp qt, 0.24 US qt) Final gear oil drain bolt Be sure no foreign material enters the final gear case. 5. Install the drain bolt, and then tighten it to the specified torque. 7. Install the oil filler bolt, and then tighten it to the specified torque. 8. Check for oil leakage. If oil leakage is found, check for the cause. 9.
USER'S MANUAL Differential gear oil replacement 1. Place the machine on a level surface. 2. Place a container under the differential gear case to catch the oil. 3. Remove the oil filler bolt and oil drain bolt to drain the oil. ① Differential gear oil drain bolt 4. Install the oil drain bolt, and then tighten it to the specified torque. Tightening torque: Didderential gear oil drain bolt: 10 Nm (1.
USER'S MANUAL 5. Fill the differential gear case with the specified amount of the recommended oil. Be sure no foreign material enters the differential gear case. 6. Install the oil filler bolt, and then tighten it to the specified torque. NOTE: Do not exceed the specified differential gear oil quantity when filling. Overfilling will cause the oil to seep out of the breather hose during and after riding. Tightening torque: Differential gear oil filler bolt: 23 Nm (2.
USER'S MANUAL Axle boots. Check the protective boots for holes or tears.If any damage is found, have them replaced by a ATV dealer. Spark plug inspection Removal. 1. Remove the spark plug cap.
USER'S MANUAL 2. Use the spark plug wrench in the owner’s tool kit to remove the spark plug as shown. Instead, take theATVto aATV dealer.You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. Specified spark plug: DR8EA (NGK) Installation 1.
USER'S MANUAL NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. 4. Install the spark plug cap. a Spark plug gap 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug and tighten it to the specified torque.
USER'S MANUAL Air filter element cleaning. NOTE: There is a check hose at the bottom of the air filter case. If dust or water collects in this hose, empty the hose and clean the air filter element and air filter case. ① Holder ( 4) ② Air filter case cover 1 Air filter case check hose 1. Remove the seat. (See page 28 for seat removal and installation procedures.) 2. Remove the air filter case cover by unhooking the holders. 3. Remove the air filter element assembly.
USER'S MANUAL 4. Wash the element gently but thoroughly in solvent. POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. ① Air filter element frame ② Air filter element ③ Lock plate 6. Squeeze the excess solvent out of the air filter element and let it dry. 5.
USER'S MANUAL 8. Apply atv foam air filter oil or other quality foam air filter oil to the air filter element. NOTE: The air filter element should be wet but not dripping. 9. Pull the air filter element over its frame, and then install the lock plate. 10. Install the air filter element assembly. 11. Install the air filter case cover by hooking the fasteners onto the air filter case. 12. Install the seat. NOTE: The air filter element should be cleaned every 20-40 hours.
USER'S MANUAL V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct check hose, remove the hose and clean it. V-belt case drain plug After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the water from the case. NOTE: If water drains from the V-belt case after removing the plug, have a dealer inspect the ATV as the water may affect other engine parts.
USER'S MANUAL Spark arrester cleaning. Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the tailpipe by pulling it out of the muffler. ① Spark arrester 4. Insert the tailpipe into the muffler and align the bolt holes. 5. Install and tighten the bolts. ① Bolt ( 3) ② Tailpipe 3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe.
USER'S MANUAL Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a ATV dealer who has the professional knowledge and experience to do so. However, the idling speed may be performed by the owner as a part of the usual maintenance routine. POTENTIAL HAZARD Improper cleaning of the spark arrester.Hot exhaust system. WHAT CAN HAPPEN Could injure the eyes. Could cause burns.
USER'S MANUAL Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer to the spark plug lead, and then set the idle to the specified idling speed by adjusting the throttle stop screw.
USER'S MANUAL Select lever safety system cable adjustment Throttle lever adjustment. The select lever safety system cable streches with use , NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. 1. Loosen the locknut. 2. Turn the adjusting bolt until the throttle lever free play is 3 5 mm (0.12- 0.20 in). 3. Tighten the locknut. resulting in improper function. To prevent this, the cable must be adjusted regularly. This adjustment, however, should be left to a ATV dealer.
USER'S MANUAL Front brake pad check Check the brake pads for damage and wear. If a brake pad thickness is less than 1 mm (0.04 in), have a ATV dealer replace the pads as a set. a Throttle lever free play a Brake pad thickness NOTE: The wheels need to be removed to check the brake pads. (See pages 134--135 for removal and installation procedures.
USER'S MANUAL Rear brake shoe inspection A wear indicator is provided on the rear brake.This indicator allows checking of brake shoe wear without disassembling the brake. Apply the rear brake and check the position of the indicator. If the indicator reaches the wear limit line, ask a ATV dealer to replace shoes as a set. Brake fluid level check Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective.
USER'S MANUAL Recommended brake fluid: DOT 4 Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance. Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
USER'S MANUAL Brake fluid replacement Complete fluid replacement should be done only by trained service personnel. Have a dealer replace the following components during periodic maintenance or when they are damaged or leaking. Replace the oil seals every two years. Replace the brake hoses every four years. Front brake lever free play The front brake lever should have a free play of zero mm (zero in) at the lever end.
USER'S MANUAL POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag. Make sure the brakes are not spongy. All air must be bled from the brake system. Replacement of brake components requires professional knowledge.
USER'S MANUAL Brake lever free play adjustment 1. Loosen the locknut and fully turn in the adjusting bolt at the brake lever.
USER'S MANUAL 2. Turn in the adjusting nut on brake cable toprovide a gap of 0-1 mm (0-0.04 in) between the brake camshaft lever and the pin. 3. Turn the adjusting bolt at the brake lever until the free play at the brake lever pivot is 3-5mm (0.12-0.20 in). ① Locknut ② Adjusting bolt a Rear brake lever free play ① Adjusting nut (brake lever cable) a Gap 4. Tighten the locknut.
USER'S MANUAL Adjusting the rear brake light switch The rear brake light switch, which is activated by the POTENTIAL HAZARD brake pedal and rear brake lever, is properly adjusted Operating with improperly serviced or adjusted brakes. when the brake light comes on just before braking takes WHAT CAN HAPPEN effect. If necessary, adjust the brake light switch as follows. You could lose braking ability, which could lead to an 1. Remove panel A. (See page 102 for panel removal and accident.
USER'S MANUAL Cable inspection and lubrication POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. ① Rear brake light switch ② Adjusting nut HOW TO AVOID THE HAZARD Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends.
USER'S MANUAL Lubricating the brake levers and brake pedal Lubricate the pivoting parts. NOTE: To access the brake pedal pivot, remove panel A.(See page 102 for panel removal and installation procedures).
USER'S MANUAL Wheel removal. 1. Loosen the wheel nuts. 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel.
USER'S MANUAL Wheel installation. 1. Install the wheel and the nuts. NOTE: Tapered nuts are used for both the front and rear wheel. Install the nut with its tapered side towards the wheel. The arrow mark on the tire must point toward the rotating direction of the wheel. ① Arrow mark 2. Lower the ATV so that the wheel is on the ground. 3. Tighten the wheel nuts to the specified torque. Wheel nut torque: Front: 55 Nm (5.5 m·kgf, 40 ft·lbf) Rear: 55 Nm (5.
USER'S MANUAL Battery This machine is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or add distilled water in the battery. If the battery seems to have discharged, consult a ATV dealer. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Get prompt medical attention. EYES: Flush with water for 15 minutes and get prompt medical attention.
USER'S MANUAL Fuse replacement 1. The main fuse case and the fuse box are located under the seat. 2. If a fuse is blown, turn off the main switch and install a new fuse of the specified amperage. Then turn on the switches. If the fuse immediately blows again, consult a ATV dealer. Battery maintenance 1. When the machine is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation.
USER'S MANUAL ① Main fuse ③ Fuse box ① ② ③ ④ ⑤ ② Spare main fuse Headlight fuse Ignition fuse Four-wheel drive fuse Signaling system fuse Spare fuse ( 3) Specified fuses: Main fuse: Headlight fuse: Ignition fuse: Four-wheel drive fuse: Signaling system fuse: 138 30A 15 A 15 A 3A 10 A
USER'S MANUAL Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the bulb holder cover at the rear of the headlight by pulling it off. POTENTIAL HAZARD Using an improper fuse. WHAT CAN HAPPEN An improper fuse can cause damage to the electrical system which could lead to a fire. HOW TO AVOID THE HAZARD Always use a fuse of the specified rating. Never use a material in place of the proper fuse.
USER'S MANUAL 2. Remove the headlight bulb holder by turning it counte rclockwise. ① Headlight bulb holder tab ( 2) ① Headlight bulb holder 3. Remove the defective bulb by unhooking the headlight bulb holder tabs.
USER'S MANUAL POTENTIAL HAZARD A headlight bulb is hot when it is on and immediately after it is turned off. WHAT CAN HAPPEN You can be burned, or a fire could start if the bulb touches something flammable. HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it. ① Do not touch the glass part of the bulb. 4. Insert a new headlight bulb into the bulb holder,and then secure the bulb by hooking the tabs onto the bulb.
USER'S MANUAL 5. Install the headlight bulb holder by turning it clockwise. 6. Install the headlight bulb holder cover at the rear of the headlight. Headlight beam adjustment It is advisable to have a ATV dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a . To lower the beam, turn the adjusting screw in direction b.
USER'S MANUAL Troubleshooting Although ATV machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a ATV dealer. The skilled technicians at a ATV dealership have the tools, experience, and knowhow to properly service your machine.
USER'S MANUAL POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage. HOW TO AVOID THE HAZARD Do not smoke when checking the fuel system. Make sure there are no open flames or sparks in the area, including pilot lights from water heaters or furnaces.
USER'S MANUAL tuen the cock lever to “ON”. 1.Fuel There is fuel. turn the fuel cock lever to “OFF”. Remove the fuel hose from the fuel cock. Check if there is fuel in the fueltank. Some fuel. Turn the fuel cock lever to “RES”. Restart the engine. No fuel. Supply fuel. 2.Compression Use the electric starter to see if there is compression Check the fuel flow. Nofuel. fuel cock is clogged. Compression nomal. There is compression. No compression. Ask a ATV dealer to inspect. 3.
USER'S MANUAL CLEANING AND STORAGE A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2.
USER'S MANUAL 6. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 7. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. POTENTIAL HAZARD Operation with wet brakes after washing.
USER'S MANUAL 2. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug. Ground the spark plug wire and turn the engine over several times to coat the cylinder wall with oil. 3. Lubricate all control cables. 4. Block up the frame to raise all wheels off the ground. 5. Tie aplastic bag over the exhaust pipe outlet to prevent moisture from entering. 6.
USER'S MANUAL 7. Remove the battery and charge it. Store it in a dry place and recharge it once a month. Do not store the battery in an excessively warm or cold place (less than 0 ° C(30 °F) or more than30 °C (90 ° F)). NOTE: Make any necessary repairs before storing the machine.
USER'S MANUAL SPECIFICATIONS Model Rd400 Di mensions: Overall length Overall width Overall height Seat height Wheel base Ground clearance Minimum turing radius 76.8in 41.3in 42.9in 32.3in 48.2in 9.6 in 118.1in Basic weight: With o il and full fuel tank 577.7 lbs Engine: Engine type Cylinder arrangement Di splacement Bore I stroke Compression ratio Star ting system Lubrication system Oil cooling 4-stroke, SOHC Forward-inclined single cylinder 387cc 83* 71.6 mm 9.
USER'S MANUAL Rd400 Model Final gear case oil: Type Quantity: SAE80 API GL-4 Hypoid gear oil 0.23 L (0.20 Imp qt, 0.24 US qt) Differen tial gear case oi l: Type Quantity: SAE80 API GL-4 Hypoid gear oil 0.35 L (0.31 Imp qt, 0.37 US qt) Air filter : Wet element Fuel: Type Fuel tank capacity Fuel reser ve amount UNLEADED GASOLINE ONLY 13.5 L (2.97 lmp gal, 3.57 US gal) 3.3 L (0.73 lmp gal, 0.
USER'S MANUAL Model Rd400 Transmission: Primary reduction system Secondary reduction system Secondary reduction ratio Transmission type Operation Forward gear Reverse gear V-belt Shaft dr ive 41/21 24/18 33/9 (9.545) V-belt automatic Left hand operation 35/20 (1.750 ) 26/15 (1.733) Chassis: Frame type Caster angle Trail Steel tube frame 4 21 mm (0.
USER'S MANUAL Model Rd400 Suspension: Front suspension Re ar suspension Double wishbone Swingarm (monocross) Shock absorber: Front shock absorber Rear shock absorber Coil spring / oil damper Coil spring / oil damper Wheel travel: Front wheel travel Rear wheel travel 160 mm (6.30 in) 180 mm (7.09 in) Electrical: Ignition system Generator system Battery type Battery capacity DC-C.D.I. A.C.
USER'S MANUAL Model Rd400 Bulb voltage, wattage !A quantity: Headlight Tail/brake light Neutral indicator light Reverse indicator light Oil temperature warning light Four-wheel drive indicator light 12 V, 30/30 W 2 12 V, 5/21 W 1 12 V, 1.7 W 1 12 V, 1.7 W 1 12 V, 1.7 W 1 12 V, 1.
USER'S MANUAL NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design
USER'S MANUAL MAINTENANCE RECORDS Mileage Date Times Items Maintained 1 M D Y 500 Oil 2 M D Y 1000 Oil/Filter All nuts 3 M D Y 1500 Oil/Filter 4 M D Y 3000 Oil/Filter 5 M D Y 4500 Oil/Filter 6 M D Y 6000 Oil/Filter Air Filter 7 M D Y 7500 Oil/Filter 8 M D Y 9000 Oil/Filter 9 M D Y 10500 10 M D Y 12000 Oil/Filter Oil/Filter Spark plug/Brake fluid 156 Dealer
USER'S MANUAL MAINTENANCE RECORDS Mileage(km) Date Times 11 M D Y 12 M D Y 13 M D Y 14 M D Y 15 M D Y 16 M D Y 17 M D Y 18 M D Y 19 M D Y 20 M D Y 10000 Items Maintained Oil / Air Cleaner Spark plug / Brake fluid 157 Dealer
USER'S MANUAL Warranty Registration Within 7 days dealer must register product warranty after a vehicle is sold. QLINK MOTOR will keep record of all the registration forms for the warranty policy on all the units. No warranty claim will be processed unless the product warranty is registered with QLINK MOTOR. Vehicle Owner's Responsibilities: Vehicle's owner must properly use, maintain and care for the vehicle as outline in the QLINK MOTOR owner's manual.
USER'S MANUAL Limited Warranty All new QLINK MOTOR motorcycles and scooters are covered with 2 YEAR LIMITED WARRANTY, and ATVs are covered with 1 YEAR LIMITED WARRANTY. Only QLINK MOTOR authorized dealers can submit warranty claim not consumers. The warranty registration needs to be on file with QLINK MOTOR before a warranty claim can be processed, unless the claim is due to shipping or crate damage and the unit has not yet been sold.
USER'S MANUAL Motorcycle / Scooter: Covered Parts Description Covered Period Motor Engine & Transmission 2 Mechanical Components Carburetor 2 Years (Unlimited Miles) Electrical Harness, CDI, Inst.
USER'S MANUAL ATV: Covered Parts Description Covered Period Motor Engine & Transmission 1 Mechanical Components Carburetor 1 Year (Unlimited Miles) Electrical Harness, CDI, Inst.
USER'S MANUAL Parts Not Covered Under Warranty: Spark Plugs Throttle Cable, Idle Cable Brake Line Cable, Clutch Cable Drive Chains, Drive Belts Air Cleaner’s Element & Bracket Rear Brake Shoes Front / Rear Brake Pads Swing Arm Bushing Light Bulbs Fuses Rubber Parts Front / Rear Tires & Tubes Front / Rear Rims Gear / Engine Oil Front / Rear Brake Rotors Brake / Clutch Levers Steering Stem Bearings Floor Boards / Pegs Oil / Fuel Filters Grips Motor Mount Bushing Any damage which results
