Bennche Bighorn 400 Owner'S Manual Download

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1-2 Location of the Warning and Safety Labels

Summary of Contents for Bighorn 400

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Page 3: ...knowledge needed to have safe and enjoyable UTV operation If you have any questions regarding the operation or maintenance of your UTV please consult the dealer IMPORTANT SAFETY MESSAGES READ THIS MAN...

Page 4: ...e following notations The Safety Alert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator bystander or...

Page 5: ...s below 4 F 20 C park the UTV in a place where the temperature is higher than 4 F 20 C Start the UTV after the UTV has warmed up Please see page 6 3 on the warming up process Follow the proper parking...

Page 6: ...ifferential Gear Lock Indicator 4 6 Fault Code Indicator 4 7 Switches 4 9 On Command Four Wheel Drive and Differential Gear Lock Switches 4 10 Throttle Pedal 4 14 Brake Pedal 4 15 Parking brake pedal...

Page 7: ...Fasteners 5 10 Lights 5 10 Switches 5 10 How to measure tire pressure 5 13 Tire Wear Limit 5 14 Operation 6 1 Starting a Cold Engine 6 1 Starting a Warm Engine 6 2 Jump Starting 6 2 Warming Up 6 4 Dri...

Page 8: ...To Close 8 7 EFI System 8 8 EFI System inspection 8 11 Engine Oil and Oil Filter Cartridge 8 11 To Check Engine Oil Level 8 11 To Change the Engine Oil With or Without Oil Filter Cartridge Replacemen...

Page 9: ...Accelerator Pedal Lubrication 8 37 Rear Knuckle Upper and Lower Pivot Lubrication 8 37 Steering Shaft Lubrication 8 38 Wheel Installation 8 39 Battery 8 40 Battery Maintenance 8 42 Fuse Replacement 8...

Page 10: ...of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes...

Page 11: ...1 2 Location of the Warning and Safety Labels 5 6 7...

Page 12: ...Location of the Warning and Safety Labels 1 3 8 9 10 11 12...

Page 13: ...1 4 Location of the Warning and Safety Labels 13 14 15 16...

Page 14: ...Location of the Warning and Safety Labels 1 5 17...

Page 15: ...handgrip fixed before the seat Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or h...

Page 16: ...right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if...

Page 17: ...er than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply the brake several times to let friction dry out...

Page 18: ...the vicinity of sparks open flames or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an u...

Page 19: ...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 yo...

Page 20: ...ttery 6 Fuses 7 Left body protection plate 8 Driver seat belt 9 Air filter element 10 Cargo bed 11 Tail brake lights 12 Spark arrester 13 Rear shock absorber assembly 14 CVT belt case 15 Fuel tank cap...

Page 21: ...ight switch 26 On Command four wheel drive and differential lock switches 27 Multi function display gauge 28 Auxiliary DC jack 29 Drive select lever 30 Accelerator pedal 31 Brake pedal 32 Release park...

Page 22: ...for assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle Identification Number Th...

Page 23: ...electrical circuits are supplied with power Headlights and taillights come on when the light switch is turned to the on position OFF All electrical circuits are switched off The key can be removed in...

Page 24: ...lectric starter could result See starting instructions prior to starting the engine See pages 6 1 6 3 for details Indicator and Warning Lights 1 Four wheel locked showing light 2 Differential gear loc...

Page 25: ...is in the R reverse position Coolant Temperature Warning Light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the light...

Page 26: ...g NOTE If the engine is overheating stop the UTV immediately Do not start the engine again until the UTV has been inspected and repaired by a service center Low Battery charge indicator Indicates a lo...

Page 27: ...anel there are two large buttons one located on the left side and one on the right side Quickly pressing the button on the left side toggles the display from the odometer to the tripometer and then to...

Page 28: ...to set the minutes 4 Press the left button again and the clock will exit the set mode Four wheel drive indicator There are two 4WD indicators on the display panel The left 4WD indicator has a blinkin...

Page 29: ...e the stability and safety of the UTV operation CAUTION When the selector is set to 4WD the right 4WD symbol front axle will have an X in the middle When riding on good surfaces you should unlock the...

Page 30: ...be shown Then after five seconds the fault code returns again Only after the fault is fixed will the time show automatically The description for the fault codes are shown in Chapter 11 of this manual...

Page 31: ...the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all lights CAUTION Do not use the headlights with the engine turned off for an extended period The battery m...

Page 32: ...fferential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and the conditions Two wheel drive 2WD Power is sup plied to the rear wheels only Four wheel drive 4WD Power is s...

Page 33: ...cause the vehicle to unexpectedly handle differently This could distract the operator and increase the risk of losing control and an accident HOW TO AVOID THE HAZARD Always stop the vehicle before cha...

Page 34: ...cle make sure the On Command four wheel drive switch is set to 4WD move the select lever to position and then set the switch to LOCK 1 On Command differential lock switch 4WD LOCK 2 Select lever When...

Page 35: ...HAZARD Always ride at a slow speed when the vehicle is in 4WD LOCK and allow extra time and distance for maneuvers NOTE When the switch is set to LOCK the differential gear lock indicator and indicat...

Page 36: ...he pedal to the rest position when released Always check that the throttle pedal returns normally before staring the engine 1 Throttle pedal Before starting the engine check the throttle pedal to be s...

Page 37: ...eration of the accelerator pedal before you start the engine If the accelerator pedal does not work smoothly check for the cause Correct the problem before operating the vehicle Consult a service cent...

Page 38: ...e gradually Spring pressure helps return the pedal to the released position Be sure to fully release the parking brake before starting out Failure to do so may result in poor performance and premature...

Page 39: ...4 17 Control Functions 1 Drive select lever Fuel Tank Cap Remove the fuel tank cap by turning it counter clockwise 1 Fuel tank cap...

Page 40: ...tabs on rear of seat into the seat holders located on the UTV frame Push down the front of the seat until it snaps in place WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lo...

Page 41: ...1 Hold the latch plate as you pull the belt across your lap and chest Make sure the belt is not twisted and is not caught on any portion of the vehicle your clothing or any equipment you are carrying...

Page 42: ...e shoulder belt over your shoulder and across your chest The shoulder belt should fit against your chest If seat belt is loose pull the belt out all the way then let it retract 5 To release the buckle...

Page 43: ...t HOW TO AVOID THE HAZARD Always wear your seat belt when riding in the vehicle Be sure the seat belt is close fitting across your hips and chest and is latched securely Glove Compartment CAUTION To p...

Page 44: ...Control Functions 4 22 a Open Cargo Bed 1 Cargo bed 2 Tailgate...

Page 45: ...te in original up position then hook latches Lifting and Lowering the Cargo Bed 1 Cargo bed release lever To lift Push down cargo bed release lever on left or right side of the vehicle slowly lift up...

Page 46: ...ding away from the vehicle Keep hands and fingers away from pinch points between the bed and frame WARNING POTENTIAL HAZARD Overloading the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle han...

Page 47: ...only Front and Rear Shock Adjustment Option 1 The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if the vehicle is bottom...

Page 48: ...tions 4 26 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a service center to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Sp...

Page 49: ...hock Adjustment Option 2 WARNING These shock absorber assemblies contain highly pressurized nitrogen gas read and understand the following information before handling the shock absorber assemblies Do...

Page 50: ...ar shock absorber assemblies can be adjusted to suit the operating conditions NOTE Never turn an adjusting mechanism beyond the minimum and maximum settings Spring preload 1 Loosen the locknut 2 Turn...

Page 51: ...er the spring preload With each complete turn of the adjusting nut Spring travel setting Front Minimum soft 375mm 14 76 in Maximum hard 490mm 19 29 in Spring travel setting Rear Minimum soft 402mm 15...

Page 52: ...Rebound damping force adjusting screw Compression damping force Turn the compression damping force adjusting screw use 2 5 allen wrench in direction to increase the compression damping force and ther...

Page 53: ...ponents have cooled Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac...

Page 54: ...ork lights radios etc The auxiliary DC jack should only be used when the engine is running 1 Auxiliary DC jack cap 1 Set the light switch to OFF 2 Start the engine See pages 6 1 6 2 3 Open the auxilia...

Page 55: ...um capacity This may overload the circuit and cause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine sta...

Page 56: ...eservoir Check coolant level Fill with coolant if necessary 5 6 8 20 8 21 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 9...

Page 57: ...scribed in the Owner s Manual Brakes Always check the brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied the brake pedal should feel firm Any sponginess...

Page 58: ...ee pages 8 32 8 33 Recommended brake fluid DOT 4 Brake Fluid Leakage Check to make sure there is no brake fluid leaking out of brake hoses joints or the brake fluid reservoir Apply the brakes firmly f...

Page 59: ...u find any problems with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle inspected by a service center Fuel Make sure there is suffici...

Page 60: ...ohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended because it may cause fuel system damage or vehicle performance problems WARNING...

Page 61: ...nkcase Recommended engine oil type and quantity See page 10 2 Coolant Check the coolant level in the coolant reservoir when the engine is cold The coolant level will vary with engine temperature The c...

Page 62: ...radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Final Gear Oil Make sure the final gear oil is at the specified level Add oi...

Page 63: ...the vehicle inspected by a service center WARNING Failure to check or maintain proper operation of the throttle system can result in an accident leading to serious injuries or death Never start or op...

Page 64: ...hrottle pedal freeplay Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Set parking brake 2 Start the engine Allow engine to warm up a few minutes 3 Measure the distance the throttle pe...

Page 65: ...ve smoothly when pulled out and retract on its own when released The latch plate should click securely into the buckle and release when the release button is pushed firmly Wash off any dirt or mud whi...

Page 66: ...ur risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been approved by Manufacturer for this model Other tire combinations are not recommended 2 The tires should be set to the reco...

Page 67: ...ons The following are minimums Front 9psi 63kpa 0 64kgf cm2 Rear 9psi 63kpa 0 64kgf cm2 4 Use no more than the following Pressures when seating the tire beads Front 36psi 250kpa 2 5kgf cm2 Rear 36psi...

Page 68: ...d 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 Mi...

Page 69: ...5 14 Pre Operation Checks Tire Wear Limit When the tire groove decreases to 0 12 in 3 mm due to wear replace the tire a Tire wear limit...

Page 70: ...or function you do not understand ask your service center Starting a cold engine WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the veh...

Page 71: ...key to START NOTE If the engine fails to start release the key and then try starting again Wait a few seconds before the next attempt Each cranking should be as short as possible to preserve battery...

Page 72: ...e terminal of the charged battery and the other end of the negative lead to an unpainted metal surface of the vehicle NOTE Do not connect the negative lead of the jumper cable to the negative terminal...

Page 73: ...e whether or not the engine is warm check if it responds to the throttle normally with the choke turned off Drive select lever operation and reverse driving CAUTION Before shifting you must stop the v...

Page 74: ...ake pedal 3 Shift from neutral to reverse or vice versa by moving the drive select lever along the shift guide NOTE Depress the brake pedal before shifting to reverse position The brake pedal is attac...

Page 75: ...the accelerator pedal gradually and continue to watch to the rear while backing WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you...

Page 76: ...is never a more important period in the life of your vehicle than the period between zero and 25 hours For this reason we ask that you carefully read the following material Because the engine is bran...

Page 77: ...freely but do not use full throttle at any time After Break In The vehicle can now be operated normally Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or ove...

Page 78: ...TIAL HAZARD Parking on a hill or other incline WHAT CAN HAPPEN The vehicle could roll out of control increasing the chance of an accident HOW TO AVOID THE HAZARD Avoid parking on hills or other inclin...

Page 79: ...g and control of your vehicle Keep the following in mind when considering an accessory or operating a vehicle that has accessories Choose only accessories designed for your vehicle Your service center...

Page 80: ...oading Cargo or a trailer can change the stability and handling of a vehicle You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never...

Page 81: ...he cargo bed Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with controls or your...

Page 82: ...CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed a...

Page 83: ...2 1 2 5 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry p...

Page 84: ...ssenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only The total weight of operator...

Page 85: ...e properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying...

Page 86: ...increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the even...

Page 87: ...re attempting maneuvers that are more difficult Perform the Pre Operation Checks on pages 5 1 5 14 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine On...

Page 88: ...go out of control if you attempt sharp high speed turns You should also be careful making sharp turns on rough terrain Do not attempt to turn around or make abrupt maneuvers on slope Position your han...

Page 89: ...ow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back up slowly 4 Apply the brak...

Page 90: ...loose or slippery surfaces GOING UPHILL Do not attempt to climb hills until you have mastered basic maneuvers on flat ground Use proper driving techniques to avoid overturns on hills and slopes Drive...

Page 91: ...some hills are too steep for you to climb Maximum slope angle 15 Choose carefully which hills you attempt to climb Avoid hills with slippery surfaces or ones where you will not be able to see far eno...

Page 92: ...re climbing the hill first be sure you are operating in low range 4WD or if necessary with 4WD Diff Lock To climb a hill you need traction momentum and steady throttle Travel fast enough to keep your...

Page 93: ...ive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over Carefully choose your path and drive no faster than you will be able to react to obstacles that...

Page 94: ...slowly and carefully If the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction...

Page 95: ...13 in 33cm Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply brakes several times to let friction dry out the linings CAUTION After ri...

Page 96: ...box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine...

Page 97: ...eck hose 1 CVT Gear Box inspection hole Front Axle Differential Lock When driving on rugged or muddy roads locking the differential case in the front axle gearbox will give you the best traction In th...

Page 98: ...d lead to a rollover accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle o...

Page 99: ...oth sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger N...

Page 100: ...e tipping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the...

Page 101: ...e service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in...

Page 102: ...h vehicle service WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in...

Page 103: ...y require special tools data and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km miles 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 3...

Page 104: ...ake Duct Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Engine Oil Replace Warm engine before draining Engine Oil Filter Cartridge Replace Final Differential Gear Oil Ch...

Page 105: ...ive Shaft Universal Joint Lubricate with lithium based grease Rear Upper and Lower Knuckle Pivots Lubricate with lithium based grease Fittings and Fasteners Check all chassis fittings and fasteners Ch...

Page 106: ...Periodic Maintenance and Adjustment 8 6 Hood To Open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood...

Page 107: ...cure projections on the underside of the hood into slots on the back of the instrument panel Secure slots on the side of the hood around projections on the frame 1 Projection 2 2 Slot 2 CAUTION Make s...

Page 108: ...ifferent from the engine which uses carburetor it consist of ECU EFI cables sensors actuators and other advanced components As the following pictures 1 Oxygen sensor threaded sleeve 2 Exhaust Pipe 3 O...

Page 109: ...8 9 Periodic Maintenance and Adjustment 1 Fuel injector 2 Intake Pipe 3 Intake Pipe Joint 4 Intake temperature sensor pressure sensor 5 Throttle 1 Water temperature sensor...

Page 110: ...ngine has the different working conditions the 2 parameters opening of air damper and pressure of air intake determine the engine s working condition ECU will adjust the fuel injection volume accordin...

Page 111: ...you can also use the special EFI system failure diagnostic apparatus for inspection diagnostic apparatus can provide a more detailed failure information Diagnostic apparatus equipped with its own user...

Page 112: ...tick with a clean rag 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...

Page 113: ...used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt NOTE Skip steps 4 6 if the oil filter cartridge is no...

Page 114: ...6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench Tightening torque Oil filter cartridge 12 ft lbs 17Nm 1 7m kgf 1 Oil...

Page 115: ...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 9 Star...

Page 116: ...ype to raise it to the correct level CAUTION Be sure no foreign material enters the final gear case 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final ge...

Page 117: ...he recommended final gear oil up to the brim of the filler hole Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 42 qt 0 4 L CAUTION Be sure no foreign material enters the final gear case...

Page 118: ...level CAUTION 1 Be sure no foreign material enters the differential gear case 2 Please clean the sensor every 310 miles 500km 1 Install the differential gear oil filler bolt and then tighten it to the...

Page 119: ...16 3 ft lbs 23Nm 2 3m kgf 5 Fill the differential gear case with the recommended oil Recommended oil SAE 80 API GL 5 Hypoid gear oil Oil quantity 0 3 qt 0 28L CAUTION Be sure no foreign material enter...

Page 120: ...is broken immediately replace a new one because the flying stone can easily break the oil cooler and cause oil leak CAUTION If the oil cooler is blocked it will make the oil temperature overheated an...

Page 121: ...he reservoir cap add coolant to the maximum level mark install the reservoir cap and then close the hood Coolant reservoir capacity up to the maximum level mark 0 663 qt 0 627L CAUTION Mix anti freeze...

Page 122: ...k 0 65 qt 0 627 L NOTE Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant have a service center check the antifreeze content of the coolan...

Page 123: ...ear axle boot 2 each side Spark Plug Inspection Removal 1 Remove seat See pages 4 18 for remove seat 2 Remove the spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as...

Page 124: ...ot attempt to diagnose such problems yourself Instead take the vehicle to a service center You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug...

Page 125: ...17 5 Nm 1 75 m kgf NOTE If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tight...

Page 126: ...for seat removal 2 Remove the Engine cover 3 Remove the connecting rubber tube between air cleaner and throttle valve and the screws fixing the air cleaner and then remove the air cleaner 1 Holder 3 2...

Page 127: ...ly but thoroughly in solvent WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or exp...

Page 128: ...e to the sponge material NOTE The sponge material should be wet but not dripping 10 Pull the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover and b...

Page 129: ...air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect throttle valv...

Page 130: ...que Tightening torque Tailpipe bolt 8 5 ft lbs 12 Nm 1 2 m kgf WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause bur...

Page 131: ...k Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake system To check the brake pad wear check the wear indicator...

Page 132: ...he brake pads as a set Checking the Brake Fluid Level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake f...

Page 133: ...harmful chemical reaction and lead to poor braking performance Be careful that water does not enter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fl...

Page 134: ...ve a service center check the brakes at the intervals specified in the periodic maintenance and lubrication chart There should be no free play in the brake pedal The brakes should operate smoothly and...

Page 135: ...mponents requires professional knowledge These procedures should be performed by a service center Brake Light Switch Adjustment The brake light switch which is activated by the brake pedal is properly...

Page 136: ...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 HOW TO AV...

Page 137: ...rake Pedal and Accelerator Pedal Lubrication Lubricate the pivoting parts Recommended lubricant Lithium based grease all purpose grease Rear Knuckle Upper and Lower Pivot Lubrication Lubricate the knu...

Page 138: ...ustment 8 38 Steering Shaft Lubrication Lubricate the pivot points Recommended lubricant Lithium based grease all purpose grease Upper universal joint steering transmission shaft Lower universal joint...

Page 139: ...ance rod 1 Nut 4 Wheel Installation 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and...

Page 140: ...quipped 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 service center CAUTION...

Page 141: ...ARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or...

Page 142: ...special battery charger constant voltage ampere or constant voltage is required for recharging a sealed type battery Using a conventional battery charger may shorten the battery life Fuse Replacement...

Page 143: ...replacing a fuse WARNING 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 u...

Page 144: ...in Fuse Headlight Fuse ECU Fuse Auxiliary DC Jack Fuse Signaling System Fuse 2WD 4WD Fuse Backup Fuse Speedometer ECU normal open Fuse 30 0A 15 0A 15 0A 10 0A 10 0A 10 0A 5 0A 10 0A 15 0A 5 0A 4 Turn...

Page 145: ...s 2 Remove the cover at the rear of the headlight by pulling it off 1 Cover at the rear of the headlight 3 Remove the headlight bulb holder cover by pulling it off 1 Headlight bulb holder cover 4 Remo...

Page 146: ...OID THE HAZARD Wait for the bulb to cool before touching or removing it CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the l...

Page 147: ...beam if necessary Tail Brake Light Bulb Replacement If a tail brake light bulb burns out replace it as follows 1 Take down the tail light from carrier 1 Rear tail light 2 Remove the bulb holder togeth...

Page 148: ...y 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 ma...

Page 149: ...le 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...

Page 150: ...urself please contact your service center Table1 Solution of Common Problems in Appearance S N Problems Solutions 1 Plastic cover damaged 1 Replace whit a new plastic cover 2 Check if support brackets...

Page 151: ...ions 3 Damaged Front Skip Plate 1 Replace Front Skid Plate with a new one 2 Check if the gearbox or front differential rear axles are damaged or leaking 3 Check plastic cover for damaged and replace i...

Page 152: ...ight have gotten on either 3 Check brake fluid and refill if necessary 3 Grinding noises from front brake or brake rotor become red during operation due to heat 1 Check brake rotor for excess wear 2 C...

Page 153: ...rake power has caused the rear wheels to lock up locked before front wheels 3 Check if the left and right absorber springs are applying the same force and are within the specifications 4 Check if the...

Page 154: ...Check if the tie rod and steering column locknut has loosened or become damaged or if the steering knuckle and steering column locknut has loosened or is damaged 2 Check if the tie rod two ball joints...

Page 155: ...inner splines and rear wheel axle outer splines are worn or loose 5 Check if the rubber washers connected to rear suspension rocker arms and frame are damaged 5 Wheels hop during operation 1 Check if...

Page 156: ...g use 1 Check if the drive shaft spline is broken 2 Check if the splines in left right axles and front rear drive shafts are broken 3 Check if the gears in rear drive shaft and reduction gear box diff...

Page 157: ...n rear reduction gear box is damaged 3 Check if any wires are broken 3 Rear differential will not work 1 Check if the control switch on meter board works well 4 Rear differential will not work 1 Check...

Page 158: ...sconnected 3 Check if the engine speed signal sensor is broken 4 Check if the engine speed signal to ECU connection is disconnected 5 Check if the inlet pressure temperature sensor is damaged or the E...

Page 159: ...low 3 Engine is difficult to start at low temperatures 1 Check if the battery voltage goes down when the temperature goes down 2 If the temperature is under 18 place the vehicle in warmer place for st...

Page 160: ...ken 4 Check if the cylinder gasket is broken 5 Check if the cylinder body is worn damaged or seized 7 Piston and piston rings 1 Check for an improperly installed piston ring 2 Check if the piston ring...

Page 161: ...S N Problems Solutions 9 Crankcase and crankshaft 1 Check if the crankcase installed improperly 2 Check if the crankshaft is seized 10 Valve gear 1 Check for improperly adjusted valve clearance 2 Che...

Page 162: ...oon as possible WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO...

Page 163: ...ntbrush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage...

Page 164: ...leaner waxes as many contain abrasives that may scratch the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet br...

Page 165: ...the fuel from the fuel system as much as possible and pour the drained fuel into the fuel tank Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel...

Page 166: ...all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge Store it in a dry place and recharge it once a month Do not...

Page 167: ...Bighorn 400 1550mm 61 0 in for Bighorn 400 HD 1870mm 73 6 in 840mm 33 1 in 1830mm 72 0 in 300mm 11 8 in 3500mm 137 8 in Basic weight with oil and full fuel tank 590kg 1301 lb Engine Engine type Cylin...

Page 168: ...e replacement API service SG type or higher JASO standard MA CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oi...

Page 169: ...fferential gear case oil Type Quantity SAE80 API GL 5 Hypoid gear oil 0 28L 0 3 qt Radiator capacity including all routes 1 5 L 1 59 qt Air filter Wet element Fuel Type Fuel tank capacity Unleaded gas...

Page 170: ...Secondary reduction system CVT reduction ratio Transmission type Operation V belt Shaft drive 1 75 35 20 V belt automatic Right hand operation Chassis Frame type Caster angle Trail Steel tube frame 5...

Page 171: ...Right hand operation Dual disc brake Left hand and right foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock abso...

Page 172: ...ge quantity Headlight Tail brake light Front Rear turning light License light 12V35 0W 35 0W 2 12V5 0W 21 0W 2 12V10 0W 10 0W 2 12V3 0W Indicator lights Neutral indicator light Reverse indicator light...

Page 173: ...10 7 Specifications Model Bennche Bighorn 400 Main Fuse Headlight Fuse ECU Fuse Auxiliary DC Jack Fuse Signaling System Fuse 2WD 4WD Fuse 30 0A 15 0A 15 0A 10 0A 10 0A 10 0A...

Page 174: ...uit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 P0117 Coolant Oil Temperature Sensor Circuit Low Voltage KsDGDM_CoolantShortLow 117 279...

Page 175: ...n KsDGDM_INJ_CYL_B_Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor...

Page 176: ...DM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56 P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_N...

Page 177: ...a warrantable condition exists BENNCHE will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part will be repaired...

Page 178: ...road vehicle A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency and the Cali...

Page 179: ...iness during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the BENNCHE dealer BENNCHE shall not be liabl...

Page 180: ...d durability may be used in the performance of any maintenance or repairs by the owner However BENNCHE is not liable for these parts The owner is responsible for the performance of all required mainte...

Page 181: ......

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Bennche Bighorn 400, Owner'S Manual

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