Catvic 350ATV Instruction Manual Download Page 67

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POTENTIAL HAZARD

Operating with improperly serviced or

adjusted brakes.

W H AT CAN HAPPEN

You could lose braking ability, which

could lead to an accident.

H O W

TO AV OID 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 fro m

the brake system.

Replacement of brake components re-

quires professional knowledge. These

procedures should be performed by

AT V a dealer.

Rear brake pedal and lever adjustment

Brake pedal free play adjustment

1. Fully loosen the adjusting nut on the brake

lever cable at the rear wheel.

1. Adjusting nut (brake pedal cable)

2. Adjusting nut (brake lever cable)

128

Summary of Contents for 350ATV

Page 1: ...mation is distinguished in this manual by the following notations A CAUTION indicates special precautions that must be taken to avoid damage to the machine A NOTE provides key information to make procedures easier or clearer injury or death to the machine operator a bystander or a person The Safety Alert Symbol means ATTENTION BECOME ALERT IMPORTA N T MANUAL INFORMATION inspecting orrepairing the ...

Page 2: ... S 3 3 H a n d l e b a rs w i t c h e s 1 7 T h r o t t l el e v e r 2 0 S p e e dl i m i t e r 2 1 F r o n tb r a k el e v e r 2 2 B r a k ep e d a la n dr e a rb r a k e l e v e 2 2 P a r k i n gb r a k e 2 3 D r i v es e l e c tl e v e r 2 4 R e c o i ls t a r t e r 2 4 F u e lt a n kc a p 2 5 F u e lc o c k 2 6 S t a r t e r c h o k e 2 7 S e a t 2 8 S t o r a g eb o x 2 9 F r o n tc a r r i e...

Page 3: ...t m e n t 1 2 1 I d l es p e e da d j u s t m e n t 1 2 2 Va l v ec l e a r a n c ea d j u s t m e n t 1 2 2 T h r o t t l el e v e ra d j u s t m e n t 1 2 3 F r o n tb r a k ep a dc h e c k 1 2 4 R e a rb r a k es h o ei n s p e c t i o n 1 2 5 B r a k ef l u i dl e v e lc h e c k 1 2 5 B r a k ef l u i dr e p l a c e m e n t 1 2 7 F r o n tb r a k el e v e rf r e ep l a y 1 2 7 R e a rb r a k e...

Page 4: ...L O C ATION OF THE W ARNING A N D S P E C I F I C ATION LABELS 1111 1 111111 1 ...

Page 5: ...3 ...

Page 6: ...instruction Take a Training Course Begin n e r ss h o u l dr e c e i v et r a i n i n gf r o mac e r t i f i e di n s t r u c t o r C o n t a c t a n a u t h o r i z e d ATV d e a l e r Always follow the age recommendation A child under 16 years old should never operate an AT V with engine size greater than 90cc Never allow a child under age 16 to operate an AT V without adult supervision and neve...

Page 7: ...dures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the AT V Never attempt to turn the AT V around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if p o s s i b l e Always use proper procedures if y...

Page 8: ...gnition such as the pilot lights of water heaters and clothes dry e r s When transport i n g t h e AT V in another vehicle be sure it is kept upright and that the fuel cock is in the OFF posi tion Otherwise fuel may leak out of the carbure t o r o r f u e lt a n k W H AT CAN HAPPEN Gasoline is poisonous and can cause i n j u r i e s H O W TO AVOID THE HAZARD If you should swallow some gasoline or ...

Page 9: ...b er a ss e mb ly s pr i ng pr el o ad ad ju st in g r i ng 1 3 V be lt c oo li ng du c t c he c k hos e 1 4 Oi l fi lte r c ar tr i dg e 1 5 E n gi ne oi l di ps ti ck 1 6 R ea r br a ke l ev er 1 7 L ef t ha nd le ba r sw i tc hes 1 8 S ta r ter c h ok e 1 9 D r iv e se l ec t l ev er 2 0 M a i n s w i t c h 2 1 F uel ta nk c a p 2 2 R ig ht ha ndl eb arsw it ch 2 3 T hr ott le l ev er 2 4 F ro ...

Page 10: ...f the respective switch positions a r e a s f o l l o w s ON The engine can be started only at this position and the headlights and taillight come on when t h el i g h ts w i t c hi so n OFF A l l e l e c t r i c a l c i r c u i t s a r e s w i t c h e d o ff The key c a n b e r e m o v e d i n t h i s p o s i t i o n 1 Main switch 13 ...

Page 11: ...f AT V and can keeps memory Right turning indicator light A f t e r open r i g ht turning light cntrol r i g ht turning indicator light is on Metric system demenstration indicator light Metric system demenstration indicator light is on it indicates that vehhicle speed demenstraton is KM h Metric English system transfer indicator button Metric English system transfer indicator button can control tr...

Page 12: ...i t P r e s st u r n i n gl i g h ts w i t c hm i d d l e a l lt u r n i n gl i g h ta n d t u r n i n gi n d i c a t o rl i g h ta r eo u t W h e n l i g h t s w i t c h i s p u s h e d t o o f t h e f i r s t g e a r t a i l l i g h t f r o n tl i g h ta n dm e t e rl i g h tw i l ll i g h t When light switch is pushed to of the second g e a r t a i l l i g h t f r o n t l i g h t l a r g e h e ...

Page 13: ...p the AT V before changing from 2WD to 4WD or vice versa 19 Emergency light switch When ATV h a p p e n st ob et r o u b l e s o m eo r o t h e rc o n d i t i o n sd o n e e ds t o pt h ev e h i c l e r i g h ta w a yt ow a r no t h e rd r i v e r s On Command four wheel drive switch 2WD 4WD To change from two wheel drive 2WD to f o u r wheel drive 4WD stop the ATV a n d set the switch to the 4WD ...

Page 14: ...usting screw a 12 mm 0 47 in POTENTIAL HAZARD Improper adjustment of the speed limit e r and thro t t l e W H AT CAN HAPPEN The throttle cable could be damaged Improper t h rottle operation could re s u l t You could lose control have an acci dent or b e i n j u re d H O W TO AVOID THE HAZARD Do not turn the adjusting screw out more than 12 mm 0 47 in Always make sure the thro t t l e l e v e r f ...

Page 15: ...se an accident You could also wear out the brakes pre maturely H O W TO AVOID THE HAZARD Always set the parking brake before starting the engine Always be sure you have released the parking brake before you begin to ride 23 POTENTIAL HAZARD Improper use of the parking brake W H AT CAN HAPPEN The AT V c o u l d s t a rt moving unexpect edly if the parking brake is not applied before start 1 s e e e...

Page 16: ...AL HAZARD Starting the engine without shifting into the neutral position W H AT CAN HAPPEN The AT V could start to move unexpect edly which could cause an accident H O W TO AVOID THE HAZARD Shift the drive select lever into the neu tral position and apply the parking brake befores t a rt i n g t h e e n g i n e 25 ...

Page 17: ...r t e r c i r c u i t s u p p l i e s t h i s m i x t u r e Move in direction a to turn on the starter c h o k e Move in direction b to turn off t h e s t a r t e r c h o k e Refer to Starting a cold engine for proper op e r a t i o n S e e p a g e 4 3 1 Arrow mark pointing to RES 2 7 1 S t a r t e r c h o k e ...

Page 18: ...ols or sharply edged prod ucts directly in the storage box If they must be stored wrap them in appropriate cushion material 1 Storage box 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 1 Storage box check hose 29 ...

Page 19: ... r e c t i o n a To decrease the spring preload turn the ad j u s t i n gr i n gi nd i r e c t i o n b 1 S p r i n g p r e l o a d a d j u s t i n g r i n g 2 P o s i t i o n i n d i c a t o r POTENTIAL HAZARD Improper shock absorber adjustment W H AT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident H O W TO AVOID THE HAZARD Always adjust t...

Page 20: ... c k o i l l e v e l Engine oil F i l lw i t ho i l i fn e c e s s a r y Check for leakage F i n alg e a ro i l d i ff e re n t i a l g e a r o i l C h e c k f o r p r o p e r t h r o t t l e c a b l e o p e r a t i o n Thro t t l e Check tire pressure wear and damage Wheels and tire s C h e c k a l l f i t t i n g s a n d f a s t e n e r s Fittings and fasteners Check for proper operation Lights ...

Page 21: ...h e b r a k e s a t s l o w s p e e d a f t e r s t a r t i n g o u t t o make sure they are working properly If the brakes do not provide proper braking per formance inspect the brake pads and shoes for wear See page 123 POTENTIAL HAZARD Riding with improperly operating brakes W H AT CAN HAPPEN You could lose braking ability which could lead to an accident H O W TO AVOID THE HAZARD Always check t...

Page 22: ...NTIAL HAZARD Improper c a re when re f u e l i n g W H AT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could s p i l l o u t d u e t o h e a t f rom the engine or t h e s u n H O W TO AVOID THE HAZARD Do not overfill the fuel tank Be care f u l not to spill fuel especially on the engine o r exhaust pipe W ipe u...

Page 23: ... e r r e p a i r a s n e c e s s a r y f o r p r o p e r o p e r a t i o n Fittings and fasteners Always check the tightness of chassis fittings and f a s t e n e r s b e f o r e a r i d e Ta k e t h e m a c h i n e t o a ATV dealer or refer to the Service Manual for correct t i g h t e n i n g t o r q u e Switches Check the operation of all switches Have a ATV d e a l e r r e p a i r a s n e c e ...

Page 24: ...d i r t i n t h e g a u g e c o u l d c a u s e t h e f i r s t r e a d i n g t o b e i n c o r r e c t S e t p r e s s u r e w i t h t i r e s c o l d S e t t i r e p r e s s u r e s t o t h e f o l l o w i n g s p e c i f i c a t i o n s 0 25kgf cm Recommended p r e s s u r e F r o n t Rear Minimum Maximum 25kPa 3 6 p s i 25kPa 0 25kgf cm 3 6 p s i 22kPa 0 22kgf cm 3 2 p s i 22kPa 0 22kgf cm 3 2...

Page 25: ...and ask your AT V d e a l e r Starting a cold engine POTENTIAL HAZARD Freezing control cables in cold weather W H AT CAN HAPPEN You could be unable to contro lt h e AT V which could lead to an accident or colli s i o n H O W TO AVOID THE HAZARD When riding in cold weather always make s u rea l lc o n t rol cables work smoothly before you begin riding 1 Apply the brake pedal 2 Turn the fuel cock to...

Page 26: ...d n o t b e u s e d T h e t h r o t t l e s h o u l d b e o p e n e d s l i g h t l y W arming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see whether or not the e n g i n e i s w a r m c h e c k i f i t r e s p o n d s t o t h e t h r o t t l e n o r m a l l y w i t h t h e s t a r t e r c h o k e t u r n e d o ff 7 I ft ...

Page 27: ...e d r i v e s e l e c t l e v e r a l o n g t h es h i f tg u i d e NOTE W h e n i n r e v e r s e t h e r e v e r s e i n d i c a t o r l i g h t s h o u l d b e o n I f t h e l i g h t d o e s n o t c o m e o n a s k a ATV d e a l e rt oi n s p e c t 1 D r i v es e l e c tl e v e r 4 Check behind for people or obstacles then r e l e a s et h eb r a k ep e d a l 5 Open the throttle lever graduall...

Page 28: ...ive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm t h e e n g i n e 0 10 hours Av o i d c o n t i n u o u s o p e r a t i o n a b o v e h a l f t h r o t t l e Allow a cooling off p e r i o d o f f i v e t o t e n m i n u t e s a f t e r e v e r y h o u r o f o p e r a t i o n Va r y t h e s p e e d o f t h e m a c h i n e f r...

Page 29: ...n a hill or other incline W H AT CAN HAPPEN The AT V c o u l d ro l l o u t o f c o n t ro l i n c re a s ing the chance of an accident H O W TO AVOID THE HAZARD Avoid parking on hills or other i n c l i n e s I f you must park on an incline place the machine transversely across the incline apply the parking brake and block the fro n t and rear wheels with rocks or o t h e r o b j e c t s Do not p...

Page 30: ... l b f Do not exceed the maximum tongue weight You can measure tongue weight with a bathroom s c a l e P u t t h e t o n g u e o f t h e l o a d e d t r a i l e r o n t h e s c a l e w i t h t h e t o n g u e a t h i t c h h e i g h t Adjust the l o a d i n t h e t r a i l e r i f n e c e s s a r y t o r e d u c e t h e w e i g h t o n h i t c h If you are carrying cargo and towing a trailer inclu...

Page 31: ...Indicates a potential hazard that could re s u l t i n s e r i o u s i n j u ryo r d e a t h 55 ...

Page 32: ...57 ...

Page 33: ...ff e re d b y AT V They should then regularly practice the skills learned in the course and the operating techniques described in this Owner s Manual For more information about the training course contact an author i z e d AT V d e a l e r Riding your AT Vrequire s s k i l l s a c q u i re d t h rough practice over a p e r i o d o f t i m e Ta k e t h e t i m e t o l e a r n t h e b a s i c t e c ...

Page 34: ...t h i s AT V W H AT CAN HAPPEN Gre a t l y reduces your ability to balance and contro l t h i s AT V Could cause an accident resulting in harm to you and or your passenger H O W 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 61 ...

Page 35: ...OTENTIAL HAZARD Operating this AT V a f t e r consuming alco hol or drugs W H AT CAN HAPPEN Could seriously affect your judgment Could cause you to react more s l o w l y Could affect your balance and perc e p t i o n Could re s u l t i n a n a c c i d e n t H O W TO AVOID THE HAZARD Never consume alcohol or drugs before o r while driving this AT V c 63 ...

Page 36: ...itions and your experience Speed limiter F o r r i d e r s l e s s e x p e r i e n c e d w i t h t h i s m o d e l t h i s m o d e l i s e q u i p p e d w i t h a s p e e d l i m i t e r i n t h e t h r o t t l el e v e rh o u s i n g The speed limiter keeps the t h r o t t l e f r o m f u l l y o p e n i n g e v e n w h e n t h e t h r o t t l e lever is pushed to the maximum Tu r n i n g t h e a...

Page 37: ...Removing even one hand or f o o t c a n reduce your ability to contro l t h e AT V o r could cause you to lose your balance and fall off o f t h e AT V I f y o u remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could i n j u re you or cause an accident H O W TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footboards ...

Page 38: ...in some situ ations could lead to an accident H O W TO AVOID THE HAZARD Never m o d i f y t h i s AT V t h rough improper i n s t a l l a t i o n o r u s e o f a c c e s s o r i e s All part s and accessories added to this vehicle should be genuine AT V o r equivalent com ponents designed for u s eo nt h i s AT V and should be installed and used according to instructions If you have questions cons...

Page 39: ...AZARD Failure to use extra care when operating t h i s AT V on unfamiliar t e r r a i n W H AT CAN HAPPEN You can come upon hidden ro c k s bumps or holes without enough time to react Could re s u l t i n t h e AT V o v e rturn i n g o r going out of contro l H O W TO AVOID THE HAZARD Go slowly and be extra careful when op erating on unfamiliar t e r r a i n Always be alert to changing terrain con...

Page 40: ...in areas where you might not be seen by other o ff road vehicles W H AT CAN HAPPEN You could be in a collision You could be injure d H O W TO AVOID THE HAZARD Always mount a caution flag on the AT V to make you more v i s i b l e W atch care f u l l y f o r o t h e r v e h i c l e s Do not ride in areas posted no trespassing Do n o t r i d e o n p r i v a t e p r o p e r t y w i t h o u t g e t t ...

Page 41: ... AT V could go out of contro l c a u s i n g a collision or overturn H O W TO AVOID THE HAZARD Always follow proper p rocedures for turning as described in this Owner s Manual Practice turning at low speeds beforea t tempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions As you approach a curve slow down and begin t o t u r n t h e h a n d l e b a r s i ...

Page 42: ...l e s t h a t m i g h t c a u s e y o u t o POTENTIAL HAZARD Operating on excessively steep hills W H AT CAN HAPPEN The vehicle can overturn more e a s i l y o n extremely steep hills than on level sur f a c e s o r s m a l l h i l l s H O W TO AVOID THE HAZARD Never operate the AT V on hills too steep f o r t h e AT V o r f o r your a b i l i t i e s P r a c t i c e on smaller hills before attemp...

Page 43: ...d the turning technique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid cro s s i n g t h e s i d e o f a s t e e p h i l l i f p o s s i b l e 81 I f y o u a r e c l i m b i n g a h i l l a n d y o u f i n d t h a t y o u have not properly judged your ability to make it t ot h et o p y o us h o u l dt u r nt h e ATV around while you still have for...

Page 44: ... e r t h e f r o n t b r a k e o r t h e r e a r b r a k e w i l l b r a k e a l l w h e e l s W h e n d e s c e n d i n g h i l l s u s i n g e i t h e r b r a k e l e v e r o r the brake pedal will brake the wheels on the down h i l ls i d e Av o i d s u d d e n a p p l i c a t i o n o f e i t h e r t h e f r o n t o r r e a r b r a k e b e c a u s e t h e w h e e l s o n t h e u p h i l l s i d...

Page 45: ...g may also cause al o s so ft r a c t i o n Whenever possible ride your ATV s t r a i g h t d o w n h i l l Avoid sharp angles which could allow the AT V t o t i p o r r o l l o v e r Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear 8 5 When this ATV is in 4WD all wheels front and r e a r a r e i n t e r c o n n e c t e d b y t h e d r i v ...

Page 46: ...d o w n h i l l I fy o u r ATV d o e s b e g i n t o t i p o v e r g r a d u a l l ys t e e r i n t h e d o w n h i l l d i r e c t i o n i f t h e r e a r e n o o b s t a c l e s in your path As you regain proper balance g r a d u a l l y s t e e r a g a i n i n t h e d i r e c t i o n y o u w i s h t o t r a v e l POTENTIAL HAZARD Improperly cro s s i n g h i l l s o r turning on h i l l s W H A...

Page 47: ... n d a v o i d r o c k s o r o t h e r o b s t a c l e s which may be slippery or upset the ATV D r i v e s l o w l y a n d c a r e f u l l y POTENTIAL HAZARD Operating this AT V t h rough deep or f a s t flowing water W H AT CAN HAPPEN Ti res may float causing loss of traction and loss of control which could lead to an accident H O W TO AVOID THE HAZARD Never operate this AT V in fast flowing wat...

Page 48: ...b e l t c o o l i n g d u c t c h e c k h o s e l e f t f r o n t s i d e o f ATV 1 Storage box check hose 1 D r i v e s e l e c t l e v e r b o x c h e c k h o s e 1 V b e l t c a s e d r a i n p l u g 91 ...

Page 49: ... to s l i d e i n l o o s e o r s l i p p e r y c o n d i t i o n s p o s i t i o n i n g your weight over the front wheels will sometimes h e l p I f t h e r e a r w h e e l s o f y o u r ATV s t a r tt os l i d es i d e w a y s c o n t r o l c a n u s u a l l y b e r e g a i n e d i f t h e r e i s r o o m t o d o s o b y s t e e r i n g i n t h e d i r e c t i o n o f t h e s l i d e Applying t...

Page 50: ... r o t t l e a n d o r steer to the outside of the turn See pages 77 7 8 I fy o u r ATV s t a r t st os l i d es i d e w a y s S t e e r i n t h e d i r e c t i o n o f t h e s l i d e i f y o u h a v e the room Applying the brakes or accelerating is not recommended until you have corrected t h e s l i d e S e e p a g e s 9 3 9 4 I fy o u r AT V c a n t m a k e i t u p a h i l l y o u a r e t r y ...

Page 51: ......

Page 52: ...t i o n s W H AT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situ ations could lead to an accident H O W TO AVOID THE HAZARD Never modify this AT V t h rough improper in st al l at io n o r u s e o f a c c e s s o r i e s All part s and accessories added to this vehicle should be genuine AT V o r equivalent components ...

Page 53: ...if damaged Correct if necessary Check operation Replace if damaged Check toe in Adjust if necessary Lubricate with lithium soap based grease Check operation Check operation Replace if damaged Check operation Engine oil Engine oil filter cartridge Engine oil strainer Final gear oil Differential gear oil Front brake Select lever safety system cable V belt Wheel bearing Front and rear suspension Stee...

Page 54: ...c h t i m e t h e p a n e l h a s t o b e r e m o v e d o r i n s t a l l e d 1 P a n e l A Panel A To remove R e m o v e t h e b o l t a n d t h e n t a k e t h e p a n e l o f f Toi n s t a l l P l a c et h ep a n e li nt h eo r i g i n a lp o s i t i o na n di n s t a l l t h eb o l t When installing the panel be sure not to pinch the cables or wires 1 P a n e l A 2 B o l t 102 ...

Page 55: ...p s t i c k i n t h e o i l f i l l e r h o l e w i t h out screwing it in and then remove it again t oc h e c kt h eo i ll e v e l NOTE The engine oil should be between the minimum and maximum level marks 1 Maximum level mark 2 Minimum level mark 7 I n s e r t t h e d i p s t i c k i n t o t h e o i l f i l l e r h o l e a n d t h e nt i g h t e nt h eo i lf i l l e rc a p 104 ...

Page 56: ... l t e rw r e n c hi sa v a i l a b l ea tan e a r b y ATV d e a l e r 5 A p p l y a l i g h t c o a t o f e n g i n e o i l t o t h e O ring of t h en e wo i lf i l t e rc a r t r i d g e NOTE Make sure the O ring is seated properly 1 O r i n g 106 ...

Page 57: ...he engine off immediately and check for t h e c a u s e F i n a l g e a r o i l Final gear oil measurement 1 P l a c e t h e m a c h i n e o n a l e v e l s u r f a c e 2 R e m o v e t h e o i l f i l l e r b o l t a n d t h e n c h e c k t h e o i ll e v e li nt h ef i n a lg e a rc a s e NOTE T h eo i ll e v e ls h o u l db ea tt h eb r i mo ft h ef i l l e r h o l e 1 F i n a l g e a r o i l 2 ...

Page 58: ...d oil S A E 8 0 API GL 4 Hypoid gear oil O i lq u a n t i t y 0 2 3 L 0 2 0 I m p q t 0 2 4 U S q t Be sure no foreign material enters the final gear case 7 I n s t a l l t h e o i l f i l l e r b o l t a n d t h e n t i g h t e n i t t o t h es p e c i f i e dt o r q u e 8 C h e c k f o r o i l l e a k a g e I f o i l l e a k a g e i s f o u n d c h e c k f o r t h e c a u s e 9 I n s t a l l t h...

Page 59: ... f o r e t h e o i l l e v e l c a n n o t b e a c c u r a t e l y c h e c k e d f r o m t h e o i l f i l l e r c a p h o l e Recommended oil S A E 8 0 API GL 4 Hypoid gear oil O i lq u a n t i t y 0 3 5 L 0 3 1 I m p q t 0 3 7 U S q t Be sure n o f o reign material enters the diff e r ential gear case 6 I n s t a l l t h e o i l f i l l e r b o l t a n d t h e n t i g h t e n i t t o t h es p e ...

Page 60: ... such problems y o u r s e l f 1 Spark plug wrench I n s t e a d t a k et h e ATV t oa ATV d e a l e r 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 elec trode erosion becomes excessive or if carbon and other deposits are excessive you should re p l a c e t h e s p a r k p l u g w i t h t h e s p e c ...

Page 61: ...lter element a n da i rf i l t e rc a s e 1 Air filter case check hose 1 Holder 4 2 A i r f i l t e r c a s e c o v e r 3 R e m o v e t h e a i r f i l t e r e l e m e n t a s s e m b l y 1 Air filter element assembly Á 1 Remove the seat See page 28 for seat i n g t h e h o l d e r s r e m o v a l a n d i n s t a l l a t i o n p r o c e d u r e s 2 Remove the air filter case cover by unhook 1 1 6 ...

Page 62: ...ime the air filter element maintenance is performed check the air i n l e t t o t h e f i l t e r c a s e f o r o b s t r u c t i o n s C h e c k t h e a i r f i l t e r c a s e r u b b e r j o i n t t o t h e c a r b u r e t o r a n d m a n i f o l d f i t t i n g s f o r a n a i r t i g h t s e a l T i g h t e n a l l f i t t i n g s s e c u r e l y t o a v o i d t h e p o s s i b i l i t y o f ...

Page 63: ... l i n g i t o u t o f t h em u f f l e r 1 Bolt 3 2 Ta i l p i p e 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon depos i t s f r o m t h e s p a r k a r r e s t e r p o r t i o n o f t h e t a i l p i p e 1 Spark arrester 4 I n s e r t t h e t a i l p i p e i n t o t h e m u f f l e r a n d a l i g n t h eb o l th o l e s 5 I n s t a l la n dt i g h t e nt h eb o l t s...

Page 64: ...rew Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine n o i s e To prevent this the valve clearance must be adjusted regularly This adjustment however s h o u l d b e l e f t t o a p r o f e s s i o n a l ATV s e r v i c e t e c h n i c i a n 1 S t a r t t h e e n g i n e a n d w a r m i t u p f o r a f e w minutes at approximat...

Page 65: ... damage and wear If a brake pad thickness is less than 1 mm 0 04 in h a v ea ATV d e a l e rr e p l a c et h ep a d sa sas e t a Brake pad thickness NOTE The wheels need to be removed to check the brake pads See pages 134 135 for removal a n d i n s t a l l a t i o n p r o c e d u r e s 124 ...

Page 66: ...may result in a harmful chemical reaction and lead to poor brake performance B e c a r e f u l t h a t w a t e r d o e s n o t e n t e r t h e brake f l u i dr e s e r v o i rw h e nr e f i l l i n g W a t e rw i l ls i g n i f i c a n t l y l o w e r t h e b o i l i n g p o i n t o f t h e f l u i d a n d m a y r e s u l t i n v a p o r l o c k Brake fluid may deteriorate painted surface so r p l...

Page 67: ... brakes do not drag Make sure the brakes are not spongy A l l a i r must be bled fro m the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by AT V a d e a l e r Rear brake pedal and lever adjustment Brake pedal free play adjustment 1 F u l l y l o o s e n t h e a d j u s t i n g n u t o n t h e b r a k e l e v e rc a b l ea tt h er...

Page 68: ...T u r n t h e a d j u s t i n g b o l t a t t h e b r a k e l e v e r u n t i l t h ef r e ep l a ya tt h eb r a k el e v e rp i v o ti s3 5 m m 0 1 2 0 2 0 i n 1 L o c k n u t 2 Adjusting bolt a Rear brake lever free play 4 T i g h t e n t h e l o c k n u t 2 T u r n i n t h e a d j u s t i n g n u t o n b r a k e c a b l e t o 1 3 0 ...

Page 69: ...maged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury H O W TO AVOID THE HAZARD Inspect cables frequently Replace dam aged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly a s ka AT V d e a l e r t o r e p l a c e t h e m Recommended lubricant c h a i n a n d c a b l e l u b e o r SA...

Page 70: ...1 Loosen the wheel nuts 2 Elevate the AT V and place a suitable s t a n d u n d e r t h e f r a m e 3 Remove the nuts from the wheel 4 Remove the wheel 1 N u t 4 Wheel removal Á 134 ...

Page 71: ...soned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases H O W TO AVOID THE HAZARD Avoid contact with skin eyes or c l o t h i n g Always shield eyes when working near batteries Keep out of reach of chil dren Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of wa ter or milk Follow with milk of magne sia beaten egg or vegeta...

Page 72: ... fuse 2 I g n i t i o n f u s e 3 Four wheel drive fuse 4 Signaling system fuse 5 S p a r e f u s e 3 S p e c i f i e d f u s e s M a i nf u s e H e a d l i g h tf u s e I g n i t i o nf u s e Four wheel drive fuse Signaling system fuse 30A 1 5 A 1 5 A 3A 1 0 A Á 138 ...

Page 73: ...adlight bulb holder by turning it counterclockwise 3 Remove the defective bulb by unhooking t h eh e a d l i g h tb u l bh o l d e rt a b s 1 Headlight bulb holder 1 H e a d l i g h t b u l b h o l d e r t a b 2 Á 140 ...

Page 74: ...h t b u l b h o l d e r c o v e r a t t h e r e a ro ft h eh e a d l i g h t Headlight beam adjustment It is advisable to have a AT V dealer make this adjustment To raise the beam turn the adjusting screw in d i r e c t i o n a To lower the beam turn the adjusting screw in d i r e c t i o n b 1 headinght beam adjusting screw 142 ...

Page 75: ...lame W H AT CAN HAPPEN Fuel can ignite or explode causing se vere injury or property damage H O W 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 144 ...

Page 76: ...paint brush Do not a p p l y d e g r e a s e r t o t h e w h e e l a x l e s 3 R i n s e t h e d i r t a n d d e g r e a s e r o f f w i t h a garden hose Use only enough pressure to d ot h ej o b Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical de vices Many expensive repair bills have result ed from improper high pressu...

Page 77: ... e l s y s t e m C o n s u l t a ATV d e a l e ri ft h ef u e ls y s t e mn e e d s t ob ed r a i n e di n s t e a d 2 Remove the spark plug pour about one table spoon of SAE 10W30 or 20W40 motor oil in t h es p a r kp l u gh o l ea n dr e i n s t a l lt h es p a r kp l u g Ground the spark plug wire and turn the e n g i n e o v e r s e v e r a l t i m e s t o c o a t t h e c y l i n d e r w a l l...

Page 78: ...placement Bore Á stroke Compression ratio Star ting system Lubrication system 265 kg Air cooled 4 stroke SOHC F o r w a r d i n c l i n e ds i n g l ec y l i n d e r 348 9 cm 83 0 64 5 mm 9 2 0 1 E l e c t r i ca n dr e c o i ls t a r t e r W et sump 3 150 1 984mm 78 1in 1 085mm 42 7in 1 120mm 44 1in 827mm 32 6in 1 233mm 48 5in 245mm 9 65in 3 000mm 118 1in 2 6 7k g 400ATV Air cooled 4 stroke SOHC ...

Page 79: ...nufacturer Spark plug Type manufacturer Spark plug gap Clutch type SAE80 API GL 4 Hypoid gear oil 0 2 3 L 0 2 0 I m p q t 0 2 4 U S q t SAE80 API GL 4 Hypoid gear oil 0 3 5 L 0 3 1 I m p q t 0 3 7 U S q t W et element UNLEADED GASOLINE ONLY 1 3 5 L 2 9 7 l m p g a l 3 5 7 U S g a l 3 3L 0 7 3l m pg a l 0 8 7U Sg a l BSR33 1 MIKUNI DR8EA NGK 0 6 0 7m m 0 0 2 0 0 3i n W e t c e n t r i f u g a l a u...

Page 80: ...h e e l t r a v e l R e a r w h e e l t r a v e l E l e c t r i c a l Ignition system Generator system Battery type Battery capacity Headli ght type Double wishbone Swi ngar m monocross C o i l s p r i n g o i l d a m p e r C o i l s p r i n g o i l d a m p e r 160 mm 6 30 in 180 mm 7 09 in DC C D I A C magneto YTX14AH 1 2 V 1 2 Ah Krypton bulb 154 ...

Page 81: ... n o i s e c o n t r o l p r i o r t o i t s s a l e o r d e l i v e r y t o t h e u l t i m a t e p u r c h a s e r o r w h i l e i t i s i n u s e o r 2 t h e u s e o f t h e v e h i c l e a f t e r s u c h d e v i c e o r e l e m e n t of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW T h e s e a c t s i ...

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