Farr 400UTV Owner'S Manual Download Page 95 | Manualshive

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8-1

PERIODIC MAINTENANCE AND

ADJUSTMENT

Periodic  inspection,  adjustment  and  lubrication
will keep your vehicle in the safest and most
efficient  condition  possible.    Safety  is  an
obligation  of  the  vehicle  owner.    The  most
important  points  of  vehicle  inspection,
adjustment  and  lubrication  are  explained  on
the following pages.

The  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 the Owner’s

tool kit are sufficient for this purpose, except
that a torque wrench is also necessary to
properly tighten nuts and bolts.

NOTE:

If you do not have a torque wrench available
during a service operation requiring one, take
your vehicle to dealer to check the torque
settings and adjust them as necessary.

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Summary of Contents for 400UTV

Page 1: ...FARR 400UTV OWNER S MANUAL ...

Page 2: ......

Page 3: ...n It provides information about special techniques and skills necessary to ride your UTV It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or maintenance of your UTV please consult the dealer AN IMPORTANT SAFETY MESSAGE READ THIS MANUAL TOGETHER WITH TIPS FOR THE UTV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR UTV MAKE SURE YOU ...

Page 4: ...wing notations The SafetyAlert Symbol means ATTENTION YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine 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 N...

Page 5: ...igh speed please keep engine running for 3 minutes at idle mode and make sure that the radiator fan still work for 3 minutes to prevent cooling water from boiling Then turn off the power switch to save the battery Because in this UTV its fuel tank setting position is lower than the carburetor and it is supplied fuel by negative pressure petrol pump so for the consideration of safety the factory wi...

Page 6: ...mergency light button 4 3 Horn button 4 3 Indicator and Warning Lights 4 4 Multi Function Display Gauge 4 7 Odometer and Trip Meter Modes 4 7 Clock Mode 4 8 Fuel gauge 4 8 On Command Four Wheel Drive And Differential Gear Lock Switches 4 9 Accelerator Pedal 4 13 Brake Pedal 4 14 Parking brake pedal 4 14 Drive Select Lever 4 15 Fuel Tank Cap 4 16 Starter 4 16 Seats 4 16 Seat belts 4 18 Glove Compar...

Page 7: ... Inspection 5 10 Seat Belts 5 10 Fittings and Fasteners 5 10 Lights 5 10 Switches 5 10 Tires 5 11 How To Measure Tire Pressure 5 13 Tire Wear Limit 5 14 Tires for Public use 5 14 6 OPERATION 6 1 Starting a cold engine 6 1 Starting a warm engine 6 3 Jump starting 6 3 Warming Up 6 5 Drive Select Lever Operation And Reverse Driving 6 5 Parking 6 9 Parking On A Slope 6 10 Accessories and loading 6 11 ...

Page 8: ...hange the Engine Oil With or With out Oil Filter Cartridge Replacement 8 8 Final Gear Oil Checking the Final Gear Oil Level 8 11 Changing the Final Gear Oil 8 12 Differential Gear Oil 8 13 Checking the Differential Gear Oil Level 8 13 Changing the Differential Gear Oil 8 14 Coolant 8 15 Checking the Coolant Level 8 15 Changing the Coolant 8 16 Axle Boots 8 17 Spark Plug Inspection 8 18 Removal 8 1...

Page 9: ...ot Lubrication 8 32 Steering Shaft Lubrication 8 33 Wheel Removal 8 34 Wheel Installation 8 34 Battery 8 35 Battery Maintenance 8 37 Fuse Replacement 8 37 Replacing A Headlight Bulb 8 40 Tail Brake Light Bulb Replacement 8 42 Check and solution to Common Problems in Vehicle 8 44 CLEANING AND STORAGE 9 1 A Cleaning 9 1 B Storage 9 3 SPECIFICATIONS 10 1 9 10 ...

Page 10: ...1 1 LOCATION OF THE WARNING AND SPECIFICATION LABELS ...

Page 11: ...ls 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 off a replacement label is available from your dealer ...

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Page 15: ...ved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or highway even a dirt or gravel one Never operate this vehicle without wearing an approve motorcycle helmet that fits properly You should also wear eye protection goggle or a face shield gloves over the ankle boots long sleeved shirt or jacket and long pants Never consume alcoh...

Page 16: ...r thumbs or fingers could be injured if they are in the way of the steering wheel spokes Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when driving the vehicle Never operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain Always...

Page 17: ...ity Test your brakes after leaving water If necessary apply the brake several times to let friction dry out the linings Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Do not brake abruptly when carrying loads in the cargo bed Always use the size and type of tires specified in this manual Always maintain proper ...

Page 18: ...ty 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 upright position Otherwise fuel may leak out of the carburetor or fuel tank WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot...

Page 19: ... 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 vehicle in an area with adequate ventilation ...

Page 20: ...ery 8 Fuses 9 Left body protection plate 10 Driver seat belt 11 Air filter element 12 Cargo bed 13 Tail brake lights 14 Turning light Rear 15 Spark arrester 16 Rear shock absorber assembly 17 CVT belt case 18 Fuel tank cap 19 Passenger seat belt 20 Right body protection plate 21 Spark plug 22 Oil filter cartridge 23 Radiator cap 24 Coolant reservoir 25 Turning light Front ...

Page 21: ...Ignition switch 29 Multi function display gauge 30 Auxiliary DC jack 31 Drive select lever 32 Accelerator pedal 33 Brake pedal 34 Release parking handle NOTE The vehicle you have purchased may differ slightly from those in the figures of this manual ...

Page 22: ...pare parts from a dealer or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle identification number and Model label The Vehicle Identification Number is stamped into the frame 1 Vehicle identification number 2 Model label NOTE The vehicle identification number is used to identify your vehicle ...

Page 23: ...3 4 Verification sign of EC Record the information on this label in the space provided This information will be needed to order spare parts from your dealer 1 Verification sign of EC ...

Page 24: ...t switch is on OFF All electrical circuits are switched off The key can be removed in this position START The electric starter is engaged by turning and holding the key in this position Release the key when the engine starts KEY Turning the steering wheel can lock the direction while unplugging the key 1CAUTION Do not operate the electric starter continuously for more than 5 seconds or starter dam...

Page 25: ...ge to the electric starter can result See starting instructions prior to starting the engine See pages 6 1 6 3 for details Combination switch Light switch OFF 1 Position lamp 2 Headlight switch 3 Right turn signal 4 Left turn signal 5 High beam switch 6 Emergency light button Set the switch to to turn on the low beam Set the switch to to turn on the high ...

Page 26: ...ttery may discharge to the point that the starter motor will not operate properly If this happens remove the battery and recharge it Turning light switch Setting the switch the turning light would spark correspondently The buzzer will sound Emergency light button Press this button The four turning lights will spark continuously At the same time the buzzer will sound Horn button 1 Horn switch 2 Ign...

Page 27: ...Battery Power Shorted Indicator 11 High beam indicator On Command Differential Gear Lock Indicator Light DIFF LOCK This indicator light and the On Command differential gear lock indicator in the display come on when the On command differential gear lock switch is set to the LOCK position NOTE When the switch is set to LOCK the On Command differential gear lock indicator light will flash until the ...

Page 28: ...e speed while riding have a dealer check the speed sensor circuit On Command Four Wheel Drive Indicator The On Command four wheel drive indicator comes on when the On Command four wheel drive switch is set to the 4WD position NOTE Due to the synchronizing mechanism in the differential gear case the four wheel drive indicator may not come on until the vehicle starts moving Coolant Temperature Warni...

Page 29: ...that the position light fixed in the front headlight has been turned on Coolant temperature warning indicator When the coolant temperature reaches to a specified level this light comes on to warn that the coolant temperature is too hot If the light comes on during operation stop the engine as soon as possible It is safe to do so and allow the engine to cool down for about 15 minutes CAUTION The en...

Page 30: ...utton The multi function meter unit is equipped with the following Speedometer which shows the riding speed Odometer which shows the total distance traveled Two trip meters which show the distance traveled since they were last set to zero Clock Hour meter which shows the total time the key has been turned to ON Odometer and Trip Meter Modes Pushing the TRIP ODO button switches the display between ...

Page 31: ...h Clock Mode Pushing the button switches the display between the clock mode CLOCK and the hour meter mode HOUR in the following order CLOCK HOUR CLOCK To Set the Clock 1 Set into the clock mode 2 Press the watch button for 3 5 seconds 3 Press the KM MILE button to set the hours 4 Press the TRIP ODO button to set the minutes 5 Press the watch button for 3 5 seconds and then release it the clock wil...

Page 32: ...tial Gear Lock Switches 1 On Command four wheel drive switch 2WD 4 WD 2 Differential gear lock switch LOCK 2WD This vehicle is equipped with an On Command four wheel drive switch 2WD 4WD and a differential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and the conditions Two wheel drive 2WD Power is sup ...

Page 33: ... to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while the vehicle is moving WHAT CAN HAPPEN The vehicle handles differently in 4WD than in 2WD and in 2WD Differential UNLOCK in some circumstances Changing from 2WD to 4WD or from 2WD to 2WD Differential UNLOCK or vice versa while moving may cause the vehicle to unexpectedly handle differently This could distract the operator and increa...

Page 34: ...D indicator will come on in the multi function display To change from 4WD to 2WD stop the vehicle and then set the switch to 2WD the 4WD indicator will go out in the multi function display On Command Differential Gear Lock Switch 4WD LOCK 1 On Command differential lock switch 4WD LOCK 2 Select lever To lock the differential gear in 4WD stop the vehicle make sure the On Command four wheel drive swi...

Page 35: ...ater the faster you go You may lose control and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE 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 indicator light will flash until the differential gear ...

Page 36: ...celerator pedal fully returns to the idle position as soon as it is released WARNING POTENTIAL HAZARD Malfunction of the throttle or pedal WHAT CAN HAPPEN The accelerator pedal could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the operation of the accelerator pedal before you start the engin throttle e ...

Page 37: ...eadle the parking pedal completely To release the parking brake Pull down the handle and treadle the parking pedal simultaneously Release the handle but keep treadling the pedal for a whilw then release the parking pedal completely 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 perfo...

Page 38: ... Parking brake pedal release lever Drive Select Lever The drive select lever is used to shift the vehicle into low high neutral and reverse positions Refer to pages 6 4 6 5 for the drive select lever operation 1 Drive select lever ...

Page 39: ...starter circuit supplies this mixture Move in direction to turn on the starter choke Move in direction to turn off the starter choke Refer to Starting a cold engine for proper operation See pages 6 1 6 3 A Starter choke N 1 Fully open 2 Half open 3 Closed Seats To remove a seat pull its seat lock lever upward lift the front of the seat and then slide the seat forward and up ...

Page 40: ...eat into the seat holders and push down on the seat at the front WARNING POTENTIAL HAZARD A loose seat WHAT CAN HAPPEN The operator could lose control or the operator or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched ...

Page 41: ...lt 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 2 Push the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 1 Buckle 2 Latch plate 3 Put the lap portion of the belt low on your hips Push down on the buckle end of the belt as you pull up on t...

Page 42: ...s the release button 1 Buckle 2 Release button WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident 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 ...

Page 43: ... do not put metal products like tools or sharply edged products directly in the glove compartment If they must be stored wrap them in appropriate cushion material a Open Cargo Bed 1 Cargo bed 2 Tailgate Opening and Closing the Tailgate 1 Tailgate 2 Latch 2 ...

Page 44: ... right side of the vehicle and then slowly lift up the cargo bed until it stops To lower Lower the cargo bed slowly to its original position and be sure it is locked into place Maximum load limit 150kg 330lb WARNING POTENTIAL HAZARD Pinch points WHAT CAN HAPPEN You or someone else could be pinched between the cargo bed and the frame when the bed is being lowered HOW TO AVOID THE HAZARD Before clos...

Page 45: ...ding the cargo bed WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated maximum load limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking ...

Page 46: ...ry cargo only Front and Rear Shock Adjustment The spring preload can be adjusted to suit the operating conditions You can reduce preload for a softer ride or increase preload if frequent bottoming occurs 1CAUTION Frequent or severe bottoming can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction To ...

Page 47: ...4 24 1 Spring preload adjusting ring 2 Position indicator NOTE A special wrench can be obtained at a dealer to make this adjustment Standard position B A Minimum soft E Maximum hard 1 Special wrench ...

Page 48: ...Always adjust the shock absorbers on the left and right side to the same setting Trailer Hitch Bracket This vehicle is equipped with a 5 cm 2 in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a dealer See pages 6 11 6 13 for precaution information 1 Trailer hitch bracket Auxiliary DC Jack The auxiliary DC jack is located at the right side of the front pan...

Page 49: ...ght switch to OFF 2 Start the engine See pages 6 1 6 3 3 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 4 When the auxiliary DC jack is not being used cover it with the cap 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12V 120W 10 A 1CAUTION Do not use accessories requiring more than the above maximum capacity This ...

Page 50: ...ries are used without the engine running or with the headlights turned on the battery will lose its charge and engine starting may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged ...

Page 51: ...r Check coolant level Fill with coolant if necessary 5 6 8 15 8 16 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8 5 10 Seat belts Check for proper operation and belt wear 5 10 Steering Check for proper operation 5 8 5 10 Fittings and fasteners Check all fittings and fasteners 5 11 Lights and switches Check for proper op...

Page 52: ...ibed in the Owner s Manual Brakes Always check 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 would indicate a possible fluid leak or low brake fluid level which must be corrected before riding If you discover any irregularities in brake system operation including excessive pedal travel contact your...

Page 53: ...8 28 Recommended brake fluid DOT 4 Brake Fluid Leakage Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir Apply the brakes firmly for one minute If there is any leakage have the vehicle inspected by a dealer Brake Operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking ...

Page 54: ...blem with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle inspected by a dealer Fuel Make sure there is sufficient gasoline in the tank Recommended fuel Unleaded gasoline only Fuel tank capacity 13 5L 2 97lmp gal 3 57US gal 1CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine par...

Page 55: ...ning ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended by because it may cause fuel system damage or vehicle performance problems WARNING 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 If the fuel tank is overfilled fuel could spill out due to ...

Page 56: ...age 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 coolant level is satisfactory if it is between the minimum and maximum level marks on the coolant reservoir If the coolant level is at or below the minimum level mark add additional coolant to bring the level up to maximum level mark If coolant is not av...

Page 57: ...completely removing the cap Final Gear Oil Make sure the final gear oil is at the specified level Add oil as necessary See pages 8 14 8 15 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used Differential Gear Oil Make sure th...

Page 58: ...or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Always check the pedal for free movement and return before starting the e...

Page 59: ...lay Inspection 1 Lift the parking brake to the top to park the car 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Free play should 1 16 to 1 8 inches 1 5 3mm Throttle Free play Adjustment 1 Remove both seats Remove the middle cover of the engine see PAGE 8 6 2 Loose the nut of throttle rop...

Page 60: ...en 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 which could affect operation Have a dealer repair as necessary for proper operation Fittings and Fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the vehicle to a dealer or ref...

Page 61: ... 1 The tires listed below have been approved by Motor Manufacturing corporation of America for this model Other tire combinations are not recommended 2 The tires should be set to the recommended pressure Recommended tire pressure Front 140kpa 1 4 kgf cm2 20psi Rear 140kpa 1 4 kgf cm2 20psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pre...

Page 62: ... Rear 126kpa 1 26kgf cm2 18psi 4 Use no more than the following Pressures when seating the tire beads Front 250kpa 2 5kgf cm2 36psi Rear 250kpa 2 5kgf cm2 36psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst ...

Page 63: ...cond 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 Front 140kpa 1 4kgf cm 2 10psi 126kpa 1 26kgf cm 2 9psi 250kpa 2 5gf cm 2 11psi Rear 140kpa 1 4kgf cm 2 10psi 126kpa 1 26kgf cm 2 9psi 250kpa 2 5kgf cm 2 11psi 1 Tire pressure gauge ...

Page 64: ...e to wear replace the tire a Tire wear limit Tires for Public use If you need to drive the UTV on public road please switch to the tires with public road use tread which can explore its performance Always use the public road use tires according to tires maker s recomment ...

Page 65: ...trol or function you do not understand ask your dealer Starting a cold engine WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the vehicle which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold weather always make sure all control cables work smoothly before you begin riding 1 Apply the brake 2 Shift t...

Page 66: ...ended to shift into neutral before starting the engine 3 Use the starter choke in reference to the figure Position Cold engine start ambient temperature below5 41 F Position Cold engine start ambient temperature at 0 32 F 30 86 F and warming up position Position Cold engine start ambient temperature above 25 77 F and warm engine start position a Starter choke 1 Fully open 2 Half open 3 Closed 4 Wi...

Page 67: ...o position before riding CAUTION See the Engine break in section prior to operating the engine for the first time Starting a warm engine To start a warm engine refer to the Starting a cold engine section The starter choke should not be used Press the accelerator pedal slightly Jump starting Jump starting the vehicle should be avoided The battery should be removed and charged instead However if the...

Page 68: ...ul not to touch the positive lead of the jumper cable to the negative lead reverse the polarity of the jumper cables when connecting to the batteries battery explosion and or serious damage to the electrical system may occur 6 Start the engine Refer to Starting a cold engine on pages 6 1 6 3 7 After the engine starts disconnect the negative lead of the jumper cable from the vehicle and charged bat...

Page 69: ...everse driving CAUTION Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged Shifting Neutral to Front 1 Stop the vehicle Keep your foot off the accelerator pedal 2 Apply the brakes then shift by moving the drive select lever along the shift guide NOTE Make sure that the drive select lever is completely shifted into positio...

Page 70: ... lever NOTE When in reverse the reverse indicator light should be on If the light does not come on ask a dealer to inspect the reverse indicator light electrical circuit Due to the synchronizing mechanism in the engine the light may not come on until the vehicle starts moving 4 Check behind for people or obstacles then release the brake pedal 5 Press the accelerator pedal gradually and continue to...

Page 71: ...three tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Perform the following procedures carefully Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive compon...

Page 72: ...the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid itself of the temporary build up of heat If any abnormality is noticed during this period consult a dealer 0 10 Hours Avoid continuous operation above half throttle Allow a cooling off period of five to ten minutes after every hour of...

Page 73: ...e clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Parking When parking stop the engine and shift the drive select lever into the neutral position Apply the parking brake to help prevent the vehicle from rolling 1 Parking brake pedal 2 Parking brake pedal...

Page 74: ...ly the parking brake and block the front and rear wheels with rocks or other objects Do not park the vehicle at all on hills that are so steep you could not walk up them easily 1 Bring the vehicle to a stop by applying the brakes 2 Stop the engine 3 With the brakes applied set the parking brake NOTE Like many other vehicles the parking brake acts on the rear wheels For the parking brake to have th...

Page 75: ...l over the quality or suitability of them Choose a genuine accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are operating could affect your ability to control the vehicle Do not mount an accessory where it could interfere with your ability to control the vehicle Examples include ...

Page 76: ...ler hitch point 50Kgf 110lbf Choose a trailer hitch drawbar designed for use with a 5 cm 2in receiver See page 4 25 for more information 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 Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carr...

Page 77: ...es 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 vehicle WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never excee...

Page 78: ... 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 passenger in the cargo bed WARNING POTENTIAL HAZARD Not wearing the seat belt Wearing the seat belt improperly WHAT CAN HAPPEN There is increased risk of being killed or seriously injured in an accident HOW ...

Page 79: ...e 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 passenger accessories cargo trailer tongue weight and the vehicle itself must not exceed 914Kg 1848 lb See Loading on page 6 11 Carrying a passenger and cargo can affect vehicle handling ...

Page 80: ...istributed 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 cargo or pulling a trailer The driver and passenger must always wear a seat belt and an approved motorcycle helmet Also wear eye protection and protective clothing including over the ankle boots gloves a long sl...

Page 81: ...ases 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 event of an accident HOW TO AVOID THE HAZARD Always wear an approved motorcycle helmet that fits properly You should also wear Eye Protection Goggles or Face Shield Gloves Boots Long Sleeved Shirt or Jacket Lo...

Page 82: ...before attempting more difficult maneuvers Perform the Pre Operation Checks on pages 5 1 5 15 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine Once it has warmed up and you have turned the choke off you are ready to begin driving your vehicle With the engine idling shift the drive select lever into low or high Then release the parking brake Press t...

Page 83: ...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 hands on the steering wheel so that your thumbs and fingers do not wrap around the wheel This is particularly important when driving in rough terrain The front wheels will move right and left as they res...

Page 84: ... 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 slowly 4 Apply the brakes lightly for stopping 5 Avoid making sharp turns Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly ...

Page 85: ...flat ground Use proper driving techniques to avoid overturns on hills and slopes Drive straight up hills and avoid crossing the side of a hill which increases your chance of rollover Practice first on gentle slopes before attempting steeper hills Always check the terrain carefully before attempting any hill Use common sense and remember that some hills are too steep for you to climb Maximum slope ...

Page 86: ...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 momentum going but not so fast that you cannot react to changes in the terrain as you climb Slow down when you reach the crest of the hill if you cannot clearly see what is on the other side There could be another person an obs...

Page 87: ...ownhill 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 may appear WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any...

Page 88: ...ly 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 you want to go CROSSING THROUGH SHALLOW WATER If you must cross shallow slow moving water up to the depth of the vehicle s floorboards choose your path carefully to avoid sharp drop offs large rocks or sli...

Page 89: ... 13in 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 1CAUTION After riding your vehicle in water be sure to drain the trapped water by removing the check hose at the bottom of the air filter case the CVT belt cooling duct check hose the drive select lever box check hose and ...

Page 90: ...r 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 If necessary repeat the drying procedure 7 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the CVT make sure inspect the hole without water left inside ...

Page 91: ... the front axle gearbox will give you the best traction In this case the two front wheels will be driven at the same rate It may not be useful to lock the differential case after you ve lost traction because the skid process has destroyed the soil structure Even if you lock the differential the front wheels may continue to slip and will not drive the vehicle ahead ...

Page 92: ...to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changi...

Page 93: ...ides 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 Never hold onto the enclosure so your hand is outside the vehicle Hold only onto the handgrip inside the enclosure ...

Page 94: ...ping 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 obstacle you should turn around if the ground is flat and you have the room or back up until you find a less difficult path WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Cou...

Page 95: ...ges The 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 the Owner s tool kit are sufficient for this purpose except that a torque wrench is also necessary to properly tighten nuts and bolts NOTE If you do not have a torque wrench available during a ...

Page 96: ... 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 handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accesso ries All parts and accessories added to this vehicle should...

Page 97: ...special tools data and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Spark Plug Check condition Adjust gap and clean Replace if necessary Crankcase Breather System Check breather hose for cracks or damage Replace if necessary Valves Check valve clearance Adjust if necessary Spar...

Page 98: ...cessary Every 20 40 hours More often in wet or dusty areas Engine Oil Replace Warm engine before draining Engine Oil Filter Cartridge Replace Final Gear Oil Check oil level Check oil leakage Replace Differential Gear Oil Front Brake Check operation brake pad wear fluid leakage see NOTE page 8 6 Correct if necessary Replace pads if worn to the limit Front and Rear Suspension Check operation and for...

Page 99: ... 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 Check if necessary Anti Roll Bar Bushings Check for cracks or damage NOTE Recommended brake fluid DOT4 Brake fluid replacement When disassembling the master cylinder or caliper replace the brake fluid Normally check the b...

Page 100: ...il it stops 1 Latch 2 1 Hood To Close Lower the hood slowly to its original position and then hook the hood latches Secure 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 ...

Page 101: ...ce and lubrication chart To Check Engine Oil Level 1 Place the vehicle on a level surface 2 Remove the console See page 8 9 for console removal and installation proce dures 3 Check the engine oil level on a cold engine NOTE If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil settles for an accurate read...

Page 102: ...he correct level 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 8 Install the console To Change the Engine Oil With or Without Oil Filter Cartridge Replacement 1 Remove the console See page 8 9 for console removal and installation procedures 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 ...

Page 103: ...artridge 2 Oil filter bolt NOTE An oil filter wrench is available at a nearby dealer 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 1 O ring 6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench ...

Page 104: ...ller cap and tighten it Recommended engine oil See page 10 2 Oil quantity Without oil filter cartridge replacement 2 2L 1 94 lmp qt 2 33 US qt With oil filter cartridge replacement 2 3 L 2 02 lmp qt 2 43 US qt 1CAUTION In order to prevent clutch slippage 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 ...

Page 105: ...l and correct it if necessary 11 Install the console Final Gear Oil Checking the Final Gear Oil Level 1 Place the vehicle on a level surface 2 Remove the oil filler bolt and then check the oil level in the final gear case 1 Speed meter sensor 2 Final gear oil 3 Correct oil level NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the filler hole add suffic...

Page 106: ...e Final Gear Oil 1 Place the vehicle on a level surface 2 Place a container under the final gear case to collect the used oil 3 Remove the oil filler bolt and the drain bolt to drain the oil 1 Final gear oil drain bolt 4 Install the drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 20 Nm 2 0 m kgf 14 ft lbs 5 Add the recommended final gear oil up to...

Page 107: ...lt 23 Nm 2 3 m kgf 16 3 ft lbs 7 Check for oil leakage If oil leakage is found check for the cause Differential Gear Oil Checking the Differential Gear Oil Level 1 Place the vehicle on a level surface 2 Remove the differential gear oil filler bolt and check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommended type to raise it to the...

Page 108: ...m 2 3 m kgf 16 3 ft lbs Changing the Differential Gear Oil 1 Place the vehicle on a level surface 2 Place a container under the differential gear case to collect the used oil 3 Remove the differential gear oil filler bolt and differential gear oil drain bolt to drain the oil 1 Differential gear oil drain bolt 4 Install the differential gear oil drain bolt and tighten it to the specified torque Tig...

Page 109: ...rque Differential gear oil filler bolt 23Nm 2 3m kgf 16 3 ft lbs 7 Check for oil leakage If oil leakage is found check for the cause Coolant The coolant level should be checked before each ride Checking the Coolant Level 1 Place the vehicle on a level surface 2 Open the hood See pages 8 7 8 8 for hood opening and closing procedures 3 Check the coolant level in the coolant reservoir when the engine...

Page 110: ...anti freeze with distilled water only However if distilled water is not available soft water may be used for refilling Changing the Coolant The coolant must be changed by a dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Antifreeze and water mixing...

Page 111: ...nt of the coolant as soon as possible The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If your vehicle overheats see page 8 45 for details Axle Boots Check the protective boots for holes or tears If any damage is found have them replaced by a dealer 1 Front axle boot 2 each side 1 Rear axle boot 2 each side ...

Page 112: ...rk plug cap 1 Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine The ideal color of the porcelain insulator around the center electrode is a medium to light tan for a vehicle that is being ridden normally Do not attempt to diagnose such problems yourself ...

Page 113: ...xcessive you should replace the spark plug with the specified plug Specified spark plug DR8EA NGK Installation 1 Measure the electrode gap with a wire thickness gauge and if necessary adjust the gap to specification a Spark plug gap Spark plug gap 0 8 0 9mm 0 031 0 035 in 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 I...

Page 114: ... plug cap 5 Lower the cargo bed Cleaning the Engine Air Filter Element 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 Air filter check hose 1 Remove the seats See pages 4 16 4 17 for seat removal and installation procedure 2 Remove the Engine cover See page 8 9 for Engine c...

Page 115: ... cleaner and then remove the air cleaner 1 Holder 3 2 Air filter case cover 4 Remove the air filter element 5 Remove the sponge material from its frame 1 Air filter element 1 Air filter frame 2 Sponge material 3 Element retaining plate ...

Page 116: ...ueeze the excess solvent out of the sponge material and let it dry 1CAUTION Do not twist the sponge material when squeezing it 8 Inspect the sponge material and replace it if damaged 9 Thoroughly apply foam air filter oil or other quality liquid foam air filter oil not spray type to the sponge material NOTE The sponge material should be wet but not dripping 10 Pull the sponge material over its fra...

Page 117: ...inlet to the air filter case for obstructions Check the air filter element rubber joint to the carburetor and manifold fittings securely to avoid the possibility of unfiltered air entering the engine 1CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the ai...

Page 118: ...e tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tailpipe housing 1 Tailpipe 2 Spark arrester 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe by installing the bolts and then tighten the bolts to the specified torque Tightening torque Tailpipe bolt 12 Nm 1 2 m kgf 8 5 ...

Page 119: ...O AVOID THE HAZARD When cleaning the spark arrester Always let the exhaust system cool prior to touching exhaust components Do not start the engine when cleaning the exhaust system Valve Clearance The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to...

Page 120: ... the brake pads as a set 1 Brake pad wear indicator groove NOTE The wheels need to be removed to check the brake pads See pages 8 4 18 42 for wheel removal and installation procedures Rear brake pad check 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 indica...

Page 121: ... fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage The brake fluid reservoir is located under the hood See pages 8 7 8 8 for hood opening and closing procedure 1 Minimum level mark Observe these precautions When checking the fluid level make sure the top of the brake fluid r...

Page 122: ...the brake system if the brake fluid level goes down 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 Checking the Brake Pedal Have a dealer check the brakes at...

Page 123: ...which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smo othly and that the brake pedal posi tion is correct Make sure the brakes do not drag All air must be bled from the brake system Replacement of brake components re quires professional knowledge These procedures should be performed by a dealer ...

Page 124: ...f necessary adjust the brake light switch as follows 1 Open the hood See pages 8 7 8 8 for hood opening and closing procedure 2 Turn the adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction 1 Brake light switch 2 Adjusting nut ...

Page 125: ...comes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly ask a dealer to replace them Recommended lubricant Engine oil see page 10 2 ...

Page 126: ...tion Lubricate the pivoting parts Recommended lubricant Lithium based grease all purpose grease Rear Knuckle Upper and Lower Pivot Lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium based grease ...

Page 127: ... Lubrication Lubricate the pivot points Recommended lubricant Lithium based grease all purpose grease Upper universal joint steering transmitssion shaft Lower universal joint steering transmitssion shaft Front balance rod ...

Page 128: ...e frame Remove the nuts from the wheel Remove the wheel 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 rear wheels Install the nut with its tapered side towards the wheel ...

Page 129: ...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 dealer 1CAUTION Do not try to remove the sealing caps of the battery cells You may damage the battery Wheel nut torque Front 70Nm 7 0 m kgf 49 7 ft lbs Rear 70Nm 7 0 m kgf 49 7 ft lbs ...

Page 130: ... 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 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 Keep batteries away from sparks flames cigarettes or ot...

Page 131: ...ON A 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 The main fuse and the fuse box are located under the hood See pages 8 7 8 8 for hood opening and closing procedures If a fuse is blown turn off the ignition switch and install a new fuse of the s...

Page 132: ...on switch when checking or replacing a fuse WARNING OTENTIAL 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 3 Remove the blown fuse and then install a new fuse of the specified amperage ...

Page 133: ...e Headlight Fuse Ignition Fuse Auxiliary DC Jack Fuse Signaling System Fuse Carburetor Warmer Fuse 2WD 4WD Fuse Backup Fuse 30 0A 15 0A 10 0A 10 0A 10 0A 10 0A 3 0A 10 0A 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a dealer check the electrical system 6 Install the battery compartment cover 7 Close t...

Page 134: ...over 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 Remove the headlight bulb holder by pushing it in and turning it counter clockwise 5 Remove the defective bulb by pulling it out 6 Insert a new headlight bulb into the bulb holder by pushing it in ...

Page 135: ...f the bulb touches something flammable HOW TO AVOID THE HAZARD Wait for the bulb to cool before touching or removing it 1CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth m...

Page 136: ...dlight 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 together with the bulb by turning it counter clockwise 3 Push the defective bulb in and turn it counter clockwise to remove it from the bulb holder 4 Push a new bulb in and turn it clockwise to insta...

Page 137: ...3 1 Tail brake light bulb holder 6 Install the panel by installing the quick fasteners and bolts and then tighten the bolts to the specified torque Tightening torque Panel bolt 6 5N m 0 65 m kgf 4 7 ft lbs ...

Page 138: ...nce parts and impact fittings S N Problems Solutions 1 Covers are cracked up when go crossing the field 1 Covers are cracked up when go crossing the field 2 Change for new plastic covers 3 Re paste the stickers and re rivet the warning labels 2 Vehicle s bottom protect tion plate is damaged by prominence on ground 1 Check if the reduction gear box and differential in front and rear bridge are dama...

Page 139: ...n calipers are over worn or contaminated by stuffs which can reduce friction 3 Check if there is any leakage in brake system s oil lines or conjunctions 4 Check if the post rod in brake master cylinder is deformed 5 Check if there is any air go into the oil lines and drain the air with special equipment 6 Check if the remain oil in master cylinders of front and rear brake is still above the lowest...

Page 140: ... damper rubber sleeves connecting front suspension rock and frame are damaged Table 3 Check and Solution of Common Problems in Electrical System S N Problems Solutions 1 Lamps don t work 1 Check if the headlight switch functions well 2 Check if the wires are broken 3 Check if the lamps or bulbs are broken 2 Vehicle cannot go into 4 drive mode 1 Check if the control switch on meter board works well...

Page 141: ...rk 1 Check if the switch is broken 2 Check if the wire is broken 3 Check if the CDI is broken Table 4 Check and Solution of Common Problems in Running System S N Problems Solutions 1 Swing clearance of stee ring wheel is too big 1 Check the fix screws connecting steering rod to steering stem and knuckle to find out if they are loose or broken 2 Check the bulds on the ends of steering rod to find o...

Page 142: ...ke seriously in running 1 Check the bearing in rear bridge bearing seat to find out if they are broken 2 Check the sliding bearing connecting rear bridge and rocks to find out if they are worn or loose 3 Check the inner splines of rear wheel hubs and outer splines of rear wheel axles to find out if they are worn or broken 4 Check the lock screws of rear wheels and axles to find out if they are loo...

Page 143: ...sorbers lose their damping force in their travel 6 Front bridge makes noise in running 1 Check if the spline of intermediate driving shaft is broken 2 Check if the splines in left right drive shafts of front rear bridges are broken 3 Check if the gears in rear bridge reduction gear box and differential are over worn 4 Check the dust cover of constant velocity universal joint in right left drive sh...

Page 144: ...k if the CDI s faulty 3 Power performance is falling 1 Check if the carburetor is blocked 2 Check and clean core of air cleaner 3 Check muffler for partly block and clean spark arrestor 4 Popping in engine 1 Check air cleaner and admission line for leak 2 Check the connection joint of exhaust pipe with engine or muffler for leak 3 Check the grade of gasoline to see if it s too low 5 Engine is diff...

Page 145: ...oop for mixed with air 7 Engine can not start 1 Check the battery which with low electricity may cause the motor failure 2 Check the starting motor for damage 3 Check if the carburetor is in regular situation 4 Check if the ignition loop can work in good condition 5 Check if the spark plug is foulled or burned 6 Check if the ignition signal is in good condition 7 Check if the air cleaner is blocke...

Page 146: ...ARNING 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 AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap ...

Page 147: ...aser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job 1CAUTION Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car wa...

Page 148: ...sives which 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 brakes after washing WHAT CAN HAPPEN Wet brakes may have reduced stopping ability increasing the chance of an accident HOW TO AVOID THE HAZARD Test the brakes after washing Apply the brakes several times at slow speeds to let friction...

Page 149: ... this will help prevent fuel deposits from building up 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 NOTE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult a dealer if the fuel system needs to be drained instead 3 Remove the spark plug pour about one tablesp...

Page 150: ...Do not apply oil to any rubber parts or the seat covers 8 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 32 F or more than 30 C 86 F NOTE Make any necessary repairs before storing the vehicle ...

Page 151: ... 52 0 in 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 548 kg 1 128 lb Engine Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system 4 stroke Water cooled Forward inclined single cylinder 387cm 3 83 0 71 6mm 3 26 2 81in 9 50 1 Electric starter Wet sump ...

Page 152: ...SG type or higher JASO standard MA 1CAUTION In order to prevent clutch slippage 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 2 2 L 1 94lmp qt 2 33 US qt 2 3 L 2 02lmp qt 2 43 US qt ...

Page 153: ...0 API GL 5 Hypoid gear oil 0 28L 0 25 lmp qt 0 3US qt Radiator capacity including all routes 1 5L 1 32 lmp qt 1 59 US qt Air filter Wet element Fuel Type Fuel tank capacity Unleaded gasoline only 13 5L 2 97 lmp gal 3 57 US gal Carburetor Type quantity PD36J C Spark plug Type Spark plug gap DR8EA 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic ...

Page 154: ... system CVT reduction ratio Transmission type Operation Reverse gear Forward gear V belt Shaft drive 0 625 2 714 V belt automatic Right hand operation Chassis Frame type Caster angle Trail Steel tube frame 4 0 21 0mm 0 83 in Tire Type Size Front Rear Tubeless AT25 8 12 AT25 0 12 ...

Page 155: ...Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shock absorber Coil spring oil damper Coil spring oil damper Wheel travel Front wheel travel Rear wheel travel 130mm 5 9 in 150mm 6 8 in Electrical Ignition system Generator system Battery type Battery capacity DC CDI AC magneto U1L 11 12V32Ah Headlight type Krypton bulb ...

Page 156: ...ght Reverse indicator light Coolant temperature warning light Parking brake indicator light Diff lock indicator On Command differential gear lock indicator light Foruard range indicator light LED LED LED LED LED LED LED Specified Fuse Main Fuse Headlight Fuse Ignition Fuse Auxiliary DC Jack Fuse Signaling System Fuse Carburetor Warmer Fuse 2WD 4WD Fuse Backup Fuse 30 0A 15 0A 10 0A 10 0A 10 0A 10 ...

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