Qlink RD400 User Manual Download

Page: 108 / 168

102

Panel removal and installation

The panel illustrated needs to be removed to perform some
of the maintenance described in this chapter.
Refer to this section each time the panel has to be removed or
installed.

Panel A

①

Panel A
To remove
Remove the bolt, and then take the panel off.
To install
Place the panel in the original position and install the
bolt.

When installing the panel, be sure not to pinch the cables
or wires.

Panel A

Bolt

①

②

USER'S MANUAL

Summary of Contents for RD400

Page 1: ...unsafe to operate this machine on any public street road or highway This machine complies with all applicable OFF ROAD noise level and spark arrester laws and regulations in effect at the time of manu...

Page 2: ...YOURATV MAKE SURE YOU UNDERSTANDALL INSTRUCTIONS PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION TRAINING IS AVAILABLE TO A...

Page 3: ...ns 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 death to the machine operator a bystan...

Page 4: ...ne Oil 1 Location of the warning and specification labels 1 5 3 Description and machine identification 11 Vehicle identification number 12 13 13 14 17 20 21 22 22 23 24 24 25 26 Starter choke Seat Sto...

Page 5: ...56 58 59 71 77 79 85 87 89 92 93 7 Riding Your ATV What to do if What to do Owner s manual and tool kit Periodic maintenance lubrication Panel removal and installation Engine oil and oil filter cartr...

Page 6: ...rake levers and brake pedal Wheel installation Battery 10 Specifications 11 Noise Regulation 125 125 127 127 128 131 132 133 134 136 Battery maintenance Fuse replacement Replacing a headlight bulb Hea...

Page 7: ...LOCATION OFTHE W ARNING AND SPECIFICATION LABELS 1 USER S MANUAL...

Page 8: ...PRESSURE Set with tires cold Recommended FRONT 25kPa 0 25kgf cm 3 6psi REAR 25kPa 0 25kgf cm 3 6psi Minimum FRONT 22kPa 0 32kgf cm 3 2psi REAR 22kPa 0 32kgf cm 3 2psi Never set tire pressure below mi...

Page 9: ...fast for your skills or the conditions on public roads a collision can occur with another vehicle with more than one passenger passengers affect balance and steering and increase risk of losing contro...

Page 10: ...ce of severe injury or death NEVER operate this ATV if lyou are under age 16 WARNING DRIVE SELECT LEVER Read owner s manual carefully before operating ATV MUST be stopped before shifting select lever...

Page 11: ...ng Course Begin receive training from a certified instructor Contact an authorized dealer nersshould ATV Always follow the age recommendation Achild under 16 years old should never operate anATV with...

Page 12: ...cedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the ATV during operation Always go slowly and be extra careful when operating...

Page 13: ...escribed in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered...

Page 14: ...ving water If necessary apply them 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 i...

Page 15: ...l gasoline on the engine or exhaust pipe muffler when refueling Neverrefuel while smoking orinthe vicinityofsparks open flames or other sources of ignition such as the pilot lights of water heaters an...

Page 16: ...O AVOID THE HAZARD Starting or running the engine in a closed area Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time Always operate your ATV in an area with...

Page 17: ...chine you have purchased may differ slightly from those shown in the figures of this manual DESCRIPTION AND MACHIN IDENTIFICATION 11 12 Front Shock absorber assembly Spring Preload adjusting Ring 13 V...

Page 18: ...dentification number The vehicle identification number is stamped into the frame Vehicle identification number front left side The vehicle identification number is used to identify your machine NOTE U...

Page 19: ...tch Functions of the respective switch positions are as follows Main switch 13 USER S MANUAL ON OFF The engine can be started only at this position and the headlights and taillight come on whenthe lig...

Page 20: ...ur wheel drive indicator light Oil temperature warning light Neutral indicator light N Reverse indicator light R This indicator light comes on when the drive select lever is in the N position This ind...

Page 21: ...ay overheat if the ATV is overloaded If this happens reduce the load to specification Restart after making sure that the light is out Continuous use while the light is on may cause damage to the engin...

Page 22: ...smission in neutral Oil temperature warning light comes on momentarily Oil temperature warning light does not come on Oil tempera ture is low Oil tempera ture is high Engine oil temperature and electr...

Page 23: ...he engine stop switch is set to before starting the engine The engine stop switch controls ignition and can be used at all times to stop the engine especially in an emergency The ngine will not start...

Page 24: ...the engine See page 43 for details On command four wheel drive switch 2WD 4WD Tochange from two wheeldrive 2WD tofour wheel drive 4WD stoptheATVandsettheswitchtothe 4WDposition To change fromfour whe...

Page 25: ...rently in 2WD than in 4WD in some circumstances Changing from 2WD to 4WD or from theATV to unexpectedly handle diffe ntly This could distract the operator and increase the risk of losing control and a...

Page 26: ...eck the throttle to be sure it is operating smoothly Make sure it returns to the idle position as soon as the lever is released POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Malfunction of...

Page 27: ...TV Locknut Adjusting screw a 12 mm 0 47 in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could...

Page 28: ...apply the front brake Brake pedal and rear brake lever The brake pedal islocated onthe right sideoftheATVandthe rearbrake leveris located on the left handlebar Push down on the pedal or pull the leve...

Page 29: ...APPEN The ATV could start moving unexpect edly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the A...

Page 30: ...neutral and reverse positions Refer to page 46 for the drive select lever operation Drive select lever Recoil starter Firmly grasp the handle and pull slightly until engagement can be felt Then pull...

Page 31: ...D Starting the engine without shifting into the neutral position WHAT CAN HAPPEN TheATV could start to move unexpect edly which could cause an accident HOW TOA VOID THE HAZARD Shift the drive select l...

Page 32: ...is position With the lever in this position fuel flows to flow Always turn the lever to this position when the engine is not running With the lever in this position fuel will not while riding turn the...

Page 33: ...mixture Aseparate starter circuit supplies thismixture Moveindirection a toturnon thestarter choke Moveindirection toturnoffthestarter choke a Refer to tarting a cold engine for proper operation See p...

Page 34: ...up the seat at the rear Seat Seat lock lever To install the seat insert the projections on the front of the seat into the seat holders and push down on the seat at the rear Make sure that the seat is...

Page 35: ...harply edged products directly in the storage box If they must be stored wrap them in appropriate cushion material Storage box NOTE There is a check hose at the bottom of the storage box If any water...

Page 36: ...and riding conditions Adjust the spring preload as follows To increase the spring preload turn the adjusting ring in direction a To decrease the spring preload turn the adjusting ring in direction b...

Page 37: ...tion a To decrease the spring preload turn the adjusting ring in direction b Spring preload adjusting ring Position indicator POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven...

Page 38: ...al wrench can be obtained at a dealer to make this adjustment Standard position 2 1 Minimum soft 5 Maximum hard Special wrench Indicates a potential hazard that could result in serious injury or death...

Page 39: ...if necessary Check oil level Engine oil Fill with oil if necessary Check for leakage Fina l gear oil differential gear oil Check for proper throttle cable operation Throttle Check tire pressure wear a...

Page 40: ...intenance procedures and schedules described in the Owner s Manual 34 Front and rear brakes Brake levers and brake pedal Check for correct free playinthe front brake lever If the free play is incorrec...

Page 41: ...starting out to make sure they are working properly If the brakes do not provide proper braking performance inspect the brake padsandshoes for wear See page 123 POTENTIAL HAZARD Riding with improperly...

Page 42: ...will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system YourATV engine has been designedtouse regularunleaded gasoline with a pump octan...

Page 43: ...TENTIAL 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 du...

Page 44: ...lity than specified In addition donot useoilslabeled ENERGYCONSERVING II or higher Make sure that no foreign material enters the crankcase Final gear oil Make sure the final gear oil is at the specifi...

Page 45: ...en released Have aATV dealer repair as necessary for proper operation Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride Take the machine to aATV dealer...

Page 46: ...the recom mended pressure Recommended tire pressure Front 25 kPa 0 25 kgf cm2 3 6 psi Rear 25 kPa 0 25 kgf cm2 3 6 psi Check and adjust tire pressures when the tires are cold Tire pressures must be e...

Page 47: ...eading 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 0 25kgf cm Recommended pressure Front Rea...

Page 48: ...42 Tire wear limit When the tire groove decreases to 3 mm 0 12 in due to wear replace the tire a Tire wear limit USER S MANUAL...

Page 49: ...not understand ask yourATVdealer Starting a cold engine POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control theATV which could lead to an accident o...

Page 50: ...rting the engine 5 Use the starter choke in reference to the figure Position 1 Cold engine start ambient temperature below 5 C 40 F Position 2 Cold engine start ambient temperature at 0 C 30 F 30 C 90...

Page 51: ...should not be used The throttle should be opened slightly starting a cold Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine...

Page 52: ...amaged Shifting forward 1 Bring the machine to a complete stop and return the throttle lever to the closedposition 2 Shift the gear from neutral to forward and vice versa by moving the drive select le...

Page 53: ...nd vice versa by moving the drive select lever along the shift guide 4 Check behind for people or obstacles then release the brake pedal 5 Open the throttle lever gradually and continue towatch to the...

Page 54: ...D THE HAZARD Improper operation in reverse You could hit an obstacle or person behind you resulting in serious injury Whenyoushift intoreverse makesure there are no obstacles or people behind you When...

Page 55: ...y condition which might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine 0 10 hours Avoid continuous...

Page 56: ...throttle Rev the machine freely but do not use full throttle at any time Avoid prolonged full throttle operation Vary speeds occasionally Parking When parking stop the engine and shift into neutral Tu...

Page 57: ...AN HAPPEN TheATV could roll out of control increas the chance of an accident ing HOW TOA VOID THE HAZARD Avoid parking on hills or other inclines If you must park on an incline place the machine trans...

Page 58: ...one that is equivalent in design and quality Accessories Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could affect your abi...

Page 59: ...kgf 33 lbf 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 loa...

Page 60: ...efully Added weight affects the stability and handling of the ATV POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Overloading this ATV or carrying or towing cargo improperly Could cause chang...

Page 61: ...Indicates a potential hazard that could result in serious injury or death 55 USER S MANUAL...

Page 62: ...56 USER S MANUAL...

Page 63: ...57 USER S MANUAL...

Page 64: ...tice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of...

Page 65: ...rse offered byATV They should then regularly practice the skills learned in the course and the operating techniques described in this Owner Manual For more information about the training course contac...

Page 66: ...mendations for this ATV Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child Achild under 16 should never operate anATV with engine size great...

Page 67: ...T CAN HAPPEN Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TOA VOID THE HAZARD Never carry a passenger The lon...

Page 68: ...in the event of anaccident Operating without an approved motorcycle helmet increases your chances of a severe head injury ordeath in the event of an accident Operatingwithoutprotectiveclothingincreas...

Page 69: ...ENTIAL HAZARD Operating thisATV after consuming alco ol or drugs h WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Co...

Page 70: ...e operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating this ATV...

Page 71: ...iders less experienced with this model this model is equipped with a speed limiter in the throttle lever housing The speed limiterkeepsthe throttle from fully opening even when the throttle lever is p...

Page 72: ...itch Pulling load 500 kgf 1 102 lbf Totalweightoftrailerand cargo Tongue weight 15 kgf 33 lbf Vertical weight on trailer hitch point POTENTIAL HAZARD Overloading this ATV or carrying or towingcargo im...

Page 73: ...emoving even one hand or foot can reduce your ability to control theATV or could cause you to lose your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come...

Page 74: ...e ATV or overturn Attempting wheelies jumps and other stunts Increases the chance of an accident includinganoverturn Never attempt stunts such as wheelies or jumps Don t try to show off POTENTIAL HAZA...

Page 75: ...in some situations could lead to an accident HOW TOA VOID THE HAZARD Never modify thisATV through improper installation or use of accessories All parts and accessories added to this vehicle should be...

Page 76: ...ATV in a place where others might be likely to touch it POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Hot exhaust system Dry grass or brush or other combustible material accumulated around...

Page 77: ...ously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Always avoid paved surfaces including sidewalks driveways parking lots andstreets BE...

Page 78: ...NTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operating thisATVon public streets roads or highways You can collide with another vehicle Never operate this ATV on any public street road or highw...

Page 79: ...ilure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in theATV overturn ing or...

Page 80: ...terrain Could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned an...

Page 81: ...perating in areas where you might not be seen by other off road vehicles WHAT CAN HAPPEN You could be in a collision You could be injured HOW TOA VOID THE HAZARD Always mount a caution flag on theATV...

Page 82: ...cause the tires to lose traction reducing control and increasing the possibility of an accident Select a large flat area off road to become familiar with your ATV Make sure that this area is free of o...

Page 83: ...rol causing acollision or overturn HOW TOA VOID THE HAZARD Always follow proper procedures for turning as described in this Owner Manual Practice turning at low speeds before at tempting to turn at fa...

Page 84: ...ave learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures such as abrupt throttle changes excessive braking incorrect bodymovements o...

Page 85: ...to lose control POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN Thevehiclecanoverturnmoreeasilyonextremelysteep hills than on level surfaces or small hills HOW TOA VOID THE HAZAR...

Page 86: ...cribed in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the thr...

Page 87: ...mastered the turning technique as described in the Owner Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill ifpossible If you are climbing a hill...

Page 88: ...ossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV USE...

Page 89: ...nt brake or the rear brake will brake all wheels When descending hills using either brake lever or the brake pedal will brake the wheels on the down hill side Avoid sudden application of either the fr...

Page 90: ...en fully stopped apply the rear brake as well and then lock the parking brake 4WD Apply both front and rear brakes gradually When fully stopped lock the parking brake Dismount on uphill side or to a s...

Page 91: ...ing may also cause a loss of traction Whenever possible ride your ATV straight down hill Avoid sharp angles which could allow the ATV to tip or roll over Carefully choose your path and ride no faster...

Page 92: ...n hills as described in this Owner s Manual Note a special technique is required when braking as you go down a hill Always check the terrain carefully before you start down any hill Shift your weight...

Page 93: ...yourATV does begin to tip over 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 wish totravel PO...

Page 94: ...88 USER S MANUAL...

Page 95: ...and carefully llow POTENTIAL HAZARD Operating thisATV through deep or fast flowing water WHAT CAN HAPPEN Tiresmayfloat causinglossoftractionandlossofcontrol which could lead to an accident HOW TOAVOI...

Page 96: ...re to drain the trapped water by removing the check hose at the bottom of the air filter case the V belt cooling duct check hose the drive select lever box check hose and the storage box check hose Al...

Page 97: ...Drive select lever box check hose V belt case drain plug 91 V belt cooling duct check hose left front side ofATV Storage box check hose USER S MANUAL...

Page 98: ...the ATV as loss of control and damage to the ATV may result POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Improperly operating over obstacles Could cause loss of control or a collision Coul...

Page 99: ...for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimeshelp If the rear wheels of yourATV start to slide side ways control can usuall...

Page 100: ...ch as ice since all control may be lost POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Skidding or sliding improperly You may lose control of this ATV You may also regain traction unexpected...

Page 101: ...ary gradually let off the throttle and or steer to the outside of the turn See pages 77 78 If yourATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the bra...

Page 102: ...the ATV is going to tip over dismount on the uphill side See pages 87 88 If your ATV encounters shallow water Rideslowlyandcarefullythroughslowmovingwater watching for obstacles Be sure to let water d...

Page 103: ...rt fires Turn off the engine when performing maintenance unless otherwise specified Have aATVdealerperformserviceifyouarenotfamiliar with machine service Owner s manual and tool kit You are recommende...

Page 104: ...this ATV with improper modifications Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident Never modify...

Page 105: ...400 2400 4800 200 750 1500 1500 3000 20 75 15 15 30 Every 20 40hours More often in wet or dusty areas Valves Spark plug Check valve clearance Adjust if necessary Check condition Adjust gap and clean R...

Page 106: ...eck operation Select lever safety system cable Check operation Adjust if necessary V belt Wheel Check operation Check for cracks or damage Check balance damage runout Repair if necessary Check bearing...

Page 107: ...re special tools data and technical skills have a HSUNdealer pertorm the sevice NOTE Recommended brake fluid DOT 4 Brake fluid replacement When disassembling the master cylinder or caliper replace the...

Page 108: ...n this chapter Refer to this section each time the panel has toberemoved or installed Panel A Panel A To remove Remove the bolt and then take the panel off To install Place the panel in the original p...

Page 109: ...oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart 1 Place the ATV on a level surface 2 Start the engine warm it up for several minutes and then...

Page 110: ...neoilshouldbebetweentheminimumandmaximum level marks NOTE Maximum level mark Minimum level mark 7 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 6 If the engine oil i...

Page 111: ...ce an oil pan under the engine to collect the used oil and then remove the engine oil filler cap 3 Remove the engine oil drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil f...

Page 112: ...er wrench is available at a nearby ATVdealer 5 Apply a light coat of engine oil to the O ring of the new oil filter cartridge Make sure the O ring is seated properly NOTE NOTE O ring Oil filter wrench...

Page 113: ...ng torque Engine oil drain bolt 23 N m 2 3 m kgf 16 ft lbf 8 Add the specified amount of recommended engine oil and then install the engine oil filler cap and tighten it Tightening torque Oil filter c...

Page 114: ...art the engine and warm it up for several minutes While warming up check for oil leakage If oil leakage is found turn the engine off immediately and check for the cause 10 Turn the engine off and then...

Page 115: ...ase 4 Install the oil filler bolt and then tighten it tothe specified torque Tightening torque Final gear oil filler bolt 23Nm 2 3m kgf 16ft lbf 2 Place the machine on a level surface 3 Place a contai...

Page 116: ...m of the filler hole Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 23 L 0 20 Imp qt 0 24 US qt Be sure no foreign material enters the final gear case 7 Install the oil filler bolt and...

Page 117: ...ear case to catch the oil 3 Remove the oil filler bolt and oil drain bolt to drain the oil Differential gear oil filler bolt Differential gear oil drain bolt 4 Install the oil drain bolt and then tigh...

Page 118: ...pacity is greater than the recommended oil quantity therefore the oil level cannot be accurately checked from the oil filler cap hole Recommended oil SAE 80 API GL 4 Hypoid gear oil Oil quantity 0 35...

Page 119: ...Check the protective boots for holes or tears If any damage is found have them replaced by a ATV dealer Axle boot 2 each side Spark plug inspection Removal 1 Remove the spark plug cap Spark plug cap...

Page 120: ...ormally Do not attempt to diagnose such problems yourself Inspection Instead take theATVtoaATVdealer Youshouldperiodically remove and inspect the spark plug because heatanddeposits will cause the spar...

Page 121: ...spark plug threads 3 Install the spark plug and tighten it to the specified torque NOTE If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque i...

Page 122: ...hose and clean the air filter element and air filter case 1 Remove the seat See page 28 for seat 2 Remove the air filter case coverbyunhook NOTE removal and installation procedures ingtheholders 3 Re...

Page 123: ...THE HAZARD Using low flash point solvents or gasoline to clean the air filter element Low flash point solvents or gasoline can catch fire or explode Use parts cleaning solvent to clean the air filter...

Page 124: ...more often if the machine is operated in extremely dusty areas Each time the air filter element maintenance is performed check the air inlet to the filter case for obstructions Check the air filter c...

Page 125: ...eck hose Left front side ofATV V belt case drain plug After riding in water deep enough to allow it to enter the V belt case remove this plug to drain the water from the case NOTE If water drains from...

Page 126: ...2 Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly and then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe Spark arreste...

Page 127: ...start the engine when cleaning the exhaust system Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjustment Most adjusting should be left to aATV de...

Page 128: ...and then set the idle to the specified idling speed by adjusting the throttle stop screw Turn the screw in directiona to increase the engine speed and in direction b to decrease the engine speed Speci...

Page 129: ...nt however should be left to aATV dealer Select lever safety system cable adjustment Throttle lever adjustment Adjust the engine idling speed before adjusting the throttle lever free play 1 Loosen the...

Page 130: ...ke pads for damage and wear If a brake pad thickness is less than 1 mm 0 04 in have a ATV dealer replace the pads as a set The wheels need to be removed to check the brake pads See pages 134 135 for r...

Page 131: ...to replace shoes as a set Brake fluid level check Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid...

Page 132: ...fluid DOT 4 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake fluid re...

Page 133: ...e the following components during periodic maintenance or when they are damaged or leaking Replace the oil seals every two years Replace the brake hoses every four years Front brake lever free play Th...

Page 134: ...uld lead to an accident 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 ble...

Page 135: ...129 Brake lever free play adjustment 1 Loosen the locknut and fully turn in the adjusting bolt at the brake lever Locknut Adjusting bolt USER S MANUAL...

Page 136: ...between the brake camshaft lever and the pin Adjusting nut brake lever cable a Gap 3 Turn the adjusting bolt at the brake lever until the free play at the brake lever pivot is 3 5mm 0 12 0 20 in Lockn...

Page 137: ...onal knowledge These procedures should be performed by a dealer Adjusting the rear brake light switch The rear brake light switch which is activated by the brake pedal and rear brake lever is properly...

Page 138: ...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 Inspect cables frequently Replace damaged ca...

Page 139: ...d brake pedal Lubricate the pivoting parts To access the brake pedal pivot remove panel A See page 102 for panel removal and installation procedures Recommended lubricant Lithium soap based grease all...

Page 140: ...134 Wheel removal 1 Loosen the wheel nuts 2 Elevate the ATV and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel Nut 4 USER S MANUAL...

Page 141: ...s tapered side towards the wheel The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nut NOTE 2 Lower the ATV so that the wheel is on the ground 3 Tighten the whee...

Page 142: ...could be poisoned You could be severely burned by the sulfuric acid in battery electrolyte Batteries produce explosive gases Avoid contact with skin eyes or clothing Always shield eyes when working ne...

Page 143: ...or recharging a sealed type battery Using a conventional battery charger may shorten the battery life 2 Always make sure the connections are correct when putting the battery back in the machine Fuse r...

Page 144: ...Fuse box Specified fuses Main fuse 30A Headlight fuse 15 A Ignition fuse 15 A Four wheel drive fuse 3 A Signaling system fuse 10 A Headlight fuse Ignition fuse Four wheel drive fuse Signaling system f...

Page 145: ...e a fuse of the specified rating Never use a material in place of the proper fuse To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse Replacing a headligh...

Page 146: ...2 Remove the headlight bulb holder by turning it counte rclockwise 3 Remove the defective bulb by unhooking the headlight bulb holder tabs Headlight bulb holder Headlight bulb holder tab 2 USER S MAN...

Page 147: ...it 4 Insert a new headlight bulb into the bulb holder and then secure the bulb by hooking the tabs onto the bulb Do not touch the glass part of the bulb Do not touch the glass part of the headlight b...

Page 148: ...ulb holder cover at the rear of the headlight Headlight beam adjustment It is advisable to have aATV dealer make this adjustment To raise the beam turn the adjusting screw in direction a To lower the...

Page 149: ...an cause poor starting and loss of power The troubleshooting chart describesa quick easyprocedure for making checks If your machine requires any repair take it to a ATV dealer The skilled technicians...

Page 150: ...l system while smoking or near an open flame Fuel can ignite or explode causingsevereinjuryorproperty damage Do not smoke when checking the fuel system Make sure there are no open flames or sparks in...

Page 151: ...f there is compression There is compression No compression Compression nomal Ignition system is nomal 3 Lgnition Remove thespark plug and check the electrodes Wet Dry Wipe clean with dry cloth Attach...

Page 152: ...to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings br...

Page 153: ...ves which may mar the paint or protective finish When finished start the engine and let it idle for several minutes POTENTIAL HAZARD WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Operation with wet brakes a...

Page 154: ...minates the need to drain the fuel system Consult a ATV dealer if the fuel system needsto be drained instead 2 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the sp...

Page 155: ...e it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F or more than30 C 90 F Make any necessary repairs before stori...

Page 156: ...base Ground clearance Minimum turing radius Basic weight With o il and full fuel tank 577 7 lbs Oil cooling 4 stroke SOHC Forward inclined singlecylinder 387cc 83 71 6 mm 9 50 1 Electronic Ignition wi...

Page 157: ...Carburetor Type quantity Manufacturer Spark plug Type manufacturer Spark plug gap Clutch type SAE80 API GL 4 Hypoid gear oil 0 23 L 0 20 Imp qt 0 24 US qt SAE80 API GL 4 Hypoid gear oil 0 35 L 0 31 Im...

Page 158: ...r angle Trail Tire Type Size Brake Front brake Rear brake V belt Shaft dr ive 41 21 24 18 33 9 9 545 V belt automatic Left hand operation 35 20 1 750 26 15 1 733 Steel tube frame 4 21 mm 0 83 in Tubel...

Page 159: ...ck absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery capacity Head li ght type Double wishbone Swingarm monocross Coil spring...

Page 160: ...t Reverse indicator light Oil temperature warning light Four wheel drive indicator light Fuses Main fuse Headlight fuse Ignition fuse Four wheel drive fuse Signaling system fuse 12 V 30 30 W 2 12 V 5...

Page 161: ...o the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CO...

Page 162: ...Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y 1 2 3 4 5 6 7 8 9 10 500 1000 1500 3000 4500 6000 7500 9000 10500 12000 USER S MANUAL 156 Oil Oil Filter All nuts Oil Filter Oil Filter Oil Filter Oil Filte...

Page 163: ...e Mileage km Items Maintained Dealer M D Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y M D Y 11 12 13 14 15 16 17 18 19 20 10000 Oil Air Cleaner Spark plug Brake fluid USER S MANUAL 157 MAINTENANC...

Page 164: ...ONLY by authorized QLINK MOTOR dealers Any warranty work done by an unauthorized QLINK MOTOR dealer will not be covered under the warranty policy Periodic services and inspections can be performed by...

Page 165: ...crate damage and the unit has not yet been sold Initial dealer pre delivery inspections and set up of the product is very important in ensuring trouble free operation Warranty starts from date of purc...

Page 166: ...ster 2 Years Unlimited Miles Battery when purchased with new unit Battery 30 Days Unlimited Miles Suspension Shocks Forks 1 Year Unlimited Miles Brake Caliper 2 Years Unlimited Miles Exhaust Header pi...

Page 167: ...trical Harness CDI Inst Cluster 1 Year Unlimited Miles Battery when purchased with new unit Battery 30 Days Unlimited Miles Suspension Shocks Forks 1 Year Unlimited Miles Exhaust Header pipe Muffler 1...

Page 168: ...Boards Pegs Oil Fuel Filters Grips Motor Mount Bushing Any damage which results from the following are not covered by warranty Unavoidable natural disasters fire collision theft improper storage or t...

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