Coleman 400UTV-2 Owner'S Manual Download

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POWERSPORTS

OWNER’S MANUAL

(888)-405-8725 Coleman Powersports

364 S. Smith Rd. Tempe, AZ. 85281

400UTV-2

400UTV-3

No one under the

age of 16 should

operate this ATV

Summary of Contents for 400UTV-2

Page 1: ...888 405 8725 Coleman Powersports 364 S Smith Rd Tempe AZ 85281 400UTV 2 400UTV 3 No one under the age of 16 should operate this ATV POWERSPORTS POWERSPORTS 400UTV 2 400UTV 3 No one under the age of 1...

Page 2: ...Owner s Manual...

Page 3: ...dge needed to have safe and enjoyable UTV operation If you have any questions regarding the operation or maintenance of your UTV please contact Coleman Powersports 888 405 8725 IMPORTANT SAFETY MESSAG...

Page 4: ...he following 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 bystander or...

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

Page 6: ...tem 4 4 Speedometer Unit 4 5 Odometer and Trip Meter Modes 4 6 Fault code indicator 4 8 Switches 4 10 On Command Four Wheel Drive and Differential Gear Lock Switches 4 11 Throttle Pedal 4 15 Brake Ped...

Page 7: ...ring Wheel Inspection 5 10 Seat Belts 5 10 Fittings and Fasteners 5 10 Lights 5 10 Switches 5 10 Tires 5 11 Measuring Tire Pressure 5 13 Tire Wear Limit 5 14 Operation 6 1 Starting a Cold Engine 6 1 S...

Page 8: ...Chart 8 4 Hood 8 6 To Open 8 6 To Close 8 7 EFI System 8 8 ECU and EFI System inspection 8 11 Engine Oil and Oil Filter Cartridge 8 11 To Check Engine Oil Level 8 11 To Change the Engine Oil With or...

Page 9: ...tion 8 38 Brake Pedal and Accelerator Pedal Lubrication 8 38 Rear Knuckle Upper and Lower Pivot Lubrication 8 39 Steering Shaft Lubrication 8 40 Wheel Installation 8 41 Battery 8 43 Battery Maintenanc...

Page 10: ...Owner s Manual...

Page 11: ...r from the date of purchase shown on the original sales receipt What is a Defect The Product is warranted to be free from manufacturing defects in material and workmanship for a period of 1 year from...

Page 12: ...oleman Powersports A COPY OF YOUR SALES RECEIPT IS REQUIRED FOR WARRANTY SERVICE What this Warranty Does Not Cover This warranty does not cover the following 1 Damage due to lack or improper maintenan...

Page 13: ...sonal items Length of Implied Warranties Any implied warranties are limited to the duration set forth in this warranty Coleman Powersports does not make any claim as to the merchantability or fitness...

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

Page 15: ...ll of the labels on your vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or come...

Page 16: ...Location of the Warning and Safety Labels 1 3 5 6 7 8 9 10...

Page 17: ...1 4 Location of the Warning and Safety Labels 11 12 13 14 15...

Page 18: ...Location of the Warning and Safety Labels 1 5 16 18 17 19...

Page 19: ...handgrip fixed before the seat Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on any public street road or h...

Page 20: ...right and left as they respond to the terrain and this movement will be felt in the steering wheel A sudden jolt could wrench the steering wheel around and your thumbs or fingers could be injured if...

Page 21: ...er than the floorboards on this model Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply the brake several times to let friction dry out...

Page 22: ...the vicinity of sparks open flames or other sources of ignition such as the pilot light of water heaters and clothes dryers When transporting the vehicle in another vehicle be sure it is kept in an u...

Page 23: ...Starting or running the engine in a closed area WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time HOW TO AVOID THE HAZARD Always operate yo...

Page 24: ...ttery 6 Fuses 7 Left body protection plate 8 Driver seat belt 9 Air filter element 10 Cargo bed 11 Tail brake lights 12 Spark arrester 13 Rear shock absorber assembly 14 CVT belt case 15 Fuel tank cap...

Page 25: ...ight switch 26 On Command four wheel drive and differential lock switches 27 Multi function display gauge 28 Auxiliary DC jack 29 Drive select lever 30 Accelerator pedal 31 Brake pedal 32 Release park...

Page 26: ...for assistance when ordering spare parts from a service center or for reference in case the vehicle is stolen 1 VEHICLE IDENTIFICATION NUMBER 2 MODEL LABEL INFORMATION Vehicle Identification Number Th...

Page 27: ...electrical circuits are supplied with power Headlights and taillights come on when the light switch is turned to the on position OFF All electrical circuits are switched off The key can be removed in...

Page 28: ...d result See starting instructions prior to starting the engine See pages 6 1 6 3 for details Indicator and Warning Lights 1 Four wheel locked showing light 2 Fault indicator light of EPS system 3 Dif...

Page 29: ...ver is in the R reverse position Coolant Temperature Warning Light When the coolant temperature reaches a specified level this light comes on to warn that the coolant temperature is too hot If the lig...

Page 30: ...ystem Fault is displayed by the fault indicator light and the fault code indicator of the EPS system so the driver can acknowledge fault of the EPS in time to take some measures to keep himself hersel...

Page 31: ...the engine is overheating stop the UTV immediately Do not start the engine again until the UTV has been inspected and repaired by a service center Low Battery charge indicator Indicates a low charge...

Page 32: ...es On the display panel there are two large buttons one located on the left side and one on the right side Quickly pressing the button on the left side toggles the display from the odometer to the tri...

Page 33: ...he left button again and the clock will exit the set mode Four wheel drive indicator There are two 4WD indicators on the display panel The left 4WD indicator has a blinking circle on the front axle wh...

Page 34: ...y of the UTV during operation CAUTION When the selector is set to 4WD the right 4WD symbol front axle will have an X in the middle When riding on good surfaces you should unlock the differential and p...

Page 35: ...be shown Then after five seconds the fault code returns again Only after the fault is fixed will the time show automatically The description for the fault codes are shown in Chapter 11 of this manual...

Page 36: ...the switch to to turn on the high beam and the taillights Set the switch to OFF to turn off all lights CAUTION Do not use the headlights with the engine turned off for an extended period The battery...

Page 37: ...fferential gear lock switch 4WD LOCK Select the appropriate drive according to terrain and the conditions Two wheel drive 2WD Power is sup plied to the rear wheels only Four wheel drive 4WD Power is s...

Page 38: ...stances 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 increas...

Page 39: ...o 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 2WD LOCK To lock the differential gear in 4WD...

Page 40: ...and have an accident if you cannot make a sharp enough turn for the speed you are traveling HOW TO AVOID THE HAZARD Always operate at a slow speed when the vehicle is in 4WD LOCK and allow extra time...

Page 41: ...he pedal to the rest position when released Always check that the throttle pedal returns normally before staring the engine 1 Throttle pedal Before starting the engine check the throttle pedal to be s...

Page 42: ...ARD Check the operation of the accelerator pedal before you start the engine If the accelerator pedal does not work smoothly check for the cause Correct the problem before operating the vehicle Consul...

Page 43: ...the parking brake gradually Spring pressure helps return the pedal to the released position Be sure to fully release the parking brake before starting out Failure to do so may result in poor performan...

Page 44: ...Control Functions 4 18 1 Drive select lever Fuel Tank Cap Remove the fuel tank cap by turning it counter clockwise 1 Fuel tank cap...

Page 45: ...turn close choke Refer to Starting a cold engine for proper operation See pages 6 1 6 3 A Choke knob 1 Fully open 2 Half open 3 Closed Seats To remove the seat bench pull front of seat upward then sli...

Page 46: ...r and or passenger could fall if the seat is loose during operation HOW TO AVOID THE HAZARD Make sure the seat is securely latched Seat belts This vehicle is equipped with three point seat belts for b...

Page 47: ...ush the latch plate into the buckle until it clicks Pull up on the latch plate to make sure it is secure 3 Place the lap portion of the belt low on your hips Push down on the buckle end of the belt as...

Page 48: ...RD Not wearing the seat belt or wearing the seat belt improperly WHAT CAN HAPPEN There is an increased risk of being killed or seriously injured in an accident HOW TO AVOID THE HAZARD Always wear your...

Page 49: ...ompartment CAUTION To prevent damage to the glove compartment do not place metal products like tools or sharp edged products directly in the glove compartment If they must be stored wrap them in appro...

Page 50: ...ctions 4 24 Cargo Bed 1 Cargo bed 2 Tailgate Opening and Closing the Tailgate 1 Tailgate 2 Latch 2 To open Unhook latches and lower the tailgate To close Place tailgate in original up position then ho...

Page 51: ...bed slowly to its original position and be sure it locks into place Maximum load limit 350lb 158kg WARNING POTENTIAL HAZARD Pinch points WHAT CAN HAPPEN You or someone else could be pinched between th...

Page 52: ...limit for this cargo bed Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking WARNING POTENTIAL HAZARD Carrying a passenger in...

Page 53: ...out on rough terrain CAUTION Frequent or severe bottoming out can cause increased wear or damage to the vehicle Adjust the spring preload as follows To increase the spring preload turn the adjusting...

Page 54: ...wrench WARNING POTENTIAL HAZARD Improper shock absorber adjustment WHAT CAN HAPPEN Uneven adjustment can cause poor handling and loss of stability which could lead to an accident HOW TO AVOID THE HAZA...

Page 55: ...high heat source This may cause the unit to explode due to excessive gas pressure Do not deform or damage the cylinders in any way Cylinder damage will result in poor damping performance Do not dispo...

Page 56: ...and thereby soften the suspension A special wrench can be obtained at a HSUN dealer to make this adjustment The spring preload setting is determined by measuring distance A shown in the illustration T...

Page 57: ...en the locknut NOTE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque Rebound damping force Turn the rebound damping force adjusting screw in direction S...

Page 58: ...he damping 1 Compression damping force adjusting screw WARNING Suspension components become hot during operation Never touch the compression damping force adjusting screw the rebound damping force adj...

Page 59: ...can be obtained at a service center 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 panel The...

Page 60: ...ted capacity for the auxiliary DC jack DC 12V 120W 10 A CAUTION Do not use accessories requiring more than the above maximum capacity This may overload the circuit and cause the fuse to blow If access...

Page 61: ...reservoir Check coolant level Fill with coolant if necessary 5 6 8 20 8 21 Final gear oil Differential gear oil Check for leakage 5 7 Accelerator pedal Check for proper accelerator pedal operation 5 8...

Page 62: ...scribed in the Owner s Manual Brakes Always check the brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied the brake pedal should feel firm Any sponginess...

Page 63: ...e pages 8 33 8 34 Recommended brake fluid DOT 4 Brake Fluid Leakage Check to make sure there is no brake fluid leaking out of brake hoses joints or the brake fluid reservoir Apply the brakes firmly fo...

Page 64: ...find any problems with the brakes If a problem cannot be corrected by the adjustment procedures provided in this manual have the vehicle inspected by a service center Fuel Make sure there is sufficie...

Page 65: ...ohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended because it may cause fuel system damage or vehicle performance problems WARNING...

Page 66: ...nkcase Recommended engine oil type and quantity See page 10 2 Coolant Check the coolant level in the coolant reservoir when the engine is cold The coolant level will vary with engine temperature The c...

Page 67: ...radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the cap Final Gear Oil Make sure the final gear oil is at the specified level Add oi...

Page 68: ...the vehicle inspected by a service center WARNING Failure to check or maintain proper operation of the throttle system can result in an accident leading to serious injuries or death Never start or op...

Page 69: ...hrottle pedal freeplay Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Set parking brake 2 Start the engine Allow engine to warm up a few minutes 3 Measure the distance the throttle pe...

Page 70: ...ve smoothly when pulled out and retract on its own when released The latch plate should click securely into the buckle and release when the release button is pushed firmly Wash off any dirt or mud whi...

Page 71: ...risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been approved by the Manufacturer for this model Other tire combinations are not recommended 2 The tires should be set to the rec...

Page 72: ...s The following are minimums Front 9psi 63kpa 0 64kgf cm 2 Rear 9psi 63kpa 0 64kgf cm 2 4 Use no more than the following Pressures when seating the tire beads Front 36psi 250kpa 2 5kgf cm 2 Rear 36psi...

Page 73: ...use the second reading Dust or dirt in the gauge could cause the first reading to be incorrect Set pressure with tires cold Set tire pressures to the following specifications Recommended pressure Mini...

Page 74: ...Pre Operation Checks 5 14 Tire Wear Limit When the tire groove decreases to 0 12 in 3 mm due to wear replace the tire a Tire wear limit...

Page 75: ...or function you do not understand ask your service center Starting a cold engine WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the veh...

Page 76: ...brake is applied However it is recommended to shift into neutral before starting the engine 3 Use the starter choke in reference to the figure Position Cold engine start ambient temperature below 41 F...

Page 77: ...ion 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...

Page 78: ...ecially careful 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 dama...

Page 79: ...ff Drive select lever operation and reverse driving CAUTION Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged Shifting Ne...

Page 80: ...ifting to reverse position 5 The brake pedal is attached to a cable that is connected to a position pin in the gearshift assembly Only when the brake pedal is depressed will the gearshift lever be abl...

Page 81: ...eed go slowly Vehicle Break in Period The break in period for your new UTV vehicle is the first 25 hours of operation or the time it takes to use the first three tanks full of gasoline No single actio...

Page 82: ...on or any condition that 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 Each full throttle a...

Page 83: ...reak in of the clutch and drive belt will ensure a longer life and better performance Break in the clutch and belt by operating at slower speeds during the break in period as recommended Pull only lig...

Page 84: ...apply 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...

Page 85: ...accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory that can shift position or come off while you are operating could affect your...

Page 86: ...with a 1 in receiver See page 4 29 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 wi...

Page 87: ...id 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 Overload...

Page 88: ...2 1 2 5 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger The driver and passenger must always wear a seat belt Never carry p...

Page 89: ...ssenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger in the cargo bed The cargo bed is designed to carry cargo only The total weight of operator...

Page 90: ...e properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking Always follow the instructions in your Owner s Manual for carrying...

Page 91: ...increases your chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the even...

Page 92: ...re attempting maneuvers that are more difficult Perform the Pre Operation Checks on pages 5 1 5 14 Set the parking brake shift to neutral and follow the instructions on page 6 1 to start the engine On...

Page 93: ...r or 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 you...

Page 94: ...ow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Apply the throttle lightly Never open the throttle suddenly 3 Back up slowly 4 Apply the brak...

Page 95: ...loose or slippery surfaces GOING UPHILL Do not attempt to climb hills until you have mastered basic maneuvers on flat ground Use proper driving techniques to avoid overturns on hills and slopes Drive...

Page 96: ...some hills are too steep for you to climb Maximum slope angle 15 Choose carefully which hills you attempt to climb Avoid hills with slippery surfaces or ones where you will not be able to see far eno...

Page 97: ...re climbing the hill first be sure you are operating in low range 4WD or if necessary with 4WD Diff Lock To climb a hill you need traction momentum and steady throttle Travel fast enough to keep your...

Page 98: ...ive your vehicle straight downhill Avoid sharp angles that could allow the vehicle to pitch or roll over Carefully choose your path and drive no faster than you will be able to react to obstacles that...

Page 99: ...slowly and carefully If the vehicle starts to tip gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction...

Page 100: ...13 in 33cm Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply brakes several times to let friction dry out the linings CAUTION After ri...

Page 101: ...box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs 6 Attempt to start the engine...

Page 102: ...Box inspection hole Front Axle Differential Lock When driving on rugged or muddy roads locking the differential case in the front axle gearbox will give you the best traction In this case the two fro...

Page 103: ...r accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could occur WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrai...

Page 104: ...oth sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger N...

Page 105: ...e tipping Go only fast enough to maintain your momentum but still give yourself plenty of time to react to changes in conditions If there is any question about your ability to maneuver safely over the...

Page 106: ...e service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor repairs The tools provided in...

Page 107: ...h vehicle service WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in...

Page 108: ...y require special tools data and technical skills ITEM ROUTINE Whichever Comes first INITIAL EVERY Month 1 3 6 6 12 Km miles 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 3...

Page 109: ...Intake Duct Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Engine Oil Replace Warm engine before draining Engine Oil Filter Cartridge Replace Final Differential Gear Oil...

Page 110: ...Drive Shaft Universal Joint Lubricate with lithium based grease Rear Upper and Lower Knuckle Pivots Lubricate with lithium based grease Fittings and Fasteners Check all chassis fittings and fasteners...

Page 111: ...8 6 Periodic Maintenance and Adjustment Hood To Open Unhook the hood latches and then slowly tilt the hood up until it stops 1 Latch 2 1 Hood...

Page 112: ...cure projections on the underside of the hood into slots on the back of the instrument panel Secure slots on the side of the hood around projections on the frame 1 Projection 2 2 Slot 2 CAUTION Make s...

Page 113: ...em EFI engine was completely different from the engine which uses carburetor it consist of ECU EFI cables sensors actuators and other advanced components As the following pictures 1 Oxygen sensor 2 Ox...

Page 114: ...ltage wire 2 Ignition signal plug 3 Ignition coil 1 Fuel injector 2 Bent pipe inlet pipe 3 Intake air temperature sensor pressure sensor 4 Ducting dampers 2 Water temperature sensor 1 Air damper degre...

Page 115: ...ondition ECU will adjust the fuel injection volume according to different negative pressure and opening of air damper Adjust the engine fuel injection volume can adjust the output power and output tor...

Page 116: ...ration In addition the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart To Check Engine Oil Level 1 Place the vehi...

Page 117: ...mmended type to raise it to the 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 Filt...

Page 118: ...s not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter bolt NOTE An oil filter wrench is available at a nearby service center 5 Apply a li...

Page 119: ...orque wrench Tightening torque Oil filter cartridge 12 ft lbs 17Nm 1 7m kgf 1 Oil filler cartridge 2 Torque bolt 7 Install the engine oil drain bolt and then tighten it to the specified torque Tighten...

Page 120: ...han specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign material enters the crankcase 9 Start the engine and then let it idle for several minutes whi...

Page 121: ...ype to raise it to the correct level CAUTION Be sure no foreign material enters the final gear case 4 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final ge...

Page 122: ...ing torque Final gear oil drain bolt 14 ft lbs 20 Nm 2 0 m kgf 5 Add the recommended final gear oil up to the brim of the filler hole Recommended oil SAE 80 API GL 4Hypoid gear oil Oil quantity 0 42 q...

Page 123: ...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 oi...

Page 124: ...lbs 23Nm 2 3 m kgf 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 gea...

Page 125: ...5 Hypoid gear oil Oil quantity 0 3 qt 0 28L CAUTION Be sure no foreign material enters the differential gear case 6 Install the differential gear oil filler bolt and then tighten it to the specified t...

Page 126: ...one can easily break the oil cooler and cause oil leak CAUTION If the oil cooler is blocked it will make the oil temperature overheated and damage the engine Coolant The coolant level should be checke...

Page 127: ...oir capacity up to the maximum level mark 0 663 qt 0 627L CAUTION Mix anti freeze with distilled water only However if distilled water is not available soft water can be used for refilling Changing th...

Page 128: ...content of the coolant If water is used instead of coolant have a service center check the antifreeze content of the coolant as soon as possible The radiator fan is automatically switched on or off ac...

Page 129: ...tment 1 Rear axle boot 2 each side Spark Plug Inspection Removal 1 Remove hood See pages 8 6 2 Remove the spark plug cap 3 Use the spark plug wrench in the tool kit to remove the spark plug as shown 1...

Page 130: ...ot attempt to diagnose such problems yourself Instead take the vehicle to a service center You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug...

Page 131: ...17 5 Nm 1 75 m kgf NOTE If a torque wrench is not available when you are installing the spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tight...

Page 132: ...Remove the Engine cover See page 8 16 8 17 for Engine cover removal and installation procedure 3 Remove the connecting rubber tube between air cleaner and throttle valve and the screws fixing the air...

Page 133: ...ly but thoroughly in solvent WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the sponge material WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or exp...

Page 134: ...al NOTE The sponge material should be wet but not dripping 10 Pull the sponge material over its frame 11 Install the air filter element 12 Install the air filter case cover and be sure the crankcase b...

Page 135: ...moved This will allow unfiltered air to enter causing rapid engine wear and possible engine damage Additionally operation without the air filter element will affect throttle valve jetting with subsequ...

Page 136: ...e bolts to the specified torque Tightening torque Tailpipe bolt 8 5 ft lbs 12 Nm 1 2 m kgf WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could inj...

Page 137: ...chnician Front 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...

Page 138: ...low you to check the brake pad wear without having to disassemble the brake system To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indic...

Page 139: ...n 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 S...

Page 140: ...the brake fluid level goes down Brake Fluid Replacement Complete fluid replacement should be done only by trained service personnel Have a service center replace the following components during perio...

Page 141: ...raking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the brakes operate smoothly and that the brake pedal position is correct Make sure the brakes do not dr...

Page 142: ...ng takes effect If necessary adjust the brake light switch as follows 1 Open the hood See pages 8 6 8 7 for hood opening and closing procedure 2 Turn the adjusting nut while holding the brake light sw...

Page 143: ...peration 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...

Page 144: ...Periodic Maintenance and Adjustment 8 39 Rear Knuckle Upper and Lower Pivot Lubrication Lubricate the knuckle upper and lower pivots with a grease gun Recommended lubricant Lithium based grease...

Page 145: ...d Adjustment Steering Shaft Lubrication Lubricate the pivot points Recommended lubricant Lithium based grease all purpose grease Upper universal joint steering transmission shaft Lower universal joint...

Page 146: ...ance rod 1 Nut 4 Wheel Installation 1 Install the wheel and the nuts NOTE The arrow mark on the tire must point toward the rotating direction of the wheel Tapered nuts are used for both the front and...

Page 147: ...nd Adjustment 1 Arrow mark 1 Tapered nut 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 49 7 ft lbs 70Nm 7 0 m kgf Rear...

Page 148: ...th a sealed type battery Therefore it is not necessary to check the electrolyte or add distilled water in the battery If the battery seems to have discharged consult a service center CAUTION Do not tr...

Page 149: ...ARD Avoid contact with skin eyes or clothing Always shield eyes when working near batteries Keep out of reach of children Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or...

Page 150: ...etely recharge the battery before reinstallation 2 Always make sure the connections are correct when putting the battery back in the vehicle 1 Negative battery lead 2 Positive battery lead CAUTION A s...

Page 151: ...e ignition switch and install a new fuse of the specified amperage If a fuse is blown replace it as follows 1 Remove the battery compartment cover by lifting it up and pulling it out 1 Battery compart...

Page 152: ...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 amper...

Page 153: ...the electrical circuit in question to check if the device operates 5 If the fuse immediately blows again have a service center check the electrical system 6 Install the battery compartment cover 7 Clo...

Page 154: ...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...

Page 155: ...ht 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 h...

Page 156: ...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...

Page 157: ...If your vehicle requires any repair take it to a service center The skilled technicians at a service center have the tools experience and know how to properly service your vehicle Imitation parts may...

Page 158: ...able1 Solution of Common Problems in Appearance Parts and Impact Fittings S N Problems Solutions 1 Covers are cracked Repair cover at authorized service center Change for new plastic covers Attach the...

Page 159: ...of calipers are deformed 2 Brake performance is diminished Check if the brake discs are over worn Check if the brake blocks in calipers are over worn or contaminated by debris Check if there is any l...

Page 160: ...4 Vehicle pulls left or right when braking at high speed Check both left and right front brakes make sure there is no deviation when applying the brake Check to make sure the rear brakes do not lock...

Page 161: ...Vehicle will not go into 4wd Mode Check if the control switch on consol is working Check if the differential lock control magneto plug in rear bridge reduction gear box is broken Check if wire is loos...

Page 162: ...ot working Check if the switch is broken Check if wire is loose or broken Check if the CDI is broken Table 4 Solution of Common Problems in Running System 1 Too much play in the steering wheel Check t...

Page 163: ...wheel axles to find out if they are worn or broken Check rubber bushings between the front suspension shocks and frame to find out if they are worn or missing 3 Rear wheels shake during use Check the...

Page 164: ...if shock absorbers have lost damping force 6 Front and or rear differential is making noise Check if the spline of intermediate driving shaft is broken Check if the splines in left right drive shafts...

Page 165: ...voltage wire is in poor contact Check if CDI s faulty 3 Loss of power performance Check if the carburetor or fuel filter is clogged by debris Check and clean core of air cleaner Check muffler and spa...

Page 166: ...temperature sensor of radiator for damage and Check fan for failure Check antifreeze make sure vehicle has the correct type and quantity Check to make sure the coolant system does not have air pocket...

Page 167: ...e temporarily used provided that it is changed to the recommended coolant as soon as possible WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot WHAT CAN HAP...

Page 168: ...ntbrush Do not apply degreaser to the wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job CAUTION Excessive water pressure may cause water seepage...

Page 169: ...leaner waxes as many contain abrasives that may scratch the paint or protective finish When finished start the engine and let it idle for several minutes WARNING POTENTIAL HAZARD Operation with wet br...

Page 170: ...fuel from the fuel system as much as possible and pour the drained fuel into the fuel tank Specified amount 1 oz of stabilizer to each gallon of fuel or 7 5 ml of stabilizer to each liter of fuel NOT...

Page 171: ...all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat covers 8 Remove the battery and charge Store it in a dry place and recharge it once a month Do not...

Page 172: ...for HS400UTV 2 1550mm 61 0 in for HS400UTV 3 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 543kg 1197 lb Engine Engine type Cylinde...

Page 173: ...ge replacement API service SG type or higher JASO standard MA CAUTION In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use o...

Page 174: ...fferential gear case oil Type Quantity SAE80 API GL 5 Hypoid gear oil 0 28L 0 3 qt Radiator capacity including all routes 1 5 L 1 59 qt Air filter Wet element Fuel Type Fuel tank capacity Unleaded gas...

Page 175: ...on Primary reduction system Secondary reduction system CVT reduction ratio Transmission type Operation V belt Shaft drive 1 75 35 20 V belt automatic Right hand operation Chassis Frame type Caster ang...

Page 176: ...brake Right hand operation Dual disc brake Left hand and right foot operation Suspension Front suspension Rear suspension Double wishbone Double wishbone Shock absorber Front shock absorber Rear shoc...

Page 177: ...age quantity Headlight Tail brake light Front Rear turning light License light 12V35 0W 35 0W 2 12V5 0W 21 0W 2 12V10 0W 10 0W 2 12V3 0W Indicator lights Neutral indicator light Reverse indicator ligh...

Page 178: ...Specifications 10 7 Model HS400UTV 2 HS400UTV 3 Main Fuse Headlight Fuse Ignition Fuse Auxiliary DC Jack Fuse Signaling System Fuse 2WD 4WD Fuse 30 0A 15 0A 10 0A 10 0A 10 0A 3 0A...

Page 179: ...uit Low Voltage KsDGDM_IAT_ShortLow 112 274 P0113 IAT Circuit High Voltage or Open KsDGDM_IAT_ShortHigh 113 275 P0117 Coolant Oil Temperature Sensor Circuit Low Voltage KsDGDM_CoolantShortLow 117 279...

Page 180: ...n KsDGDM_INJ_CYL_B_Fault 202 514 P0230 FPR Coil Circuit Low Voltage or Open KsDGDM_FPP_CircuitShortLow 230 560 P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShortHigh 232 562 P0336 CKP Sensor...

Page 181: ...DM_O2_2_ShortHigh 138 312 P0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh 38 56 P0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow 37 55 P0500 VSS No Signal KsDGDM_VSS_N...

Page 182: ...ed pollutant Where a warrantable condition exists HISUN will repair your vehicle at no cost to you including diagnosis parts and labor If an emission related part on your vehicle is defective the part...

Page 183: ...ach new 2013 HISUN brand off road vehicle A is designed built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Pr...

Page 184: ...of business during customary business hours This warranty does not cover inconvenience or loss of use of the vehicle or transportation of the vehicle to or from the HISUN dealer HISUN shall not be li...

Page 185: ...by the owner However HISUN is not liable for these parts The owner is responsible for the performance of all required maintenance Such maintenance may be performed at a service establishment or by any...

Page 186: ...POWERSPORTS 888 405 8725 Coleman Powersports 364 S Smith Rd Tempe AZ 85281...

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Coleman 400UTV-2, Owner'S Manual

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