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BR400 4WD

Owner’s Manual

Содержание BR400 4WD

Страница 1: ...BR400 4WD Owner s Manual ...

Страница 2: ... ATV This will ensure ATV performance and safety This manual describes detailed instructions of correct operation maintenance and adjustment of BR400 4WD to ensure durable safe and comfortable riding In order for you to ride more safely and more comfortably please read this manual thoroughly before riding it Have a nice time riding If data and relevant pictures contained in this manual differ from...

Страница 3: ... 32 Do Not Apply Emergency Brake and Have a Quick Turn 33 Riding with Particular Attention in Raining Days 33 How to Stop the ATV When The ATV Comes to a Full Stop 34 When parking the ATV 35 When transporting the ATV 35 6 Checks Before Riding 36 Pre riding Check Oil Check and Refilling 36 Recommended Oil Specification and Grade 37 Changing Oil 38 Differential gear oil Change the differential gear ...

Страница 4: ...3 Important Message Negligence of the following signs and warnings may cause serious damage and even death Warning sticker location 4 5 3 2 1 6 7 ...

Страница 5: ...4 1 3 4 2 5 6 7 ...

Страница 6: ... ATV you can only ride it with instruction by a licensed or qualified instructor First of all you have to ride it slowly to feel and adjust yourself to the ATV even if you are an experienced rider Do not attempt to utilize the maximum limits of this ATV Notes A You should familiarize yourself with basic operations of this ATV before you try more difficult operational techniques B To ensure the rid...

Страница 7: ...duct a pre riding check in accordance with Check before riding in user s manual on Page 32 before riding to ensure safety and the service life of this ATV Your ability of controlling this ATV will be affected by insufficient tire pressure or a tire that is out of specification Contact your service center for inspection to reduce the risk of an accident ...

Страница 8: ...the risk of fire do not park this ATV near a dry lawn or flammable substances Load Weight Limit Maximum allowable weight for this ATV is 150 kg two riders When you carry loads on the ATV slow down your speed to increase effective braking distance When you carry loads on the ATV you should keep loads in balance to avoid loss of control of the ATV due to imbalance Notes 1 Load weight limit 150 kg 2 ...

Страница 9: ...s etc to avoid the risk of an accident When riding with poor visibility e g riding at night turn on the headlight and slow down your speed to ensure safety When riding in the area where your viewing angle is limited e g riding on a rough road in hills it is advisable to attach a flag of some height in the rear of the ATV for warning purposes This can assure safety for the rider other riders and on...

Страница 10: ...s possible Also sit in the front part of the seat and bend your upper body forward Keep a steady speed in the uphill process and keep the ATV balanced Notes 1 If the slope is too high to proceed and the ATV is moving backward apply the front brake to slow down and carefully control the ATV to slip down If it is beyond control the rider should immediately get off from the left side to avoid the ris...

Страница 11: ...ast or is deep the performance of the ATV will be affected which may cause unsafety to the rider Notes Do not ride across a river with fast current or great depth to avoid loss of control of the ATV and cause risk of hazard to the rider After crossing the water area you should check that the brake function is normal If it is not slow down your speed and also intermittently apply both front and rea...

Страница 12: ...11 take it to the nearest service center for inspection and servicing ...

Страница 13: ...e ATV Functionality of the ATV is dependant upon its structure Any modification without our permission may cause performance degradation and in turn affect the service life of the ATV and riding safety It is illegal to modify this ATV without our permission Do not attempt to make any modification ...

Страница 14: ...13 2 Naming of Each Component 01 Headlight position light 02 Front brake handle lever 03 Right front turn signal light 04 Left front turn signal light 3 4 2 1 ...

Страница 15: ...rear turn signal light 06 Rear light brake light 07 Ignition switch 08 Left rear turn signal light 09 Exhaust pipe 10 License plate light 11 Battery 12 Accompanying tools 13 Accelerator lever 5 8 7 9 12 6 11 13 10 ...

Страница 16: ...15 14 Shift stick 15 Front brake reservoir 16 Seat 17 Aux liquid bottle 18 Right footrest 19 Left footrest 20 Foot brake 1 for 4 wheel 15 14 16 17 18 20 19 ...

Страница 17: ...ke handle lever 23 High low beam switch Startup rocker switch Warning light switch Turn signal light switch Horn switch 24 Fuel tank cap 25 Throttle Bottom Clamp 26 parking lever 27 Manual Choke 28 Power Supplier 12V 21 22 26 23 24 27 28 25 ...

Страница 18: ... light comes on The engine can be started up 1 Key hole 2 Key Note Do not turn the key to the OFF position while riding This is the major cause of an accident 1 Reverse Indicator Light The reverse indicator light comes on red light when you turn on the ignition switch when the transmission is at the reverse gear 2 Neutral Indicator Light The neutral indicator light comes on green light when you tu...

Страница 19: ...ator light comes on you must stop the engine and let it cool down 5 Left Right signal indicator When operating the Left right turn signal light switch this indicator will come on 6 Fuel level indicator When the pointer of the fuel level indicator rests near the last scale the fuel remaining in the tank is about 3 7 liters Refuel with 95 unleaded gasoline as early as possible Note There is no need ...

Страница 20: ...19 7 Four wheel drive switch 2WD 4WD ...

Страница 21: ... on At this position the headlight comes on and the light is beaming at a far distance The headlight will not come on if the ignition switch is not turned on Startup Rocker Switch When the engine is started electrically be sure to pull tight the front or rear brake handle lever to energize the system Then the engine can be started while pressing the startup rocker switch ...

Страница 22: ...ahead when the engine is started Accelerator Limiting Device To protect a new rider who is not familiar with this ATV from an accident this ATV is fitted with an accelerator limiting device that can adjust the travel of the throttle valve which in turn limits engine power Adjustment Loosen the retaining nut and then turn the adjusting screw with a screwdriver rider Turning clockwise will reduce th...

Страница 23: ...e ATV to stop move forward or reverse use the shift stick to shift gears With pulling and releasing the rear brake handle lever L Low range H High range N Neutral R Reverse Note The shift stick should be placed at the N position when the engine starts up or stops to avoid the risk of hazard After the engine starts up and when operating the shift stick you should also pull the rear brake handle lev...

Страница 24: ...r brake will be relieved at the same time Note When starting the engine or parking the ATV apply the parking lever to lock the rear wheels to prevent the ATV from moving and causing the risk of hazard If the play of the brake handle level is incorrect the rear wheels may not be locked which may cause the risk of a hazard Flagpole Holder This allows you to position the desired flags in the holder ...

Страница 25: ...nt the seat Push the retaining tab under the front seat into the holder on the frame Then push downward the rear part of the seat and the seat can be attached on the frame Note After the seat is mounted you need to ascertain that it is firmly attached to the frame by moving it upward downward and forward backward If the seat is not firmly attached it may cause the rider to lose control of the ATV ...

Страница 26: ...25 LCD Instrument Panel Adjustment ...

Страница 27: ...26 ...

Страница 28: ...ng the engine first check oil and fuel levels Turn the ignition switch to the ON position 1 Key hole 2 Key Note When the ignition switch is turned on check that the neutral indicator light comes on The gear should be in neutral when the engine is started ...

Страница 29: ...n the brake pedal Note When starting the engine the ignition circuit for the electric startup can only be energized with actuation of the startup switch in combination with the front or the rear brake handle lever being pulled tight or the brake pedal being depressed ...

Страница 30: ...t If the engine does not start within 3 4 seconds after pressing the startup switch you may need to push the choke lever to the left which can help engine start up Note After the engine warms up for 2 3 minutes you must push the choke lever back to its original position Otherwise the engine speed will be affected If the ATV has been stored for a long time or when the fuel tank is empty it is very ...

Страница 31: ...Usage When riding The rear brake handle lever is kept at the braking position and then put the shift stick to the H or R position Note When the engine is idling do not push the accelerator to rev the engine L H N R ...

Страница 32: ... on floor panel and keep his body upright with two hands holding the handlebars Do not make haste relax carefully heed surrounding conditions and ride safely Note Before riding the rear brake handle levers should be kept at braking positions ...

Страница 33: ...easing the parking brake on the rear wheels do not push or press the accelerator lever to avoid jerking ahead and causing the risk of hazard Release the rear brake handle lever and slowly push the accelerator lever the ATV will start to run smoothly Note Do not push the accelerator with force to avoid dash out of the ATV ...

Страница 34: ...utions The speed of the ATV is controlled via the accelerator lever Pushing the accelerator lever the speed increases The accelerator lever should be pushed slowly When going uphill slowly push the accelerator lever the engine will rev up and power increases Return to original position the speed decreases ...

Страница 35: ...el drive indicator comes on in the multifunction meter unit display To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position Warning What can happen The ATV handles differently in two wheel drive than in four wheel drive in some circumstances Changing from two wheel drive to four wheel drive or from four wheel drive to two wheel drive while moving ...

Страница 36: ...s supplied to the rear and front wheel and the differential gear locked Unlike in four wheel drive all wheel turn at the same speed To lock the differential gear in four wheel drive make sure the On Command four wheel drive switch is pushed in to the 4WD position Stop the ATV move the differential gear lock lever to position a and then push the differential gear lock switch in to the LOCK position...

Страница 37: ...ng from four wheel drive differential gear lock to four wheel drive Warning Potential hazard Riding to fast while the ATV is in four wheel drive differential gear lock What can happen All wheels turn at the same speed when the differential gear is locked so it takes more effort to turn The ATV The effort needed to turn increases with the riding speed You may lose control and have an accident if yo...

Страница 38: ...he accelerator lever back to its OFF position firmly hold the brake handle levers and step on foot brake Ideally when applying brakes start to slowly pull the brake handle levers and then pull them firmly to the end Notes Care should be taken if applying only one brake handle lever on one side it is easy to cause the ATV to skid and be unstable Do not attempt to apply emergency brakes during ridin...

Страница 39: ... very dangerous for the rider Riding with Particular Attention in Raining Days In raining days the condition of road surface differs from that in clear days The brake distance will be extended Ride at a lower speed and apply brakes earlier When going downhill put the accelerator lever back to the OFF position and intermittently apply brakes Ride at a slower speed ...

Страница 40: ...ke handle levers which will activate the brake light to alert coming ATVs in the back When the ATV Comes to a Full Stop Put the shift stick at the N position and turn the ignition switch to the OFF position 1 Key hole 2 Key Note Turning off the ignition switch and removing the key during riding will cause the electrical system to disable This is a major cause of an accident Do not do that until th...

Страница 41: ...the rear brake handle lever is incorrect it will not lock the rear wheels which will lead to the risk of hazard When transporting the ATV First drain fuel in the tank and the carburetor Loosen the draining screw of the carburetor Use a container to keep drained fuel After the fuel is drained tighten the draining screw Draining screw Note Smoking is strictly prohibited when draining fuel ...

Страница 42: ...stitute Oil capacity Full capacity 2 5 liter Replacing volume 1 8 liter Note To prevent using low grade oil it is recommended you go to a workshop of the dealer from whom you purchased your ATV or the service center for oil change Oil Check and Refilling Oil level check 1 Start the engine and let it warm up for 2 3 minutes Then turn off the ignition switch for 2 3 minutes Visually check the oil wi...

Страница 43: ...e Engine oil tank and gear box are integrated In order to drain the oil thoroughly remove the engine oil tank drain plug 1 and gear box oil drain plug 2 4 After oil is drained up tighten the oil pan drain plug Then fill in correct oil with appropriate volume 5 Visually check that the oil level is between the upper and lower limits Then tighten the oil filling cap 6 The tightening torque for the oi...

Страница 44: ...bolt to drain the oil from the differential gear case Drain bolt 4 Install the drain bolt and then tighten it to the specified torque Tightening torque differential gear oil drain bolt 1 5kg m 5 Add the recommended differential gear oil to the brim of the filler hose as shown Filler bolt 6 Install the filler bolt and then tighten it to the specified torque Tightening torque differential gear oil f...

Страница 45: ... drain the oil from the final gear case Drain bolt 4 Install the drain bolt and then tighten it to the specified torque Tightening torque final gear oil drain bolt 1 5kg m 5 Add the recommended final gear oil to the brim of the filler hose as shown Filler bolt 6 Install the filler bolt and then tighten it to the specified torque Tightening torque final gear oil filler bolt 1 5kg m 7 Check the fina...

Страница 46: ...hen starting the engine turn the ignition switch from the OFF to ON position Notes Smoking is strictly prohibited when refueling the ATV Stop the engine before refueling No need to add any additive in fuel when refilling Addition of any additive may cause engine failure Do not top up fuel to the opening Otherwise fuel may spill as it may expand by heat or sunlight and lead to the risk of hazard 1 ...

Страница 47: ...stem Ride your ATV to the dealer s workshop or service center for inspection Brake fluid refilling 1 Position the handlebars in the middle Remove two fixing screws on the cover of the brake fluid reservoir and then take out the cover 2 Refill brake fluid recommended DOT 4 grade until it reaches the upper limit Then position back the cover and tighten two fixing screws 3 Change brake fluid once a y...

Страница 48: ... the front and rear brake performance is good Brake Light Check Turn the ignition switch to the ON position Pull both the front and rear brake handle levers to make sure that the brake light illuminates Check that the brake light housing is clean or damaged ...

Страница 49: ...m or low beam illuminates Check that the headlight housing is clean or damaged Headlight Beaming Distance Adjustment Headlight s beaming distance is adjustable How to adjust it Turn on the ignition switch and also turn on the headlight switch Then screw in or out the adjusting screw to adjust the beaming distance ...

Страница 50: ...3 92 PSI 0 25 kgf cm2 3 5 PSI 0 35 kgf cm2 5 PSI Rear wheel 0 28 kgf cm2 3 92 PSI 0 25 kgf cm2 3 5 PSI 0 35 kgf cm2 5 PSI If metal chips or small stones are found in tire grooves remove them before riding If tire crack is found or tire wear exceeds the prescribed limit immediately change the tire If tire groove depth is less than 3mm immediately change the tire ...

Страница 51: ...ght on the handlebars and rear hand rest and shake them upward downward to check that the shock absorbers are OK Front Rear Shock Absorber Adjustment To ensure riding comfort the spring pre compression of rear shock absorber is adjustable 1 2 3 4 5 ...

Страница 52: ...l drops significantly it usually represents a problem in the system Recommended anti freeze Te she Anti freeze Name Anti freeze Prescribed concentration 30 50 in cold zone Concentration and anti freeze temperature 12 25 15 30 24 40 35 50 Notes Use soft water to mix with anti freeze Note that low grade coolant will shorten the radiator service life Under normal conditions coolant should be replaced...

Страница 53: ...y open it In case that coolant drips on the painted surface immediately rinse it with clean water How to drain coolant 1 First open the cover 2 Push downward the radiator cap and turn counterclockwise to open the cap 3 Remove the draining bolt and let coolant drain out Tilting the ATV rightward may facilitate coolant to drain faster 4 Take out the Aux Liquid Bottle and pour out coolant Cover Right...

Страница 54: ...an two times Then stop the engine Be sure to wait until the radiator cools down before opening the cap to avoid getting burnt 5 Open the radiator cap and check that coolant level is still at the upper limit if not refill coolant and then firmly tighten the cap 6 Start the engine again and let it run for 1 2 minutes Open the radiator cap and check that the coolant level is still at the upper limit ...

Страница 55: ... as above for replacing it Notes If the air cleaner is not mounted correctly dirt dust may directly be drawn in the cylinder causing engine wear power drop and resulting in shorter engine life Do not wet the air cleaner when washing the ATV Wet air cleaner may cause the engine to be difficult to start Check and replace the air cleaner at a shorter period under the following conditions 1 Often ridi...

Страница 56: ...clean it Adjustment The gap between two poles normally is 0 6 0 7 mm as shown in Figure A Your ATV comes equipped with a NGK CR8E spark plug Do not use a spark plug other than a recommended one Note When the engine stops it is still very hot Be careful not to get burnt First put the spark plug with hand tight and then tighten it using a spark plug spanner NGK CR8E A ...

Страница 57: ... ends should be lubricated if necessary If a cable is damage or dose not move smoothly please take it to a dealer or service center check or replace it Lubricating the drive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Lubricating the steering shaft The steering shafts must be lubricated at the...

Страница 58: ...rt of the ATV Visually check that all parts that need lubrication are sufficiently lubricated Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is found please take it to a dealer or service center check or replace it Front axle boots ...

Страница 59: ...equired Conduct those operations in accordance with the description in the regular check record Notes Ensure safety when serving the ATV Use suitable tools Make preparation while the engine stops When the engine stops the engine and exhaust pipe are still very hot Care should be taken to avoid getting burnt ...

Страница 60: ...ve gap 4T A A A A A Spark plug 4T C R Ignition system Ignition circuit I I I Important body bolts T T T T T T T T T T T T T T T Others Brake system I I I I I I I I I I I I I I I I I Inspect A Adjust C Clean R Replace T Tighten If cleaning lubrication refill adjustment or replacement are found necessary during riding or inspection you can take corrective actions directly provided that exhaust emiss...

Страница 61: ...the enclosed battery that contains battery electrolyte If the ATV has not been used for a long period of time the battery may have discharged and reduced its power In this case remove the battery and recharge it to its full power and then put it in a cool and well ventilated place If the ATV will not be used for a long period of time remove the connecting wire at the negative pole Notes While remo...

Страница 62: ...in that the fuse has good contact A loose fuse will generate heat Fuse rating 20A To replace the battery lamps use only the original components of the prescribed specification If components are not original or out of specification the fuse can easily be blown and the battery will not be in balanced status When washing the ATV do not wash it with high pressure water jet Notes To remove the fuse Car...

Страница 63: ...62 Consumer information SERIAL NUMBER Location of Frame Serial Number Vehicle Identification Number Location of Engine Serial Number ...

Страница 64: ...function during use please take it to a dealer or service center for inspection If The Engine Stops If the engine stops during riding first check the following Is fuel available The way to start the engine is correct Any failure occurs on other part ...

Страница 65: ... drive CHASSIS Suspension Front Dual A arm with 5 way preload adjustable shocks Suspension Rear Dual A arm with 5 way preload adjustable shocks Brakes Front R L Disc brake Brakes Rear R L Disc brake Tires Font 25x8 12 Tires Rear 25x10 12 DIMENSIONS Overall length 2060 mm 81 1 in Overall width 1215 mm 47 8 in Overall height 1210 mm 47 6 in Seat height 910 mm 35 8 in Wheelbase 1260 mm 49 6 in Ground...

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Содержание BR400 4WD

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